The hearth of “heat transfer method” and the ceramic cup synthetic hearth bottom of “heart isolation method” are two most popular designs for blast furnace (BF). Although there are successful real examples, some d...The hearth of “heat transfer method” and the ceramic cup synthetic hearth bottom of “heart isolation method” are two most popular designs for blast furnace (BF). Although there are successful real examples, some disadvantages, for instance large heat loss and high cost, still exist for these designs. According to the theory of heat transfer, based on the calculation of temperature distribution of the hearth bottom, it is elucidated that all brick layers at the hearth bottom may not be considered as the only reason why different structures exhibited different temperature distributions although total heat resistance is the same, and then based on the effect of hot metal and cold water on different temperature distribution ranges, the concepts of “heat resistance” and “cooling enhancement” are put forth. Based on this, the disadvantages and the factors affecting temperature distribution, of the two types of hearth bottoms were illustrated. On the basis of these analyses, a novel structure for BF hearth bottom designing that can easily form “self-protecting” slag layer stably, called “the method of gradient brick layout that has an optimum combination of cooling enhancement and heat resistance” was proposed; it can not only prolong the hearth bottom longevity but also reduce the cost and heat loss. Also, the optimum arrangement of thermal couples in hearth bottom was suggested based on the previous studies on erosion prediction carried out by the author.展开更多
One of the bottlenecks of the blast furnace (BF) campaign is the life length of hearth bottom. The basic reason for the erosion of hearth bottom is its direct contact with hot metal. According to the theory of heat tr...One of the bottlenecks of the blast furnace (BF) campaign is the life length of hearth bottom. The basic reason for the erosion of hearth bottom is its direct contact with hot metal. According to the theory of heat transfer, models of BF hearth bottom are built based on the actual examples using software and VC language, and the calculated results are in good agreement with the data of BF dissection after blowing out. The temperature distribution and the capability of the resistance to erosion for different structures of hearth bottom are analyzed, especially the two prevalent kinds of hearth bottom arrangements called “the method of heat transfer” for all-carbon brick bottom and “the method of heat isolation” for ceramic synthetic hearth bottom. Features of the two kinds of hearth bottoms are analyzed. Also the different ways of protecting the hearth bottom are clarified, according to some actual examples. After that, the same essence of prolonging life, and the fact that the existence of a “protective skull” with low thermal conductivity between the hot metal and brick layers is of utmost importance are shown.展开更多
One of the methods forming the shell is to appropriately design the cooling staves and hearth without overheating duringthe campaign life of the furnace. The three-dimensional steady mathematical models for calculatin...One of the methods forming the shell is to appropriately design the cooling staves and hearth without overheating duringthe campaign life of the furnace. The three-dimensional steady mathematical models for calculating the temperature distribution inthe coolers and two-dimensional unsteady mathematical models with phase-change latent heat for calculating the temperature dis-tribution of the hearth bottom were established. The calculation results show that the formation of the slag-metal protection shell canbe achieved by optimizing the design parameters of the coolers. Increasing the heat conductivity of the carbon brick can move theisothermal line of 1150℃ upward outside the hearth bottom.展开更多
The hearth of “heat transfer method” and the ceramic cup synthetic hearth bottom of “heart isolation method” are two most popular designs for blast furnace (BF). Although there are successful real examples, some d...The hearth of “heat transfer method” and the ceramic cup synthetic hearth bottom of “heart isolation method” are two most popular designs for blast furnace (BF). Although there are successful real examples, some disadvantages, for instance large heat loss and high cost, still exist for these designs. According to the theory of heat transfer, based on the calculation of temperature distribution of the hearth bottom, it is elucidated that all brick layers at the hearth bottom may not be considered as the only reason why different structures exhibited different temperature distributions although total heat resistance is the same, and then based on the effect of hot metal and cold water on different temperature distribution ranges, the concepts of “heat resistance” and “cooling enhancement” are put forth. Based on this, the disadvantages and the factors affecting temperature distribution, of the two types of hearth bottoms were illustrated. On the basis of these analyses, a novel structure for BF hearth bottom designing that can easily form “self-protecting” slag layer stably, called “the method of gradient brick layout that has an optimum combination of cooling enhancement and heat resistance”was proposed; it can not only prolong the hearth bottom longevity but also reduce the cost and heat loss. Also, the optimum arrangement of thermal couples in hearth bottom was suggested based on the previous studies on erosion prediction carried out by the author.展开更多
