A significant part of the steel industry wastes are steel smelting slags, the output of which is estimated at an average from 150 to 200 kg/ton of steel. With the existing volumes of steel production in theRussian Federationannually approximately 9 million tons of steelmaking slag is generated. They contain 8 – 11 % of pure metal, and 15 – 40 % in the form of iron oxides. The total amount of iron reaches 20 – 30 % of the mass of the slag. Steelmaking slags are valuable iron-containing technogenic materials that require further processing and recycling in the production. For the processing of the formed steel-smelting slags, JSC “EVRAZ ZSMK” operates a slag processing complex, which is a technological line allowing step-by-step separation of iron-containing inclusions from converter slag due to the use of magnetic separation methods. The obtained iron-containing concentrate is a fraction material: 0 –10 mm– intended for use in agglomeration production, 10 –80 mm– in blast-furnace production and 80 –250 mmin steelmaking. The analysis of the possibility of the use of iron-containing concentrates with the fraction of 0 – 10 and 10 –80 mmduring steel smelting in 160-ton converters was carried out. On the basis of the developed mathematical model, a series of multivariate calculations were carried out to study the dynamics of melting and averaging the addition of iron-containing concentrates at various trajectories of input and its various amounts. Analysis of the results of mathematical modeling made it possible to obtain new information on hydrodynamic processes during the blowing of the converter bath with addition of iron-containing concentrates of the slag processing complex JSC “EVRAZ ZSMK”. 

The shortcomings of modern technology of thick-plate rolling, leading to the problems in production of welded pipes, are described. Advantages of thin slab casting technology are indicated, in which casting and reduction of a billet with a liquid phase are combined. The design of the combined continuous casting and deformation installation is described and the technology of steel plate production for welded pipes is provided. The main task of the article was to determine the stress-strain state of metal during formation of a strip from the ingot steel coat with a liquid phase by the coat with a liquid phase narrow walls bending. Computational experiment based on the solution of continuum mechanics task by means of the finite element method was used as a method of investigation. For calculations, a grid of finite elements was taken for a quarter of the model and a coat narrow wall with a facet length of0.5 mm. The elastic-plastic contact task is solved considering large displacements and deformations, and a stress-strain state during formation of a strip in a zone of bending of a coat with liquid phase narrow walls is determined. The calculation was carried out in a flat setting (flat deformed state). The initial data for the solution of the task using advanced ANSYS software are presented. The task statement and the boundary conditions are described. Dependences for calculation of the modulus of elasticity and plastic deformation resistance on temperature, strain degree and strain rate are presented. Epures of displacements, stresses and deformations of metal in the bending zone of a coat with a liquid phase narrow wall are presented. The regularities of distribution of tensile stresses along the outer surface and along the thickness of a coat narrow wall with a liquid phase are described as well as the ways of reducing tensile stresses on the side surfaces of a coat with a liquid phase. 

In the domestic pipelines the large-diameter pipes of different methods of manufacturing are used − the straight-line-seam welded pipes, the one- and double-seam welded pipes and the spiral-seam welded pipes. The diameters of pipes are up to 1420 mm, the strength class of pipes is up to K65 per the API standard. The world’s latest innovative technologies for the production of the large-diameter straight-line-seam single-joint welded pipes (the diameters are 1020 mm, 1220 mm and 1420 mm, the grade strengths of steel are K38 − K65 and X42 − X80, the wall thickness is up to 52 mm, the length is up to 18 m and the working pressure is up to 22.15 MPa) are the processes developed by the German company SMS Meer and based on the step-by-step process of press forming according to the scheme JCOE. The SMS Meer technologies are widely used by the Russian pipe plants − JSC “Vyksa Steel Works”, JSC “Izhora Pipe Mill”, PJSC “Chelyabinsk Pipe-Rolling Plant”, as well as the plants in Germany, China and India. However, the accident statistics of Russian pipelines shows that the stress corrosion of metal of the pipe’s wall occurs mainly on the pipelines with the large diameter 700 − 1420 mm. With more than 80 % of the destruction of pipelines with the signs of stress corrosion are observed on the pipelines with the diameters of 1020 – 1420 mm. The main cause of the corrosion-mechanical cracking of metal of pipe’s wall is the combined effect of three factors: 1) low steel-smelting quality of metal and the manufacturing defects of pipes (the large residual stresses, the microcracks and microexfoliation of metal after the pipe blanks’ forming, the corrugation and hairlines defects, the rolled burnt-on defects, the faulty fusion of weld seam and so on); 2) presence of corrosive-active environment and its access to the metal surface; 3) high-cycle fatigue and fracture of metal due to the pulsations of the in-tube working pressures and hydroblows. On the domestic pipelines pipes’ ruptures are almost two times more frequent than in the United States and Europe due to the manufacturing defects and the construction-installation defects. Therefore, it is necessary to study carefully the causes of the known cases of pipelines’ rupture due to the manufacturing defects. In this work, the pipe with the rolled burnt-on and the hairline defect on the outer surface of pipe is considered. The mathematical criterion for determining the critical in-tube pressure at which the elastic-plastic rupture of the pipe’s wall is taken place is obtained. The results of the investigation can be used in the diagnostics of the rupture’s causes of the steel major- and medium-diameter pipes on the main and interfield pipelines.

