Mathematical modeling in education process, research and low-energy metallurgical technologies

The article presents a retrospective of scientific and educational activities of the Chair “Applied Information Technologies and Programming”. At the time of organization (in 1980), the Chair’s staff has set a task: to create specialists of a new plan (problem programmers) who simultaneously possess methods of research and mathematical description of specific objects (including metallurgical ones) and computer programming. By special order of the RSFSR Ministry of Higher Education, a new specialization was created in experimental order: “Computer support and computers in metallurgy”, which after 20 years of pedagogical experiment developed into the specialty “Information systems and technologies (by industry)”. The Chair was the first to produce such specialists not only in the region, but also in the country, and this experience was then adopted by other universities. The staff of the newly created Chair was one of the first in the country to create mathematical models of metallurgical processes, and then simulators and training systems based on them. An activity-based approach to learning based on a mathematical model of specific subject area was adopted as a pedagogical concept. Many years of experience in applying this approach has shown its high effectiveness. For the first time in metallurgy, a concept and a set of models of fundamentally new metallurgical process and unit with elements of self-organization was developed, characterized by an order of magnitude lower specific volume and one and a half times less energy consumption. Together with the designers and specialists of ZapSibMetKombinat (West Siberian Metallurgical Plant), a large-scale pilot installation of JER unit process was created, which confirmed the correctness of the proposed concept, worked out the main design points, and showed the practical feasibility of a number of new technologies developed. In a new process creating, software and tool systems were worked out: an algorithm for calculating the interrelated parameters of the process and the unit, the “Engineeringmetallurgy” system, a system for modeling complex heat transfer processes, and a system for simulating the particle level using the Monte Carlo method.

scientific research, educational activity, mathematical model, simulator, training system, theory of self-organization, new metallurgical process

1. Tsymbal V.P. Control of oxidizing ability of open hearth furnace based on the static model using boiling bath self-regulating. Izvestiya. Ferrous Metallurgy. 1975, no. 4, pp. 162–165. (In Russ.).

2. Kurdyumov S.P., Malinetskii G.G. Sinergetika – teoriya samoorganizatsii [Synergetics – Theory of self-organization]. Мoscow: Znanie, 1983, 64 p. (In Russ.).

3. Nicolis G., Prigogine I. Self-Organization in Non-Equilibrium Systems. New York: Wiley, 1977, 504 p.

4. Haken H. Synergetics. Berlin: Springer, 1978, 351 p.

5. Prigogine I., Stengers I. Order out of Chaos. Man’s New Dialogue with Nature. New York: Bantam Books, 1984, 349 p.

6. Klimontovich Yu.L. Turbulentnoe dvizhenie i struktura khaosa. Novyi podkhod k statisticheskoi teorii otkrytykh sistem [Turbulent motion and chaos structure. A new approach to statistical theory of open systems]. Moscow: Nauka, 1990, 320 p. (In Russ.).

7. Knyazeva E.N., Kurdyumov S.P. Osnovaniya sinergetiki: Rezhimy s obostreniem, samoorganizatsiya, tempomiry [Base of synergetics: Exacerbated modes, self-organization, temp worlds]. St. Petersburg: Aleteiya, 2002, 414 p. (In Russ.).

8. Tsymbal V.P., Mochalov S.P., Rybenko I.A. etc. Protsess SER metallurgicheskii struino-emul’sionnyi reaktor [JER process – metallurgical jet-emulsion reactor]. Moscow: Metallurgizdat, 2014, 488 p. (In Russ.).

9. Tsymbal V.P., Mochalov S.P., Shakirov K.M. Controlling the composition of the metal in the direct reduction of dust-sized materials and waste products in a jet-emulsion reactor. Metallurgist. 2015, vol. 59, no. 1-2, pp. 119−125.

10. Nakoryakov V.E., Pokusaev B.G., Shreiber I.R. Wave propagation in Gas-Liquid Media. Boca Raton: CRC Press, 1993, 222 p.