Furnace lining erosion is closely related to the operation stability and safety. The detection technology for hearth lining thickness of blast furnace was introduced.By using the data of thermocouples installed in the...Furnace lining erosion is closely related to the operation stability and safety. The detection technology for hearth lining thickness of blast furnace was introduced.By using the data of thermocouples installed in the bottom of furnace hearth,a mathematical model of erosion was established; the real state of the hearth and bottom erosion was studied; the erosion condition was followed,serving for the furnace longevity.展开更多
A variety of techniques, such as chemical analysis, scanning electron microscopy-energy dispersive spectroscopy, and X-ray diffraction, were applied to characterize the adhesion protective layer formed below the blast...A variety of techniques, such as chemical analysis, scanning electron microscopy-energy dispersive spectroscopy, and X-ray diffraction, were applied to characterize the adhesion protective layer formed below the blast furnace taphole level when a certain amount of titanium-bearing burden was used. Samples of the protective layer were extracted to identify the chemical composition, phase assemblage, andistribution. Furthermore, the formation mechanism of the protective layer was determined after clarifying the source of each componenFinally, a technical strategy was proposed for achieving a stable protective layer in the hearth. The results show that the protective layemainly exists in a bilayer form in the sidewall, namely, a titanium-bearing layer and a graphite layer. Both the layers contain the slag phaswhose major crystalline phase is magnesium melilite(Ca_2Mg Si_2O_7) and the main source of the slag phase is coke ash. It is clearly determinethat solid particles such as graphite, Ti(C,N) and Mg Al_2O_4 play an important role in the formation of the protective layer, and the key factofor promoting the formation of a stable protective layer is reasonable control of the evolution behavior of coke.展开更多
To solve the problem of the low added value Zn-containing rotary hearth furnace(RHF)dust,two deep eutectic solvents(DESs)were employed,such as choline chloride-urea(ChCl-urea)and choline chloride-oxalic acid dihydrate...To solve the problem of the low added value Zn-containing rotary hearth furnace(RHF)dust,two deep eutectic solvents(DESs)were employed,such as choline chloride-urea(ChCl-urea)and choline chloride-oxalic acid dihydrate(CC-OA)solvent and Zn-containing RHF dust(water-washed)as the research target.Then,we prepared ZnO nanoparticles using two DESs or their combination,namely,ChCl-urea(Method A),CC-OA(Method B),first CC-OA and then ChCl-urea(Method B-A)and first ChCl-urea and then CCOA(Method A-B),respectively.The effects of these methods on the properties of as-obtained precursors and ZnO nanoparticles were investigated in detail.The results indicated that the precursor obtained by Method A was Zn_(4)CO_(3)(OH)_(6)·H_(2)O,and those by Methods B,B-A,and A-B were all ZnC_(2)O_(4)·2H_(2)O.Moreover,the decomposition steps of the last three methods were similar.The ZnO contents of 95.486%,99.768%,99.733%,and 99.76%were obtained by Methods A,B,B-A,and A-B,respectively.Methods A,B,and B-A led to the formation of spherical and agglomerated ZnO nanoparticles with normal size distributions,where Method B showed the best distribution with an average diameter 25 nm.The ZnO nanoparticles obtained by the Method A-B did not possess good properties.展开更多
The campaign life of blast furnace (BF) hearths has become the limiting factor for safety and high efficiency production of modern BFs. However, the early warning mechanism of hearth security has not been clear. In th...The campaign life of blast furnace (BF) hearths has become the limiting factor for safety and high efficiency production of modern BFs. However, the early warning mechanism of hearth security has not been clear. In this article, based on heat transfer calculations, heat flux and erosion monitoring, the features of heat flux and erosion were analyzed and compared among different types of hearths. The primary detecting elements, mathematical models, evaluating standards, and warning methods were discussed. A novel early warning mechanism with the three-level quantificational standards was proposed for BF hearth security.展开更多