One of the main tasks of metallurgical engineering when creating and operating technological equipment is to provide the necessary indicators of its reliability. Achieving the reliability of equipment during its manufacture is associated with the operational determination of the strength characteristics of the used materials, and, above all, their endurance limit. In this paper, the acoustic emission signal is used as a parameter for estimating the endurance limit of materials. To obtain a stable signal, based on the results of an analysis of the synergistic processes taking place in various physical media of lasers and masers, the approach of obtaining a synergistic signal EVN on the basis of dislocation medium has been applied. This made it possible to provide a sufficiently powerful emission signal characterizing the motion of dislocations during the formation of certain dislocation substructures. The experiment carried out on steel samples confirms the fact that using an organized fine-graded stretching of an acoustic signal sample allows the internal processes taking place in the materials to be evaluated. The results of the experiment make it possible to isolate the areas of elastoplastic deformation of the material with different dislocation velocities. Based on the fact that the deformable metals are self-bound systems with the realization of their loading of various dissipative mechanisms at different stages, that form the corresponding dislocation structures, relation between the intensity of EVN and the structural features of the BCS was established. Simultaneously, the time of change in the intensity of the EVN is compared with the limit of its endurance. This makes it possible to use the stresses emission accompanying the formation of dislocation structures together with the fixation of the voltage that arises in the material of the sample to determine the limit of endurance.

The design of the device for air cooling of the shaft of a multi-disc furnace fan is developed. The dependences of convective heat transfer from the surface of this device to the environment of three standard sizes are obtained. It was established that the heat transfer during the motion of air in the inter-disc spaces of rotating cooling devices with different frequencies is similar to the heat transfer process in the case of its turbulent flow along the flat surface and is described in general by the power law dependence. The found values of the proportionality coefficients in this dependence take into account the design features of the studied devices and differ from the known values by 1.4 – 1.7 times. With the application of rules for thermal processes modeling, the obtained regularities can be used in the calculation of multi-disc cooling devices and for other designs of high-temperature furnace fans. The effect of changing the device external diameter on its cooling capacity was studied. It was established that a reduction in diameter from 313 to250 mmleads to an increase in the uniformity of the distribution of air flow in the inter-disc space and contributes to an increase in the average heat transfer coefficient from a surface unit by 1.6 to 1.7 times in the comparable conditions. The possibility of increasing the uniformity of air blowing of the discs surface in devices with large diameters (MD-313 and MD-290) due to the increase in the dimensions of the inlet openings is limited according to the reduction in heat removal from the fan shaft due to the reduction in the cross-section area of blades material in the zone of cylindrical surface passing through their axes. The maximum heat flow from the fan shaft is provided by the device with a diameter of290 mm, where two parameters are optimally combined: the value of the heat exchange surface and the intensity of its air blowing. Application of the developed devices allows the removed heat flow to be increased by 20 to 30 times compared to cooling of the surface of an open rotating shaft in a free environment in the comparable conditions. The presented materials can be used for the development of high-temperature fans for heating and thermal furnaces. 

