Search Results (31)

The iron and steel industry, as a major energy consumer, was critically required to enhance operational efficiency and reduce CO₂ emissions. Conventional blast furnace processing of vanadium–titanium magnetite (VTM) in China had been associated with persistent challenges, including suboptimal TiO₂ recovery rates (<50%) and elevated carbon intensity (the optimal temperature range for TiO₂ recovery lies within 1400–1500 °C). Shaft furnace technology has emerged as a low-carbon alternative, offering accelerated reduction kinetics, operational flexibility, and reduced environmental impact. This study evaluated the low-carbon PLCsmelt process for VTM smelting through energy–mass balance modeling, comparing two gas-recycling configurations. The process integrates a pre-reduction shaft furnace and a melting furnace, where oxidized pellets are initially reduced to direct reduced iron (DRI) before being smelted into hot metal. In Route 1, CO₂ emissions of 472.59 Nm³/tHM were generated by pre-reduction gas (1600 Nm³/tHM, 64.73% CO, and 27.17% CO₂) and melting furnace top gas (93.98% CO). Route 2 incorporated hydrogen-rich gas through the blending of coke oven gas with recycled streams, achieving a 56.8% reduction in CO₂ emissions (204.20 Nm³/tHM) and altering the pre-reduction top gas composition to 24.88% CO and 40.30% H₂. Elevating the pre-reduction gas flow in Route 2 resulted in increased CO concentrations in the reducing gas (34.56% to 37.47%) and top gas (21.89% to 26.49%), while gas distribution rebalancing reduced melting furnace top gas flow from 261.03 to 221.93 Nm³/tHM. The results demonstrated that the PLCsmelt process significantly lowered carbon emissions without compromising metallurgical efficiency (CO₂ decreased about 74.48% compared with traditional blast furnace which was 800 Nm³/tHM), offering a viable pathway for sustainable VTM utilization. Full article

This study introduces an integrated Multi-Criteria Decision Making (MCDM) methodology combining the Analytic Hierarchy Process (AHP), Entropy Weight Method (EWM), and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) to optimize the selection of municipal water supply pipeline materials. A comprehensive evaluation system encompassing thirteen criteria across technical, economic, and safety dimensions was developed to ensure balanced decision-making. The method employs a weight determination model based on Jaynes’ maximum entropy theory to harmonize subjective AHP-derived weights with objective EWM-derived weights, addressing inconsistencies in traditional evaluation approaches. This framework was validated in a case study involving a DN400 pipeline project in Jiaxing, Zhejiang Province, China, where five materials—steel, ductile iron, reinforced concrete, High-Density Polyethylene (HDPE), and Unplasticized Polyvinyl Chloride (UPVC)—were assessed using quantitative and qualitative criteria. Results identified HDPE as the most suitable material, followed by UPVC and reinforced concrete, with steel ranking lowest. Comparative analysis with alternative MCDM techniques demonstrated the robustness of the proposed method in balancing diverse factors, dynamically adjusting to project-specific priorities. The study highlights the flexibility of this approach, which can extend to other infrastructure applications, such as drainage systems or the adoption of innovative materials like glass fiber-reinforced plastic (GFRP) mortar pipes. By integrating subjective and objective perspectives, the methodology offers a robust tool for designing sustainable, efficient, and cost-effective municipal water supply networks. Full article

