Measures for Preventing Disruption in the Blast Furnace Operation under Use of Pulverized Coal

Semenov, Yu. S.; Horupakha, V. V.; Shumelchik, Ye. I.

doi:10.3103/s0967091220020096

Cited by 13 publications

(3 citation statements)

References 12 publications

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“…12. To achieve this value of σ[Si], it is necessary to comply with the requirements of the dynamics of changes in the RAFT and ore load, comply with the release schedule, carry out targeted washings of the hearth with hard-to-recover materials when it is cluttered [45][46][47][48][49], carry out preventive soft washings from flux residues and coke debris in the intermediate zone of the BF with a mixture of iron ore materials with a basicity of 0.65-0.85 [48,49], ensure a uniform distribution of the thermal state of the tuyere zones along the circumference of the BF by directional regulation of the pulverized coal consumption in the air tuyeres [35], use manganese-containing materials in the BF charge to maintain the manganese content of cast iron in the range of 0.25-0.35% [49], and comply with the recommendations of the developed DSS for managing the thermal state of BF smelting.…”

Section: Resultsmentioning

confidence: 99%

“…In accordance with the knowledge base obtained during the research in 2018-2021 at PrJSC "Kamet-steel" [11,35,48,49], and as a result of the work performed in 2020-2021 (detailed analysis of violations of the thermal regime of BF smelting), a DSS was developed in the mode of an adviser for managing the thermal state of BFs of PrJSC "Kamet-steel". Screenshots of the DSS software are shown in Figure 1.…”

Section: Resultsmentioning

confidence: 99%

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Development and Implementation of Decision Support Systems for Blast Smelting Control in the Conditions of PrJSC “Kamet-Steel”

Semenov

Shumelchyk

Horupakha

et al. 2022

Metals

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This article presents a description of three decision support systems (DSS) in the mode of an adviser to the technological personnel of blast furnaces (BF), which were implemented by the Iron and Steel Institute of Z.I. Nekrasov (Dnipro, Ukraine) or underwent pilot testing as part of the automated control system of the BF shop of PrJSC “Kamet-steel” (Kamianske, Ukraine). The first DSS for managing the thermal state was implemented in 2021; it includes the entire list of information necessary for personnel in a convenient and compact form, generates recommendations in case of technology deviations, and, in the case of incorrect actions by the personnel, signals the need for correct actions. The main recommendations from the DSS are to correct the raceway adiabatic flame temperature, coke consumption when its characteristics are specified in (indicators of strength and abrasion, fractional composition, humidity, ash and sulfur), and ore load change. Using the system allows both reducing the specific coke consumption and preventing unplanned downtime. The second DSS for controlling the distribution of fuel additives over air tuyeres is based on information on thermal loads determined on water-cooled elements of tuyere tools. The main recommendations from the DSS are to adjust the amount of injected pulverized coal fuel on individual tuyeres in order to ensure a uniform distribution of the raceway adiabatic flame temperature around the circumference of the BF and, as a result, the energy efficiency of BF smelting. The third DSS for adjusting the parameters of the charging mode is based on information from the means of controlling the temperatures of the gas flow above the surface of the charge in the BF. The functioning of this DSS is based on determining the reference curves for the distribution of the gas flow along the BF radii, corresponding to the minimum consumption of coke and maximum productivity, and on the search for solutions by direct and iterative optimization methods, which allow one, by adjusting the charging parameters, to ensure a rational distribution of charge materials and gas flow in the BF.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Development and Implementation of Decision Support Systems for Blast Smelting Control in the Conditions of PrJSC “Kamet-Steel”

Semenov

Shumelchyk

Horupakha

et al. 2022

Metals

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“…Since these irregularities in the functioning of BF ultimately result in a loss of production and materials and cause variations in the quality of the iron [3,4], the analysis and the prevention of the above-mentioned phenomena is of great interest. The authors of [5] give a list of measures for preventing violations in the run of a specific BF, identified through the analysis of scull slipping and channeling in the BF prior to implementation of these measures. This has encouraged a reduction in the specific consumption of coke and an increase in the productivity of the furnace.…”

Section: Introductionmentioning

confidence: 99%

CFD Analysis of Low-Cost Solutions to Minimize Gas and Dust Emissions during the Emergency Opening of Blast Furnace Bleeders

et al. 2022

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The article presents the solution adopted in an existing blast furnace with only two safety valves to minimize the dust and gas emissions to the atmosphere, in case of emergency relief due to abnormal overpressure during operating issues in the blast furnace process. Before the implementation of the system, several openings of the emergency bleeder valves were observed: These led to sensitive pollutant emissions, also in terms of acoustic and visive events, with high impact on the surrounding environment. The new relief system, in addition to the existing bleeder valves, has been engineered with a Computational Fluid Dynamic (CFD) analysis using Ansys Fluent to find out the most effective solution and to minimize modifications on the plant. Few plant modifications, while guaranteeing the achievement of the target of reducing the bleeder openings, allow to reduce the plant shutdown costs for the modifications themselves and the maintenance costs during plant operation and to simplify the operating logic of the blast furnace overpressure control systems. The new installation increased the safety operation of the blast furnace, and it drastically reduced the bleeder valves openings—4% of the pre-intervention total opening time per year—and the associated emissions in spite of the rise of the pig iron production, as recorded by the monitoring and supervision system.

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Development of stabilization measures aimed at removing zinc with smelting products and accumulating titanium in the hearth of a blast furnace

Semenov,

Horupakha,

Vashchenko

et al. 2024

Engineering Reports

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This paper presents the results of the development of stabilization measures aimed at the removal of zinc with the products of melting and accumulation of titanium in the hearth of a blast furnace. The relevance of the development and use in practice of such measures is due to the unstable fuel and raw materials conditions for the production of cast iron, when their stabilization is a complex and difficult task, as well as the need to extend the campaign of blast furnaces during the overhaul period. The negative effect of zinc oxides on the condition of the blast furnace shaft lining, accompanied by slab formation, and the overconsumption of specific coke consumption, which occurs when zinc circulates in the volume of the blast furnace, require measures to remove zinc from the smelting products. The article proposes such measures, which consist of flushing according to the proposed schedule during the operation of the blast furnace at planned blowing parameters and with the provision of the necessary thermal reserve. In order to lengthen the campaign of a blast furnace, one of the most common methods for protecting the hearth lining is the periodic introduction of titanium‐containing materials into the charge of blast furnaces. The entry of titanium oxides into the furnace, as a rule, is ensured by the use of concentrate or specially prepared ilmenite briquettes with a high titanium content as part of the sinter charge, which can be introduced directly into the composition of the blast furnace charge. The article analyzes the experience of using titanium‐containing materials as part of a blast furnace charge and formulates measures to intensify skull formation in the hearth.

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Measures for Preventing Disruption in the Blast Furnace Operation under Use of Pulverized Coal

Cited by 13 publications

References 12 publications

Development and Implementation of Decision Support Systems for Blast Smelting Control in the Conditions of PrJSC “Kamet-Steel”

Development and Implementation of Decision Support Systems for Blast Smelting Control in the Conditions of PrJSC “Kamet-Steel”

CFD Analysis of Low-Cost Solutions to Minimize Gas and Dust Emissions during the Emergency Opening of Blast Furnace Bleeders

Development of stabilization measures aimed at removing zinc with smelting products and accumulating titanium in the hearth of a blast furnace

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