The liquid flow in blast furnace hearth can result in the erosion of hearth. To prolong the campaign life of blast furnace, the effects of coke bed structure, coke porosity and deepness of taphole on liquid flow in he...The liquid flow in blast furnace hearth can result in the erosion of hearth. To prolong the campaign life of blast furnace, the effects of coke bed structure, coke porosity and deepness of taphole on liquid flow in hearth were studied by κ-ε model under different conditions. The results show that with the decrease of coke porosity, the peripheral flow is enhanced. Moreover, the existence of narrow coke free zone and the deepness reduction of taphole can increase the flowability on the bottom of hearth.展开更多
A mathematical model was established to describe the direct reduction of pellets in a rotary hearth furnace (RHF). In the model, heat transfer, mass transfer, and gas-solid chemical reactions were taken into account. ...A mathematical model was established to describe the direct reduction of pellets in a rotary hearth furnace (RHF). In the model, heat transfer, mass transfer, and gas-solid chemical reactions were taken into account. The behaviors of iron metallization and dezincification were analyzed by the numerical method, which was validated by experimental data of the direct reduction of pellets in a Si-Mo furnace. The simulation results show that if the production targets of iron metallization and dezincification are up to 80% and 90%, respectively, the furnace temperature for high-temperature sections must be set higher than 1300 C. Moreover, an undersupply of secondary air by 20% will lead to a decline in iron metallization rate of discharged pellets by 10% and a decrease in dezincing rate by 13%. In addition, if the residence time of pellets in the furnace is over 20 min, its further extension will hardly lead to an obvious increase in production indexes under the same furnace temperature curve.展开更多
A long campaign life of blast furnaces is heavily linked to the existence of a protective layer in their hearths. In this work, we conducted dissection studies and investigated damage in blast furnace hearths to estim...A long campaign life of blast furnaces is heavily linked to the existence of a protective layer in their hearths. In this work, we conducted dissection studies and investigated damage in blast furnace hearths to estimate the formation mechanism of the protective layer. The results illustrate that a significant amount of graphite phase was trapped within the hearth protective layer. Furthermore, on the basis of the thermodynamic and kinetic calculations of the graphite precipitation process, a precipitation potential index related to the formation of the graphite-rich protective layer was proposed to characterize the formation ability of this layer. We determined that, under normal operating conditions, the precipitation of graphite phase from hot metal was thermodynamically possible. Among elements that exist in hot metal, C, Si, and P favor graphite precipitation, whereas Mn and Cr inhibit this process. Moreover, at the same hot-face temperature, an increase of carbon concentration in hot metal can shorten the precipitation time. Finally, the results suggest that measures such as reducing the hot-face temperature and increasing the degree of carbon saturation in hot metal are critically important to improve the precipitation potential index.展开更多
文摘The hearth of “heat transfer method” and the ceramic cup synthetic hearth bottom of “heart isolation method” are two most popular designs for blast furnace (BF). Although there are successful real examples, some disadvantages, for instance large heat loss and high cost, still exist for these designs. According to the theory of heat transfer, based on the calculation of temperature distribution of the hearth bottom, it is elucidated that all brick layers at the hearth bottom may not be considered as the only reason why different structures exhibited different temperature distributions although total heat resistance is the same, and then based on the effect of hot metal and cold water on different temperature distribution ranges, the concepts of “heat resistance” and “cooling enhancement” are put forth. Based on this, the disadvantages and the factors affecting temperature distribution, of the two types of hearth bottoms were illustrated. On the basis of these analyses, a novel structure for BF hearth bottom designing that can easily form “self-protecting” slag layer stably, called “the method of gradient brick layout that has an optimum combination of cooling enhancement and heat resistance” was proposed; it can not only prolong the hearth bottom longevity but also reduce the cost and heat loss. Also, the optimum arrangement of thermal couples in hearth bottom was suggested based on the previous studies on erosion prediction carried out by the author.