The research conducted in this study aimed to determine whether the production of a layered casting in the material system of X46Cr13 steel (working part) and gray cast iron (base part) can be integrated with the hardening process of this steel within the conditions of the casting mold. Accordingly, a series of layered castings was produced by preparing the mold cavity, where a monolithic steel insert was poured with molten gray cast iron with flake graphite. The variable factors in the casting production process included the pouring temperature T_p and the thickness of the support part g. Importantly, given that the hardening of the X46Cr13 steel insert occurred directly within the mold, the selection of casting parameters had to balance the ability to heat the insert to the austenitization temperature Tγ_≥950°C while also creating thermokinetic conditions conducive to the rapid cooling of the system. Therefore, chromite sand—commonly regarded as a rapid-cooling material—was selected as the matrix for the molding material. Based on the conducted studies, it was determined that the thermokinetic properties of this material allowed the surface of the cast working part to be heated to the austenitization temperature. The microstructure consisted of Cr(Fe) carbides within a martensitic-pearlitic matrix, with martensite filling the grains of the primary austenite and pearlite situated along their boundaries. The carbides were primarily located at grain boundaries and, to a lesser extent, within the primary austenite grains. Through transmission electron microscopy and X-ray diffractometry, the type of Cr(Fe) carbide in the microstructure of the working part was identified as M₂₃C₆. Full article

The challenge of distributing molten iron involves the optimal allocation of blast furnace output to various steelmaking furnaces, considering the blast furnace’s production capacity and the steelmaking converter’s consumption capacity. The primary objective is to prioritize the distribution from the blast furnace to achieve a balance between iron and steel production while ensuring that the volume of hot metal within the system remains within a safe range. To address this, a constrained multi-objective nonlinear programming model is abstracted. A linear weighting method combines multiple objectives into a single objective function, while the Lagrange multiplier method addresses constraints. The proposed hybrid Archimedes optimization algorithm effectively solves this problem, demonstrating significant improvements in time efficiency and precision compared to existing methods. Full article

The iron and steel industry significantly contributes to global energy use and greenhouse gas emissions. The rising deployment of volatile renewables and the resultant need for flexibility, coupled with specific challenges in electric steelmaking (e.g., operation optimization, optimized power purchasing, effective grid capacity monitoring), require accurate energy consumption and demand forecasts for electric steel mills to align with the energy transition. This study investigates diverse approaches to forecast the energy consumption and demand of an electric arc furnace—one of the largest consumers on the grid—considering various forecast horizons and objectives with limited knowledge on process parameters. The results are evaluated for accuracy, robustness, and costs. Two grid connection capacity monitoring approaches—a one-step and a multi-step Long Short-Term Memory neural network—are assessed for intra-hour energy demand forecasts. The one-step approach effectively models energy demand, while the multi-step approach encounters challenges in representing different operational phases of the furnace. By employing a combined statistic–stochastic model integrating a Seasonal Auto-Regressive Moving Average model and Markov chains, the study extends the forecast horizon for optimized day-ahead electricity procurement. However, the accuracy decreases as the forecast horizon lengthens. Nevertheless, the day-ahead forecast provides substantial benefits, including reduced energy balancing needs and potential cost savings. Full article

Decarbonizing the current steel and power sectors through the development of the hydrogen direct-reduction iron ore–electric arc furnace route and the 100% hydrogen-fired gas turbine cycle is crucial. The current study focuses on three clusters of research works. The first cluster covers the investigation of the mass and energy balance of the route and the subsequent application of these values in experiments to optimize the reduction yield of iron ore. In the second cluster, the existing gas turbine unit was selected for the complete replacement of natural gas with hydrogen and for finding the most optimal mass and energy balance in the cycle through an Aspen HYSYS model. In addition, the chemical kinetics in the hydrogen combustion process were simulated using Ansys Chemkin Pro to research the emissions. In the last cluster, a comparative economic analysis was conducted to identify the levelized cost of production of the route and the levelized cost of electricity of the cycle. The findings in the economic analysis provided good insight into the details of the capital and operational expenditures of each industrial sector in understanding the impact of each kg of hydrogen consumed in the plants. These findings provide a good basis for future research on reducing the cost of hydrogen-based steel and power sectors. Moreover, the outcomes of this study can also assist ongoing, large-scale hydrogen and ammonia projects in Uzbekistan in terms of designing novel hydrogen-based industries with cost-effective solutions. Full article