Using the methods of modern materials science the researches and the comparative analysis are performed for the structural and phase states, dislocation substructure, mechanical and tribological properties of the surface of the thermo-mechanically strengthened and non-strengthened I-beam DP155 from low carbon steel used for mine monorails. It was found that accelerated cooling of the beam section in line 450 of the mill at “EVRAZ – Consolidated West-Siberian Metallurgical Plant” (rolling speed is 6 m/s, the water pressure on the sections of shelf cooling is 0.22 – 0.28 MPa, the temperature before the refrigerator is approximately 800 °С) forms a high defect surface layer structure characterized by higher (relatively to the unhardened state) values of hardness, wear resistance and scalar dislocation density. In the non-heat-resistant state, the microhardness of the samples is 2.70 ± 0.33 GPa, and Young’s modulus is 269.6 ± 27.1 GPa. Thermo-mechanical hardening of the material leads to a decrease in its microhardness up to 3.30 ± 0.29 GPa and to an increase in the Young’s modulus up to 228.2 ± 25.7 GPa, respectively. In addition, an increase in the range of microhardness values from 2.20 – 3.80 GPa to 2.64 – 4.60 GPa and a decrease in the Young’s modulus range from 208.0 to 403.0 GPa to 184.1 to 278.2 GPa is established during thermomechanical hardening of steel. It is shown that the thermomechanical strengthening of steel leads to an increase in the wear resistance of the surface layer in approximately 1.36 times (the wear rate varies from 5.3·10^–5 mm³/N·m  to 2.9·10^–5 mm³/N·m) and an increase in the friction coefficient by 1.36 times (from 0.36 to 0.49). In the non-strengthened state the dislocation chaos structure is observed (the dislocation scalar density is (0.9 . 1.0)·10¹⁰ cm^–2). High-temperature rolling and subsequent accelerated cooling of the samples lead to the formation of a strip dislocation substructure in the grains of ferrite and a reticular dislocation substructure in martensite grains (the average scalar dislocation density in the surface layer is 4.5·10¹⁰ cm^–2). The possible reasons for the observed regularities are discussed. 

Hydrogen interaction with Pd and Ni nanoparticles was studied by the method of molecular dynamics. The metal particle in the model was created by cutting a ball from the fcc crystal. The interaction of metal atoms with each other was described with the aid of the multiparticle Cleri-Rosato potential, constructed within the tight binding model. To describe the interactions of hydrogen atoms with metal atoms and with each other, the Morse potential was used, the parameters of which were calculated from the experimental data of absorption energy, activation energy of the above-barrier diffusion of hydrogen in the metal (at normal and high temperatures), binding energy with the vacancy and dilatations. Temperatures from 300 to 1100 K were considered. During the computer experiment the temperature in calculation block was constant. The concentration of hydrogen atoms introduced into the calculation block corresponded to a pressure of 10 and 20 MPa. The initial positions of the hydrogen atoms in the calculation block (in the metal particle or outside it) did not affect the final equilibrium distribution of hydrogen, which was established after some time of the computer experiment, depending on the temperature. As it was shown by the molecular dynamics simulation, nanoparticles are effective hydrogen accumulator having a high velocity of reversible sorption-desorption process of hydrogen. At room temperature, Pd and Ni nanoparticles sorb substantially all hydrogen which is unevenly distributed in the particle volume in an effort to form aggregates containing a few tens of hydrogen atoms. In the case of Ni particles hydrogen predominantly is located near the surface. In the Pd particles, by contrast, hydrogen strongly connected with the Pd lattice, and at increasing temperature it form larger aggregates. Intensive evaporation of hydrogen from the Pd and Ni particles occurs at temperatures above 700 K. At the same time, according to the obtained data, hydrogen is more strongly associated with the particles of Pd than with Ni particles, and the work that needs to be spent for hydrogen evacuation (desorption) in the case of Pd particles is higher than for Ni particles. 

