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Search Results (4)

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Keywords = hearth drainage

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13 pages, 4521 KiB  
Article
Estimation of the Blast Furnace Hearth State Using an Inverse-Problem-Based Wear Model
by Chengbo Zhang, Binbin Hou, Lei Shao, Zongshu Zou and Henrik Saxén
Metals 2022, 12(8), 1302; https://doi.org/10.3390/met12081302 - 3 Aug 2022
Cited by 2 | Viewed by 3368
Abstract
An undisturbed and well-controlled hearth state is an essential prerequisite for achieving a long campaign life and low production costs in an ironmaking blast furnace, because hearth wear and hot metal and slag drainage are crucial factors in its operation. With the objective [...] Read more.
An undisturbed and well-controlled hearth state is an essential prerequisite for achieving a long campaign life and low production costs in an ironmaking blast furnace, because hearth wear and hot metal and slag drainage are crucial factors in its operation. With the objective to estimate the hearth state of the refractory of a three-taphole blast furnace, a wear model of the hearth erosion and skull formation was developed. The model is based on thermocouple readings in the hearth lining and solves an inverse heat conduction problem for a series of co-axial vertical slices, where the erosion and skull lines are optimized simultaneously. The model is optimized for fast computation by adopting a novel procedure featuring fixed mesh during the looping calculation. The results revealed that the hearth refractory showed an elephant-foot-shaped profile with excessive erosion in the hearth periphery, indicating that liquid flows are suppressed in the hearth bottom and that the permeability of the core of the deadman is low. These findings were further elaborated and confirmed by a comparison between the estimated hearth state and other key operation variables, including the coke rate, blast kinetic energy, and residual carbon appetite of the hot metal. Full article
(This article belongs to the Special Issue Mathematical Modelling of the Ironmaking Blast Furnace)
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16 pages, 3555 KiB  
Review
Dead-Man Behavior in the Blast Furnace Hearth—A Brief Review
by Lei Shao, Qilin Xiao, Chengbo Zhang, Zongshu Zou and Henrik Saxén
Processes 2020, 8(11), 1335; https://doi.org/10.3390/pr8111335 - 22 Oct 2020
Cited by 16 | Viewed by 15245
Abstract
The blast furnace campaign length is today usually restricted by the hearth life, which is strongly related to the drainage and behavior of the coke bed in the hearth, usually referred to as the dead man. Because the hearth is inaccessible and the [...] Read more.
The blast furnace campaign length is today usually restricted by the hearth life, which is strongly related to the drainage and behavior of the coke bed in the hearth, usually referred to as the dead man. Because the hearth is inaccessible and the conditions are complex, knowledge and understanding of the state of the dead man are still limited compared to other parts of the blast furnace process. Since a number of publications have studied different aspects of the dead man in the literature, the purpose of the current review is to compile the findings and knowledge in a comprehensive document. We mainly focus on contributions with respect to the dead man state, and those assessing its influence on the hearth performance in terms of liquid flow patterns, lining wear and drainage behavior. A set of common modeling approaches in this specific furnace area is also briefly presented. The aim of the review is also to deepen the understanding and stimulate further research on open questions related to the dead man in the blast furnace hearth. Full article
(This article belongs to the Special Issue Process Modeling in Pyrometallurgical Engineering)
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21 pages, 5723 KiB  
Article
Experimental Model Study of Liquid–Liquid and Liquid–Gas Interfaces during Blast Furnace Hearth Drainage
by Weiqiang Liu, Lei Shao and Henrik Saxén
Metals 2020, 10(4), 496; https://doi.org/10.3390/met10040496 - 9 Apr 2020
Cited by 10 | Viewed by 3552
Abstract
The smooth drainage of produced iron and slag is a prerequisite for stable and efficient blast furnace operation. For this it is essential to understand the drainage behavior and the evolution of the liquid levels in the hearth. A two-dimensional Hele–Shaw model was [...] Read more.
The smooth drainage of produced iron and slag is a prerequisite for stable and efficient blast furnace operation. For this it is essential to understand the drainage behavior and the evolution of the liquid levels in the hearth. A two-dimensional Hele–Shaw model was used to study the liquid–liquid and liquid–gas interfaces experimentally and to clarify the effect of the initial amount of iron and slag, slag viscosity, and blast pressure on the drainage behavior. In accordance with the findings of other investigators, the gas breakthrough time increased and residual ratios for both liquids decreased with an increase of the initial levels of iron and slag, a decrease in blast pressure, and an increase in slag viscosity. The conditions under which the slag–iron interface in the end state was at the taphole and not below it were finally studied and reported. Full article
(This article belongs to the Special Issue Advances in Pyrometallurgy)
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18 pages, 4479 KiB  
Article
Principal Component Analysis of Blast Furnace Drainage Patterns
by Mauricio Roche, Mikko Helle and Henrik Saxén
Processes 2019, 7(8), 519; https://doi.org/10.3390/pr7080519 - 7 Aug 2019
Cited by 9 | Viewed by 4257
Abstract
Monitoring and control of the blast furnace hearth is critical to achieve the required production levels and adequate process operation, as well as to extend the campaign length. Because of the complexity of the draining, the outflows of iron and slag may progress [...] Read more.
Monitoring and control of the blast furnace hearth is critical to achieve the required production levels and adequate process operation, as well as to extend the campaign length. Because of the complexity of the draining, the outflows of iron and slag may progress in different ways during tapping in large blast furnaces. To categorize the hearth draining behavior, principal component analysis (PCA) was applied to two extensive sets of process data from an operating blast furnace with three tapholes in order to develop an interpretation of the outflow patterns. Representing the complex outflow patterns in low dimensions made it possible to study and illustrate the time evolution of the drainage, as well as to detect similarities and differences in the performance of the tapholes. The model was used to explain the observations of other variables and factors that are known to be affected by, or affect, the state of the hearth, such as stoppages, liquid levels, and tap duration. Full article
(This article belongs to the Special Issue Process Modeling in Pyrometallurgical Engineering)
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