The architecture of the 20th century stands as an imperative realm of experimentation. Inside it, the architecture of the Modern Movement emerged from 1900 to 1940, with shapes, features, and materials completely different from pre-industrial buildings, rejecting traditional construction practices, techniques, and materials. Its key design concepts include (i) the “Form Follows Function” principle establishing a strict relationship between building aesthetics and function, favoring minimalism, balanced composition, and visible materials; (ii) the creation of comfortable and healthy buildings with natural light and ventilation through windows, biophilia, and spacious rooms; and (iii) advancements in engineering enabling novel design possibilities (e.g., metal-framed curtain walls, complex windows) and mass-produced materials (e.g., glass, steel, reinforced concrete, plywood, Masonite, and cast iron). These criteria directly influence energy efficiency and human comfort. Otherwise, technical problems have emerged due to inadequate comprehension of the long-time performance of these experimentations, leading to deterioration and aging. This research provides a complete overview of the energy and climatic performances of Modern Architecture, discussing the building physics implications of the key design principles through several case studies. Full article

Fine dust, represented by Fe-based fine particles and emitted from the production process of the iron and steel industry, is the primary factor causing many diseases represented by industrial pneumoconiosis, and ultra-low dust emission has always been a thorny problem to be solved urgently. To explore the magnetic coagulation effect of Fe-based fine particles in the magnetic field when removing them from industrial flue gas by the magnetic field effect in the iron and steel industry, using FLUENT software, magnetic dipole force was added between particles through user defined function (UDF) based on the computational fluid dynamics-discrete phase model (CFD-DPM) method so that the collision process of particles was then equivalent to their mutual trapping process. Next, the effects of particle size, particle volume fraction, external magnetic field strength, and particle magnetic susceptibility on the magnetic coagulation process were comprehensively studied. Meanwhile, the proton balance equation (PBE) was solved using the partition method on the basis of the computational fluid dynamics-population balance model (CFD-PBM) to compare the coagulation removal effect under random and aligned orientations of magnetic dipoles, respectively. The results showed that the magnetic coagulation strength under the random orientation of magnetic dipoles was greater than that under the aligned orientation. When the particle size of Fe-based fine particles increased from 0.5 μm to 1.5 μm, the magnetic coagulation coefficient decreased from 0.5414 to 0.2882, and the difference in the removal efficiency under the two different orientations of magnetic dipoles became smaller. When the particle volume fraction increased from 0.01 to 0.03, the magnetic coagulation coefficient increased from 0.2353 to 0.5061, and the difference in the removal efficiency under two orientations was enlarged. When the applied external magnetic field strength increased from 0.5 T to 1.0 T, the magnetic coagulation coefficient increased from 0.3940 to 0.5288, and the magnetic susceptibility increased from 0.0250 to 0.0500, the coagulation coefficient increased from 0.3940 to 0.5288, and the difference under two orientations basically stayed unchanged. Full article

Because of the pressure to meet carbon neutrality targets, carbon reduction has become a challenge for fossil fuel resource-based regions. Even though China has become the most active country in carbon reduction, its extensive energy supply and security demand make it difficult to turn away from its dependence on coal-based fossil energy. This paper analyzes the Chinese coal capital—Shanxi Province—to determine whether the green, low-carbon energy transition should be focused on coal resource areas. In these locations, the selection and effect of transition tools are key to ensuring that China meets its carbon reduction goal. Due to the time window of clean coal utilization, the pressure of local governments, and the survival demands of local high energy-consuming enterprises, Shanxi Province chose hydrogen as its important transition tool. A path for developing hydrogen resources has been established through lobbying and corporative influence on local and provincial governments. Based on such policy guidance, Shanxi has realized hydrogen applications in large-scale industrial parks, regional public transport, and the iron and steel industry. This paper distinguishes between the development strategies of gray and green hydrogen. It shows that hydrogen can be an effective development model for resource-based regions as it balances economic stability and energy transition. Full article