Deformation features of fine-grained steel E2412 with 3.63 % silicon concentration and different grain sizes, mainly deforming by twinning, have been considered. Samples were stretched with In stron-5565 machine at deformation rates ≈ 0.002 . 0.660 s–1 during heating in temperature interval of 183 . 393 K. Constantly, two types of specimens among which are 80 % with grain sizes of 1,5 . 9 mmand 0,025 . 0,225 mm, have been experimentally studied. General connection between the number of crystal twins, step-like view of crystal load curve and deformation rate (for grains with dav1 = 3.55 mm) have been determined. Generation of steps is accompanied by detectable decrease of load due to high rate of twin forming at low rates of load. The value of load dropping decreases with increase of load rate. The value Δσ reverses the sign at deformation rate ≈ 0.04 s–1. The authors did not observe detectable load surges in finely crystalline steel at formation of twins (dav2 =0.12 mm). High-speed forming of twins and their small amounts lead to decrease of twin forming time in a single grain in finely crystalline material. Distribution histograms for twinned grains as functions of grain size, temperature and load rates have been plotted. It has been detected that distribution maximum of twinned grains shifts toward bigger grain against general size distribution in polycrystal. It has been determined that optimum grain size, being preferred for twinning and exceeding average grain size at initial size distribution, exists. It has been also shown that number of crystal twins depends on test temperature and deformation rate in a separate grain. Twinning intensity depends on temperature and deformation rate in maximum twinned sample. Deformation temperature, retaining constant number of crystal twins at main experimental rates, exists. 

Using methods of physico-chemical analysis (differentially– thermal and mineralogical) helped to study the oxidation process of magnetite (titanium magnetite) on samples from Olhovsk magnetite and Kachkanar titanium magnetite concentrates at low temperatures (200 –400 °C). Kinetic curves for the studied materials were obtained at different temperatures; they are typical for topochemical processes. Meanings of specific speeds of oxidation of magnetite various size at different temperatures were calculated and sizes of apparent energy of activation of the process were defined. The influence of partial pressure on kinetics of oxidation in gas phase was studied to expose the limiting point of the process of oxidation of magnetite and titanium magnetite. The order of oxidation reaction on oxygen at definite temperatures and the oxidation degree was calculated using graphical methods. The influence of titanium inclusions in magnetite on kinetics of phase change of magnetite–hematite was examined at the temperature interval of 200 –400 °C, it happens in mixed operational parameters. Then the process comes to diffusive operational parameters. Kinetic principles and the character of oxidation of the studied materials in nonisothermical conditions were defined at different speeds of heating. These results are of some interest and can be used to optimize the low temperature oxidation regimes of iron ore materials on a conveyor roasting machine. 

Practical interest, with the goal of resource conservation, is the technology of arc welding with powder wire in which the fillers are used, the tungsten oxide is WO₃ , and the material (ferrosilicon) with a reducing agent is silicon. In the work, a thermodynamic estimate of the probability of nine standard reactions under tabular thermodynamic data of reagents was carried out in the temperature range from 1500 to 3500 K. Among the reactions, the reaction of direct reduction of WO₃ oxide by silicon and the reaction of a tungsten-silicon compound with the formation of tungsten silicides are considered. As possible products of the reactions were considered W, WSi₂ , W₅Si₃ . The reduction reaction of the oxide was recorded on 1 mole of O₂ , and the reaction of the compounds of tungsten with silicon – on 1 mole of W. The probability of reactions was estimated by their standard Gibbs energy. As standard for reagent substances in the range 1500 – 3500 K, the following states were selected: W_(solid) , WO_{3 (solid, liquid)}  with a phase transition at 1745 K, WSi_{2(s., l.)}  with a phase transition at 2433 K, W₅Si_{3(s., l.)} with a phase transition at 2623 K, Si_{(s., l.)} with a phase transition at 1690 K, SiO_(l.) , SiO_{2(s., l.)} with a phase transition at 1996 K. In order to assess the degree of effect on the thermodynamic properties of the possible evaporation reactions in the tungsten oxide WO3 arc, the thermodynamic characteristics of one of the reactions were calculated in which the WO_3(l.)  state was selected as the standard state in the same temperature range. Thermodynamic analysis shows that at the reduction of WO₃ the formation of silicides WSi₂ and W₅Si₃ is most likely, then tungsten. The thermodynamic probability of formation of these silicides due to the reactions of the tungsten-silicon compound in standard states turns out to be substantially lower. The reducing ability of silicon in reactions with the formation of SiO₂ decreases with increasing temperature, while in the reactions with formation of SiO, on the contrary, it increases. Consequently, in the system under consideration at high melt temperatures (more than 2500 K), a change in the composition of the gas phase due to the formation of SiO is more likely. At temperatures below 1750 K, the slag phase can become more acidic due to the resulting silicon oxide SiO₂ . The evaporation of WO₃ in the arc increases the thermodynamic probability of the reduction reactions occurrence, but more at a low temperature. 

