Benefits and risks of blast furnaces with high intensity

Increase in the intensity of blast furnace smelting at NLMK JSC is achieved by improving quality of coke and iron ore materials, by increasing pressure under the blast furnace mouth and by oxygen enrichment. It is accompanied by an increase in the rate of wustite indirect reduction and decrease in specific heat losses with cooling water. However, the risks of burden yield problems are significantly lower with high intensity. It has been established that with the change in quality of charge materials, reason for burden yield problems can be also the variation in ore load ratio along the furnace radius. A new method for diagnosing causes of burden yield problems was developed. Using method of mathematical modeling, effect of change in ore load and size of iron-ore materials on peripheral gases temperature change and the degree of CO use were analyzed. The method is based on analysis of joint change in gas temperature and degree of CO use in peripheral area. Analysis of peripheral gases temperature variation and degree of CO use makes it possible to identify reasons of pressure drops along the furnace height. As a result of analysis of pressure drops dynamics changes along the furnace height, there have been found signs that can be used to judge the probability of burden yield problems. The possibility of reducing pressure drops due to redistribution of ore load along the furnace radius and the amount of gases is considered. It is shown that various methods of reducing the amount of gases are accompanied by different changes in coke consumption and furnace productivity. Mathematical model has been developed to select the best combination of parameters changing of the fuel-enriched blast in specific conditions.

1. Kurunov I.F., Filatov S.V., Tikhonov D.N., Basov V.I. Indirect reduction in blast-furnace smelting. Steel in Translation. 2016, vol. 46, no. 8, pp. 583-588.

2. Gotlib A.D. Domennyi protsess [Blast furnace process]. Moscow: Metallurgiya, 1966, 503 p. (In Russ.).

3. Tovarovskii I.G., Lyalyuk V.P. Evolyutsiya domennoi plavki [Evolution of blast furnace smelting]. Dnepropetrovsk: Porogi, 2001, 424 p. (In Russ.).

4. Tovarovskii I.G., Bondarenko V.I. Intensity of course and specific consumption of coke in modern and advanced conditions of blast furnace smelting. Stal’. 1978, no. 3, pp. 203-206. (In Russ.).

5. Adeline Morcel, Lena Sundqvist Okvist, Joel Orre, Bo Bjorkman, Per Lagrerwall. Low CO2 Ironmaking in the Blast Furnace. In: Proceedings of the 7th European Coke and Ironmaking Congress -ECIC 2016, pp. 274-283.

6. Tarasov V.P. Gazodinamika domennogo protsessa [Gas dynamics of blast furnace process]. Moscow: Metallurgiya, 1990, 215 p. (In Russ.).

7. Kitaev B.I., Yaroshenko Yu.G., Lazarev B.D. Teploobmen v domennoi pechi [Heat exchange in blast furnace]. Moscow: Metallurgiya, 1966, 355 p. (In Russ.).

8. Kitaev B.I., Yaroshenko Yu.G., Sukhanov E.L. etc. Teplotekhnika domennogo protsessa [Heat engineering of blast furnace process]. Moscow: Metallurgiya, 1978, 248 p. (In Russ.).

9. Metallurgiya chuguna: Ucheb. dlya vuzov [Cast iron metallurgy: Proc. for universities]. Yusfin Yu.S. ed. Moscow: Akademkniga, 2004, 774 p. (In Russ.).

10. Dmitriev A.N., Shumakov N.S., Leont’ev L.I., Onorin O.P. Osnovy teorii i tekhnologii domennoi plavki [Fundamentals of theory and technology of blast furnace smelting]. Ekaterinburg: UrO RAN, 2005, 545 p. (In Russ.).

11. Spirin N.A., Ovchinnikov Yu.N., Shvydkii V.S., Yaroshenko Yu.G. Teploobmen i povyshenie effektivnosti domennoi plavki [Heat transfer and increasing efficiency of blast furnace smelting]. Yaroshenko Yu.G. ed. Ekaterinburg: UGTU-UPI, 1995, 243 p. (In Russ.).

12. Zagainov S.A., Filatov S.V., Gileva L.Y., Lozovich A.V, Jimoh S.O. Controlling the peripheral temperature of the blast furnace. Steel in Translation. 2016, vol. 46, no. 6. pp. 378-383.

13. Gileva L.Yu., Zagainov S.A., Titov V.N., Galkin A.V. Development of structured software for solving a set of technological problems of organizing and managing of blast furnace process. In: Sovremen-nye slozhnye sistemy upravleniya. Materialy XII Mezhdunarodnoi nauchno-prakticheskoi konferentsii, t. 1 [Modern Complex Control Systems. Materials of 12th Int. Sci.-Pract. Conf. Vol. 1]. Lipetsk: izd. Lipetskogo gosudarstvennogo tekhnicheskogo universiteta, 2017, pp. 205-209. (In Russ.).

14. Korshikov G.V., Titov V.N., Mikhailov V.G., Karpov A.V. Fuel consumption and reduction kinetics in blast furnaces. Steel in Translation. 2016, vol. 46, no. 2, pp. 125-131.

15. Bokovikov B.A., Moikin V.I., Gordon Y.M., Spirin N.A., Shvid-kii V.S., Yaroshenko Y.G., Lavrov V.V. Analysis of Transient Processes in Blast Furnace. AISTech Proceedings. 4 -7 May 2015. Cleveland. Oh. USA. P. 237-244.

16. Onorin O.P., Spirin N.A., Terent’ev V.L. etc. Komp’yuternye metody modelirovaniya domennogo protsessa [Computer simulation of blast furnace process]. Ekaterinburg: UGTU-UPI, 2005, 301 p. (In Russ.).

17. Ulakhovich V.A., Raikh E.I., Sholeninov V.M. etc. Study of the dynamics of blast furnace process. Stal’. 1975, no. 1, pp. 9-14. (In Russ.).

18. Pokhvisnev A.N., Kurunov I.F., Zavidonskii V.A. etc. Experimental determination of dynamic characteristics of blast furnace. In: Pod-gotovka domennogo syr’ya k plavke: Sb. trudov MISiS [Preparation of blast furnace materials for smelting: Coll. of MISiS proc.]. Moscow: Metallurgiya, 1971, no. 69, pp. 118-121. (In Russ.).

19. Avdeev V.P., Danielyan T.M., Belousov P.G. Identifikatsiya pro-myshlennykh ob”ektov s uchetom nestatsionarnostei i obratnykh svyazei [Identification of industrial facilities with regard to nonsta-tionarity and feedback]. Novokuznetsk: SMI, 1984, 88 p. (In Russ.).

20. Kurunov I.F., Dobroskok V.A., Isteev A.I., Fursova L.A., Plesh-kov V.I., Shcherbakov P.I. Determining dynamic characteristics of 5000 m3 blast furnace. Steel USSR. 1977, vol. 7, no. 9, pp. 496-497.

21. Serov V.V., Mikhalevich A.G. Dynamics of formation of the composition of conversion pig iron in blast furnaces. Metallurgist. 1983, vol. 27, no. 1, pp. 9-13.

22. Jun-ichiro Y. Mathematical model of blast furnace, Progress and Application to New Technology Development, 6th Int. Congress on the Science and Technology of Ironmaking, Rio de Janeiro, Brazil, 2012, pp. 1660-1673.

23. Flierman G.A., Oderkerk H. Numerical simulation of the blast furnace process. Math. Process Models, Iron and Steelmak. Amsterdam, 1973, pp. 40-50; London, Discussion, 1975, pp. 37-50.