Given the accelerating depletion of iron ore resources, there is growing concern within the steel industry regarding the availability of high-phosphorus iron ore. However, it is important to note that the utilization of high-phosphorus iron ore may result in elevated phosphorus content and notable fluctuations in molten iron, thereby imposing additional challenges on the dephosphorization process in steelmaking. The most urgent issue in the process of converter steelmaking is how to achieve efficient dephosphorization. In this study, the influence of various factors on the logarithm of the phosphorus balance distribution ratio ($\lg L_{\mathrm{p}}$), the logarithm of the P₂O₅ activity coefficient ($\lg {\gamma }_{{\mathrm{P}}_2{\mathrm{O}}_5}$), and the logarithm of the phosphorus capacity ($\lg C_{\mathrm{p}}$) were examined through thermodynamic calculations. The impact of each factor on dephosphorization was analyzed, and the optimal conditions for the dephosphorization stage of the converter were determined. Furthermore, the influence of basicity and Fe_tO content on the form of phosphorus in the slag was analyzed using FactSage 7.2 software, and the precipitation rules of the slag phases were explored. The thermodynamic calculation results indicated that increasing the basicity of the dephosphorization slag was beneficial for dephosphorization, but it should be maintained below 3. The best dephosphorization effect was achieved when the Fe_tO content was around 20%. The reaction temperature during the dephosphorization stage should be kept low, as the dephosphorization efficiency decreased sharply with the increasing temperature. In dephosphorization slag, Ca₃(PO₄)₂ usually formed a solid solution with Ca₂SiO₄, so the form of phosphorus in the slag was mainly determined by the precipitation form and content of Ca₂SiO₄. The phases in the dephosphorization slag mainly consisted of a phosphorus-rich phase, an iron-rich phase, and a matrix phase. The results of scanning electron microscopy and X-ray diffraction analyses were consistent with the thermodynamic calculation results. Full article

The global steel industry uses fossil fuels to produce millions of tonnes of iron ore sinter each year. Sintering is an energy-intensive process that fuses iron ore and flux to produce material that balances a high mechanical strength at a sufficient particle size to ensure a macroporous burden in the blast furnace to enable rapid gas flow. As significant CO₂ greenhouse emissions are emitted, the defossilisation of these CO₂ emissions is vital to net-zero carbon targets. Two iterations of a new biomass–coal hybrid fuel (ecoke^®(A) and ecoke^®(B)) were compared with coke breeze and an anthracite coal using oxygen bomb calorimetry, simultaneous thermal analysis (STA) combining thermogravimetry and differential scanning calorimetry, and isoconversional kinetic modelling and pyrolysis–GCMS to study the volatile matter. The calorific values of both ecoke^®(A) and (B) were marginally higher than that of the coke breeze: 27.9 MJ/kg and 27.8 MJ/kg, respectively, compared with 26.5 MJ/kg for the coke breeze. A proximate analysis revealed both ecoke^® samples to have higher volatile matter contents (ca. 12–13%) than the coke breeze (7.4%), but less than the anthracite coal (ca. 14%). The thermogravimetric analysis of the burnout kinetics of the fuels heated up to 1000 °C, at heating rates from 5 to 25 °C/min, showed that that the coke breeze and anthracite coal had higher ignition and burnout temperatures than the ecoke^® samples. Kinetic analysis using the Freidman and Ozawa methods found that the ecoke^® samples showed comparable maximum mass loss rates to the coke breeze but lower activation energies. From these results, both ecoke^® samples have the potential to replace some of the coke breeze in the sintering process or EAF processes to help achieve net zero by offsetting up to 30% of the CO₂ emissions. Full article