The analysis of existing domestic and international technologies of processing and utilization of iron ore wastes was carried out. For theKemerovoregion, effective technologies of waste recycling were provided for additional products meeting all consumers’ requirements. These technologies were integrated into scenarios that provide a full cycle of rational nature management. The task of waste processing scenarios generation has been formulated. Scenarios for gradual processing of iron ore waste with extraction of useful components by chemical methods, reclamation of disturbed lands and creation of recreation zones in the exempt lands were developed. Recommendations and technological solutions for all-the-year processing, including winter, of iron ore waste by chemical methods are offered. The maps of tailings dumps processing with stage-by-stage processing and reclamation of disturbed lands are presented. The number of stages is determined by investments and annual capacity of waste recycling complex with possible simultaneous operation of several sections. After the complete excavation of iron ore wastes from the tailing dumps, preparatory work was carried out for construction of recreation areas, including searching for a tender, choosing the design of recreation areas, equipment, buildings and structures dismantling and selling, soil reclamation, lawns, trees and shrubs planting. Reclamation of the territory was carried out during the operation of processing plant; commissioning of recreation areas was made after the end of operation. Mathematical modeling of scenarios for concentration plants iron ore wastes processing in theKemerovoregion was carried out based on the following performance indicators: economic effect; reclamation of disturbed lands; pollution; mining area population with normative socio-cultural indicators; prevented pollution per capita. The toolkit of model experiments is a software package for Scilab environment. From the proposed scenarios, Pareto-optimal solutions were selected graphically. Selection of priorities among Pareto-optimal scenarios was carried out by ranking, based on levels of social and environmental safety (low, moderate and high) in theKemerovoregion. 

Mathematical modeling of the liquid melt flow in the mold of the continuous casting plant is still poorly investigated. Analytic solutions of melt flow in the general case are a complex mathematical problem. Nevertheless, for some cases, exact solutions have been found. Such analytical solutions serve as a means of verifying the results of numerical methods of solution. The purpose of this work is the use of the numerical method proposed by Professor V.I. Odinokov, based on the finite-difference representation of the original system of equations. The method has been successfully used in the mechanics of continuous media, in the lithium manufacturing for the mathematical modeling of the strained deformed state of shell molds of cast models, as well as in other technological works, which indicates its universality. In the present work, hydrodynamic and thermal flows of liquid metal during the steel casting into the rectangular section mold of a continuous cast steel have become objects of research, and the result is a spatial mathematical model describing the flows of liquid metal in the mold. To simulate the processes that take place during filling, the software complex “Odyssey” is used. The basis of theoretical calculations includes the fundamental equations of hydrodynamics, the equations of mathematical physics (the equation of heat conductivity with regard to mass-transfer) and the approved numerical method. The solution of the system of differential equations formulated in this work was carried out numerically. The investigated area was divided into elements of finite dimensions, for each element the resulting system of equations was recorded in the difference form. The solution result is the metal flow velocity fields and the temperature fields in the mold volume. To solve the obtained system of algebraic equations, the numerical schemes and calculation algorithms were developed. Based on the developed numerical schemes and algorithms a computational program was compiled in Fortran-4. The mathematical model allows to vary the geometric dimensions of the crystal-mash and sectional metal exit holes from the submerged nozzle, and may also help to understand the scheme of the cast metal movement that affects the heat sink walls of the mold, and to find the optimal parameters of the output of liquid metal from the submerged nozzle at different modes of casting. An example of calculating the casting of steel into a rectangular mold with a height of 100 cm and cross-sectional dimensions of 2000.40 cm is given. The casting was carried out from a submerged nozzle symmetrically on both sides in a horizontal plane. The result of the solution is presented in the graphical form. The motion of liquid metal flows in different sections of the mold is shown. The areas of the circular flow of metal are revealed, as well as the areas in the mold volume, where the vortex motion of the liquid metal is observed, their magnitudes and intensity are determined. The presented temperature field indicates the presence of a local area with a high temperature at the wall of the mold, which is explained by the directed flow of hot metal emerging from the hole in the submerged nozzle.