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Development and implementation of new approaches to diagnostics and management of the blast-furnace smelting

Work number - M 27 AWARDED

Authors: Ph.D. Shumelchyk E.I., Horupaha V.V.

Submitted by Z.I. Nekrasov Iron & Steel Institute of the National Academy of Sciences of Ukraine, Dnipro.

The aim of the work is to improve and implement the methods of diagnostics and management of the blast furnaces that ensure its energy efficiency during the charge and fuel conditions changing.

For conditions of transitional modes of blast-furnace smelting in order to ensure its stability during the qualitative and quantitative composition changing of the charge materials components, and the fuel additives changing in the blow as well, the complex information usage of the modern automated control facilities is scientifically grounded. Those are: stationary thermal probes and thermal couples of lining along the height and circumference of a blast furnace to detect the new patterns and relationships of processes with their subsequent application to substantiate the choice of control influences, and also there was proposed the new approach to the choice of energy efficient modes of charging.

The scientific novelty of work: a new approach to the choice of rational charging programs is grounded, which ensures a stable economic course of a blast furnace during the changing of the technological conditions of melting; the temperature parameters of the gas flow distribution over the radius of the furnace have been developed for the first time, their rational ranges of change were established at work in various gas-dynamic and fuel conditions; the requirements for the distribution of gas flow temperatures along the radius of the furnace have been formulated for the first time; for the first time, based on an analysis of the furnace lining temperatures along the furnace height during five years of its operation, there have been established the temperature limits at which the lining of the middle and the top of the mine is partially or fully developed; for the lining of the bottom of the mine, the decomposition and shoulders, there have been established: the temperature, which testifies to the formation in the lower zone of the furnace of an unstable protective garrison and the temperature, which characterizes its complete absence; for the first time, there has been studied the influence of the blowing mode while an increased amount of steam, natural gas, natural gas with pulverized coal and separately pulverized fuel using to change the shape of the distribution curve of the peripheral gas flow through the height of the furnace from the tar nozzle to the plunger, which became a prerequisite for the identification method development of the boundary of the viscoelastic statement zone in the furnace peripheral zone.

The scientific and practical values of the work results are: the model system of decision making support for choosing and adjusting charging programs; rational charging modes which allowed to provide a stable and economical course of melting, also they allowed to reduce the temperature of the gas stream of the peripheral zone along the entire furnace height while using the pulverized coal without the mine’s lining and provide the cooling system safety; the expert module for adjusting the charging program using established rational ranges for changing the temperature distribution of the gas flow, the method of the reasonable choice of the closed air lids location; new positions for the blast furnace blows after their long stops, which allowed to reach the targets and provide the safety of the cooling system and armor of furnaces.

The results of the work are essential for the metallurgical complex of Ukraine, have no analogues in Ukraine and are at the level of the best world developments in the blast-furnace smelting. The effectiveness of the results of work is confirmed by the total economic effect for five years (2011-2016), which amounted to 5.1 million dollars of USA.

The main statements of the scientific work are published in 18 articles, 11 articles of which are in foreign publications. 8 articles on the topic are published in the magazines included in the Scopus database. The number of references to publications on the topic of scientific work of the authors is – 15 and h–index – 2 (according to the database "Scopus"); 40 and h–index – 4 (according to the Google Scholar database). Total number of authors' publications is 55.