With the development of the energy control system of iron and steel enterprises, the urgency of solving the problem of the resource and energy saving control of steelmaking processes increases, taking into account the reconfiguration of production to a new task, intensification of the processes of recycling of raw materials, as well as reducing the waste intensity of production. The way to solve the problem of resource and energy saving of steelmaking production is the creation of a computer system. It allows one to analyze the state of the refractory converter lining, calculation of the material and thermal balances, the amount of slag-forming materials, the quantitative characteristics of slag corrosion, as well as predict the phase and chemical composition of the slag in order to impart the properties necessary in the production of mineral binders and other building materials. The computer system allows one to identify complex fuzzy relationships between process parameters and issue recommendations on the resource and energy saving control of the converter process, taking into account the waste recycling. The testing of the computer system, according to the industrial data of the enterprises CherMF (PJSC Severstal) and PJSC NLMF, confirmed its operability and the possibility of its use at iron and steel enterprises. Full article

Hard-coated surfacing of a few micrometers is widely applied to increase the efficiency of tools, e.g., for cutting, forming, and casting applications. Therefore, the base thermodiffusion surface treatment is a practical solution to these issues by hardening surface layers with interstitial elements such as carbon, nitrogen, and boron. In particular, within this study, the growth kinetics of an iron boride layer on ASTM 283 steel were investigated with two diffusion models of the powder-pack boriding technique in the temperature range of 1123–1273 K with different treatment periods. The first model, called the steady-state diffusion model, used the modified version of the mass balance equations at the Fe₂B/substrate growth interface, the parabolic growth law, and the solution of Fick’s second law without time dependence. At the same time, the second diffusion model was based on Goodman’s method, also called the integral heat balance method. Afterward, the diffusion coefficient of boron in the Fe₂B phase was calculated by fitting the experimental data to the models. Nevertheless, the estimated value for the activation energy of ASTM A238 steel in both diffusion models was coincident (168.2 kJ∙mol⁻¹). A mathematical analysis was implemented by means of a power series (Taylor series) to explain this similarity. The SEM examinations showed a solid tendency to saw-tooth morphology at the growth interface with the formation of the Fe₂B layer, whose presence was verified by XRD analysis. The tribological characterizations, including the tests of Rockwell-C indentation, pin-on-disc, and Vickers hardness test method, were used to analyze the antiwear features of the Fe₂B layers. Finally, this value of energy was compared to the literature for its experimental validation. Full article

Facing the current increasingly severe environmental problems, the government and the public make increasingly strong demands for environmental protection. It is the key to sustainable development to study how to motivate enterprises to actively fulfill their environmental responsibilities and practice green production mode. This study selects large steel enterprises of the China Iron and Steel Association from 2009 to 2017 as samples to empirically analyze the effect and mechanism of environmental responsibility on corporate performance. The results show that corporate environmental responsibility (CER) has a significant promoting effect on corporate performance, and green innovation has a significant mediating effect between them. Furthermore, from the perspective of regional and ownership heterogeneity, the differences in the mediating effect of green innovation on the relationship between corporate environmental responsibility and corporate performance are explored. Finally, based on the research results, this paper suggests that enterprise managers should balance the relationship between enterprise performance and environmental protection, so as to achieve a “win–win” situation. Full article

The iron and steel industry is a major CO₂ emitter and an important subject for the implementation of carbon emission reduction goals and tasks. Due to the complex ore composition and low iron grade, vanadium–bearing titanomagnetite smelting in a blast furnace consumes more coke and emits more carbon than in an ordinary blast furnace. Injecting hydrogen–rich gas into blast furnace can not only partially replace coke, but also reduce the carbon emission. Based on the whole furnace and zonal energy and mass balance of blast furnace, the operation window of the blast furnace smelting vanadium–bearing titanomagnetite is established in this study on the premise that the thermal state of the blast furnace is basically unchanged (raceway adiabatic flame temperature and top gas temperature). The effects of different injection amounts of hydrogen–rich gases (shale gas, coke oven gas, and hydrogen) on raceway adiabatic flame temperature and top gas temperature, and the influence of blast temperature and preheating temperature of hydrogen–rich gases on operation window are calculated and analyzed. This study provides a certain theoretical reference for the follow–up practice of hydrogen–rich smelting of vanadium–bearing titanomagnetite in blast furnace. Full article