基金Item Sponsored by National Natural Science Foundation of China (60472095)
文摘One of the bottlenecks of the blast furnace (BF) campaign is the life length of hearth bottom. The basic reason for the erosion of hearth bottom is its direct contact with hot metal. According to the theory of heat transfer, models of BF hearth bottom are built based on the actual examples using software and VC language, and the calculated results are in good agreement with the data of BF dissection after blowing out. The temperature distribution and the capability of the resistance to erosion for different structures of hearth bottom are analyzed, especially the two prevalent kinds of hearth bottom arrangements called “the method of heat transfer” for all-carbon brick bottom and “the method of heat isolation” for ceramic synthetic hearth bottom. Features of the two kinds of hearth bottoms are analyzed. Also the different ways of protecting the hearth bottom are clarified, according to some actual examples. After that, the same essence of prolonging life, and the fact that the existence of a “protective skull” with low thermal conductivity between the hot metal and brick layers is of utmost importance are shown.
基金The work was financially supported by"95"key project of China(No.1997-02-08).]
文摘One of the methods forming the shell is to appropriately design the cooling staves and hearth without overheating duringthe campaign life of the furnace. The three-dimensional steady mathematical models for calculating the temperature distribution inthe coolers and two-dimensional unsteady mathematical models with phase-change latent heat for calculating the temperature dis-tribution of the hearth bottom were established. The calculation results show that the formation of the slag-metal protection shell canbe achieved by optimizing the design parameters of the coolers. Increasing the heat conductivity of the carbon brick can move theisothermal line of 1150℃ upward outside the hearth bottom.
基金This work was financially supported by the National Natural Science Foundation of China (No.60472095)
文摘The hearth of “heat transfer method” and the ceramic cup synthetic hearth bottom of “heart isolation method” are two most popular designs for blast furnace (BF). Although there are successful real examples, some disadvantages, for instance large heat loss and high cost, still exist for these designs. According to the theory of heat transfer, based on the calculation of temperature distribution of the hearth bottom, it is elucidated that all brick layers at the hearth bottom may not be considered as the only reason why different structures exhibited different temperature distributions although total heat resistance is the same, and then based on the effect of hot metal and cold water on different temperature distribution ranges, the concepts of “heat resistance” and “cooling enhancement” are put forth. Based on this, the disadvantages and the factors affecting temperature distribution, of the two types of hearth bottoms were illustrated. On the basis of these analyses, a novel structure for BF hearth bottom designing that can easily form “self-protecting” slag layer stably, called “the method of gradient brick layout that has an optimum combination of cooling enhancement and heat resistance”was proposed; it can not only prolong the hearth bottom longevity but also reduce the cost and heat loss. Also, the optimum arrangement of thermal couples in hearth bottom was suggested based on the previous studies on erosion prediction carried out by the author.
文摘Furnace lining erosion is closely related to the operation stability and safety. The detection technology for hearth lining thickness of blast furnace was introduced.By using the data of thermocouples installed in the bottom of furnace hearth,a mathematical model of erosion was established; the real state of the hearth and bottom erosion was studied; the erosion condition was followed,serving for the furnace longevity.
基金financially supported by the Natural Science Foundation of China(No.51304014)the Natural Science Foundation of China and Baosteel(No.51134008)the National Basic Research Program of China(No.2012CB720401)
文摘A variety of techniques, such as chemical analysis, scanning electron microscopy-energy dispersive spectroscopy, and X-ray diffraction, were applied to characterize the adhesion protective layer formed below the blast furnace taphole level when a certain amount of titanium-bearing burden was used. Samples of the protective layer were extracted to identify the chemical composition, phase assemblage, andistribution. Furthermore, the formation mechanism of the protective layer was determined after clarifying the source of each componenFinally, a technical strategy was proposed for achieving a stable protective layer in the hearth. The results show that the protective layemainly exists in a bilayer form in the sidewall, namely, a titanium-bearing layer and a graphite layer. Both the layers contain the slag phaswhose major crystalline phase is magnesium melilite(Ca_2Mg Si_2O_7) and the main source of the slag phase is coke ash. It is clearly determinethat solid particles such as graphite, Ti(C,N) and Mg Al_2O_4 play an important role in the formation of the protective layer, and the key factofor promoting the formation of a stable protective layer is reasonable control of the evolution behavior of coke.
