THERMOPHYSICS – RESEARCH BASE OF ENERGY- AND RESOURCE-SAVING METALLURGICAL TECHNOLOGIES

The article presents the achievements of the Ural scientific school  of scientists and metallurgists-heating engineers in improving a wide  spectrum of metallurgical technologies determined on a scientific basis of the creative union of two sciences – physics and computer science.  In recent years, mathematical modeling in combination with physical significantly reduce the time and scope of the search for optimal  solutions and thereby provide more reliable design and commissioning of thermal regimes of established technologies and equipment.  Moderni zation of sintering machines was carried out by introduction  of automatic control systems of thermal and gas-dynamic processes  and by equipping them by the ignition furnaces of new type. These activities with the intensification of heat-mass transfer processes have  improved the feasibility and environmental performance of the sinter  plants in Russia and abroad. Technological and thermo-physical solutions du ring the pellets firing are associated with organization of the  transfer system of gas flows and reconstruction of gas duct system. As  a result of reconstruction, the productivity of machines increased by  10  –  17  %, the specific fuel consumption decreased by 8  –  15  % and  the discharge of gases after their treatment decreased by 50  –  58  %.  Such reconstruction was made for firing machines in Russia, Brazil,  Iran. In recent years, the software has been developed for the solution  of complex problems in blast furnace production. It was introduced  into commercial operation at the largest metallurgical enterprise in  Russia – JSC “MMK”. New Cowper blast heaters for blast furnaces  are able to provide heating up to 1300  °C or more by the heating of  blast furnace gas and air used for heating of Cowper blast heaters at  failure from supplements of natural gas. The problem of processing of  metallurgical liquid slag is solved by the creation at factories of ferrous metallurgy of Russia, Ukraine, India and China of units, which  are capable to provide high productivity rate of slag discharge from 3   to 15  t/ min and by annual volumes of granular slag production – from  0.66 to 2.0 million tons. The installation of the company “Norilsk  Nickel” also works successfully. The improvement of thermal modes  and equipment of heating furnaces and installations for various purposes is based on mathematical modeling of thermophysical processes,  the basis of which is the created dynamic zonal-node method of modeling radiative and complex heat transfer. This method is successfully  developing. In recent years, new designs of furnaces are developed,  hundreds of furnaces were upgraded. The organization of thermal  modes of their operation has led to a significant reduction in specific  fuel consumption, improving the quality of metal heating and during  heat treatment – the quality of the finished product.

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