11. Gordon Ya.M., Spirin N.A., Shvydkii V.S. etc. Scrap metal as an important secondary resource for improving energy efficiency and resource saving in steel industry. In: Metallurgiya: tekhnologii, innovatsii, kachestvo. Ch. 1. [Metallurgy: technology, innovation, quality. Part 1]. Novokuznetsk, 2017, pp. 390–400. (In Russ.).

12. Korostelev A.A., S’emshchikov N.S., Semin A.E. etc. Increase in EAF lining life with use of hot-briquetted iron in a charge. Refractories and Industrial Ceramics. 2018, vol. 59, no. 2, pp. 107–114.

13. Lückhoff J., Apfel J., Buttler J. Application of different kinds of metal charge materials in EAF operation. Chernye metally. 2017, no. 10, pp. 28–33. (In Russ.).

14. Abd Elkader M., Fathy A., Eissa M., Sayed Sh. Effect of direct reduced iron proportion in metallic charge on technological parameters of EAF steelmaking process. ISIJ International. 2016, vol. 5, no. 2, pp. 2016–2024.

15. Sulimova M.A., Litvinova T.E. Metallurgical production waste treatment efficiency increase. Ecology, Economics, Education and Legislation Conference Proceedings, SGEM. 2016, vol. II, pp. 569–575.

16. Duarte P., Beserra Kh. Production of high-carbon iron by direct carbon reduction (DRI) using Energiron DR technology. Chernye metally. 2016, no. 6, pp. 24–30. (In Russ.).

17. Dorofeev G.A., Yantovskii P.R., Smirnov K.G., Stepanov Ya.M. The process “orien” for smelting of high-quality steels from ore and energy raw materials based on the principle of the energy self-supplying. Chernye metally. 2017, no. 5, pp. 17–23. (In Russ.).

18. Kinaci M.E., Lichtenegger T., Schneiderbauer S. Direct reduction of iron-ore in fluidized beds. In: 28 th European Symposium on Computer Aided Process Engineering, Graz, AUSTRIA, 2018, vol. 43, pp. 217–222.

19. Schenck J., Lüngen H. Review of application of DRI processes in EC countries. Chernye metally. 2017, no. 2, pp. 25–31. (In Russ.).

20. Meijer K, van der Stel J., Zeilstra C. etc. The HIsarna ironmaking process. In: Proc. METEC and 2 nd ESTAD, 15–19 June 2015, Düsseldorf, Germany, pp. 15–19.

21. Basdag A., Arol, A.I. Coating of iron oxide pellets for direct reduction. Scandinavian Journal of Metallurgy. 2002, vol. 31, no. 3, pp. 229–233.

22. Rybenko I.A., Olennikov A.A. Inzhiniring – Metallurgiya [Engineering – Metallurgy]. Certificate of state registration of computer program no. 2017617445. 2017. (In Russ.).

23. Vatolin N.A., Moiseev G.K., Trusov B.G. Termodinamicheskoe modelirovanie v vysokotemperaturnykh neorganicheskikh sistemakh [Thermodynamic modeling in high-temperature inorganic systems]. Moscow: Metallurgiya, 1994, 353 p. (In Russ.).

24. Kroese D.P., Brereton T., Taimre T., Botev Z.I. Why the Monte Carlo method is so important today. Wiley Interdisciplinary Reviews: Computational Statistics. 2014, vol. 6, no. 6, pp. 386–392.

25. Tsymbal V., Olennikov A., Rybenko I. etc. Mathematical Modeling of SER Jet-Emulsion Process. In: Sustainable Industrial Processing Summit & Exhibition SIPS 2017. Vol. 9: Iron and Steel, Metals and Alloys. Kongoli F., Conejo A., Gomez-Marroquin M.C. eds. Montreal (Canada): FLOGEN Star Outreach, pp. 104–115.