基金Fund by Postgraduate Research&Practice Innovation Program of Jiangsu Province(No.KYCX20_3134)
文摘To solve the problem of the low added value Zn-containing rotary hearth furnace(RHF)dust,two deep eutectic solvents(DESs)were employed,such as choline chloride-urea(ChCl-urea)and choline chloride-oxalic acid dihydrate(CC-OA)solvent and Zn-containing RHF dust(water-washed)as the research target.Then,we prepared ZnO nanoparticles using two DESs or their combination,namely,ChCl-urea(Method A),CC-OA(Method B),first CC-OA and then ChCl-urea(Method B-A)and first ChCl-urea and then CCOA(Method A-B),respectively.The effects of these methods on the properties of as-obtained precursors and ZnO nanoparticles were investigated in detail.The results indicated that the precursor obtained by Method A was Zn_(4)CO_(3)(OH)_(6)·H_(2)O,and those by Methods B,B-A,and A-B were all ZnC_(2)O_(4)·2H_(2)O.Moreover,the decomposition steps of the last three methods were similar.The ZnO contents of 95.486%,99.768%,99.733%,and 99.76%were obtained by Methods A,B,B-A,and A-B,respectively.Methods A,B,and B-A led to the formation of spherical and agglomerated ZnO nanoparticles with normal size distributions,where Method B showed the best distribution with an average diameter 25 nm.The ZnO nanoparticles obtained by the Method A-B did not possess good properties.
基金financially supported by the National Natural Science Foundation of China (No. 61271303)the Fundamental Research Funds for the Central Universities of China (No. FRF-TP-12-029A)
文摘The campaign life of blast furnace (BF) hearths has become the limiting factor for safety and high efficiency production of modern BFs. However, the early warning mechanism of hearth security has not been clear. In this article, based on heat transfer calculations, heat flux and erosion monitoring, the features of heat flux and erosion were analyzed and compared among different types of hearths. The primary detecting elements, mathematical models, evaluating standards, and warning methods were discussed. A novel early warning mechanism with the three-level quantificational standards was proposed for BF hearth security.
文摘The liquid flow in blast furnace hearth can result in the erosion of hearth. To prolong the campaign life of blast furnace, the effects of coke bed structure, coke porosity and deepness of taphole on liquid flow in hearth were studied by κ-ε model under different conditions. The results show that with the decrease of coke porosity, the peripheral flow is enhanced. Moreover, the existence of narrow coke free zone and the deepness reduction of taphole can increase the flowability on the bottom of hearth.
基金financially supported by the National Key Basic Research and Development Program of China(No. 2012CB720405)
文摘A mathematical model was established to describe the direct reduction of pellets in a rotary hearth furnace (RHF). In the model, heat transfer, mass transfer, and gas-solid chemical reactions were taken into account. The behaviors of iron metallization and dezincification were analyzed by the numerical method, which was validated by experimental data of the direct reduction of pellets in a Si-Mo furnace. The simulation results show that if the production targets of iron metallization and dezincification are up to 80% and 90%, respectively, the furnace temperature for high-temperature sections must be set higher than 1300 C. Moreover, an undersupply of secondary air by 20% will lead to a decline in iron metallization rate of discharged pellets by 10% and a decrease in dezincing rate by 13%. In addition, if the residence time of pellets in the furnace is over 20 min, its further extension will hardly lead to an obvious increase in production indexes under the same furnace temperature curve.
基金supported the National Science Foundation for Young Scientists of China (No. 51304014)the Open Foundation of the State Key Laboratory of Advanced Metallurgy (No. 41603007)
文摘A long campaign life of blast furnaces is heavily linked to the existence of a protective layer in their hearths. In this work, we conducted dissection studies and investigated damage in blast furnace hearths to estimate the formation mechanism of the protective layer. The results illustrate that a significant amount of graphite phase was trapped within the hearth protective layer. Furthermore, on the basis of the thermodynamic and kinetic calculations of the graphite precipitation process, a precipitation potential index related to the formation of the graphite-rich protective layer was proposed to characterize the formation ability of this layer. We determined that, under normal operating conditions, the precipitation of graphite phase from hot metal was thermodynamically possible. Among elements that exist in hot metal, C, Si, and P favor graphite precipitation, whereas Mn and Cr inhibit this process. Moreover, at the same hot-face temperature, an increase of carbon concentration in hot metal can shorten the precipitation time. Finally, the results suggest that measures such as reducing the hot-face temperature and increasing the degree of carbon saturation in hot metal are critically important to improve the precipitation potential index.
