Data based modeling approach of iron and steelmaking processes. With the tremendous increases in the power of computer hardware and modeling software, computational modeling. Elrefaie3 abstract mass and energy balance equations are applied on top blowing bof and eaf steelmaking processes to detect the energy profile of production one ton steel by both processes. To overcome the difficulty of making measurements in actual steelmaking vessels furnace, ladle, tundish, or mold, both physical modeling water models and cfd simulations have been used extensively for melt flow visualization. The main objective of the paper is the presentation of the static control model of steelmaking converter process based on the artificial neural network approach. The purpose of the current study is to increase the understanding of different steelmaking processes at the decarburization stages by use of mathematical modeling. To provide students with wider theoretical knowledge of the theory and the technology of production of pig iron with a focus on charge materials and their treatment, technological principles of production and basic chemical, thermal and physical phenomena and processes. Due to complexity of the steelmaking process and nonlinear relationship between the process parameters, modeling the inputoutput process parameters and accurately predicting the output yield in the steelmaking shop is very difficult and has been a major research issue.
Eaf, electric arc furnace, modelling, process automation, steel making, melting, dri, simulation. From the prediction of complex weather patterns to the design of swimsuits, modeling has, over the years, quietly but steadily become an essential part of almost every field and industry and steelmaking is. Addresses fundamental principles of physical and mathematical modeling in steelmaking processes modeling of steelmaking processes meets that everpresent demand and provides a. With content designed to serve professionals and students, this book starts with an overview of steelmaking and develops into a focused description of underlying scientific fundamentals and applications. Numerical simulation of slag foaming with reaction. Lecture 38 modeling of steelmaking processes contents. More specifically, two delaval nozzles from a vod vaccum oxygen decarburization. These processes are demonstrated using the capabilities of metsim for effective process control. Many different continuous steelmaking processes have been proposed in the last 40 years. The process models focus on part production employing electric arc furnace eaf steelmaking and sand casting with chemical binders, and. Depending on the types of steel required, the following secondary steelmaking processes can be used. Simulation and modelling of metallurgical processes in. Data based modeling approach to iron and steel making processes. Part 2 of this paper explained the model development of decarburization reaction of emulsified droplets and discussed the effects of bloating behaviour of metal droplets on the overall kinetics of the.
Modeling of gas flows in steelmaking decarburization processes. However, these processes are highly complex with large variations in time and length, and this makes the systems extremely demanding to simulate. Iron and steel making processes are very complex in nature and we need. More specifically, two delaval nozzles from a vod vaccum oxygen decarburization process, which is used for producing stainless steels with ultra. Jan 12, 2018 over the last few decades, a number of cfd models have been dedicated to increasing the understanding of the decarburization processes in steelmaking. Modeling of gas flows in steelmaking decarburization. Modeling of steelmaking process with effective machine. Tech student, department of metallurgical and materials engineering, iit madras, chennai, 600036, india 2asst.
Use of the new direct reduction processes, natural gasbased or coalbased, will improve greenhouse gas emissions and lower steelmaking energy requirements while allowing steelmakers to meet end product quality requirements. Modeling of steelmaking processes dipak mazumdar, james w. As their customers become ever more quality conscious, however, steelmakers must continue their efforts to minimize harmful. Design of a physical model for fluid flow in steel melt. Steelmaking the refining of iron to make steel is where the carbon content of hot metal is lowered, usually to less than 1 % by an oxidation process in a steelmaking furnace. Computer modeling of refractoryslagmetal interactions. Modeling of gas flows in steelmaking decarburization processes zhili song doctoral thesis stockholm 20 division of applied process metallurgy department of materials science and engineering school of industrial engineering and management royal institute of technology se100 44 stockholm sweden. He is actively involved in research work related to production processes, tundish steelmaking process, mold solidification in continuous casting, etc. A comprehensive description of modern steelmaking processes along with physical and mathematical modeling and solution methodologies based on aibased techniques, especially ann, ga, cfd, and fluent software is provided by mazumdar and evans 2009. Modeling of steelmaking processes 1st edition dipak mazumdar. Modeling of steelmaking processes 1st edition dipak.
Buy modeling of steelmaking processes book online at low prices. Most recently dri facilities have developed processes to increase the carbon content and metallization of the product to make it more desirable as a charge material. The steelmaking processes involve dynamic interactions among various phases slag, metal and gas along with chemical reactions, fluid flow and heat and mass transfer. In order to achieve success, the model must accurately predict the phenomena of true interest, which for steelmaking processes include. By closing this message, you are consenting to our use of cookies. For illustration, a comparison of measured data of carbon content pi and phosphorus content 141 evaluated from metal droplets and bulk metal samples taken from a 200t top blown oxygen steelmaking furnace, is presented in figure 1. Data based modeling approach of iron and steelmaking. Addresses fundamental principles of physical and mathematical modeling in steelmaking processes.
Production scheduling of a largescale steelmaking continuous. The theoretical and practical considerations needed for modeling of oxygen steelmaking processes are discussed. More specifically, two delaval nozzles from a vod vaccum oxygen decarburization process, which is used for producing stainless steels with ultralow carbon grades, was. Indeed, many of the reactions interfere with one another. This book presents an overview of steelmaking, the relevance of modeling and.
Analysis of melt flow in metallurgical vessels of steelmaking. A comprehensive model of oxygen steelmaking that includes the kinetics of scrap melting, flux dissolution, slag chemistry, temperature profile of the system, formation and residence of metal droplets in the emulsion, and kinetics of decarburization reaction in different reaction zones was developed. How steel is made using the basic oxygen steelmaking process. Our task is to develop a predictive model which could be. Data based modeling approach to iron and steel making processes sachin santosh1, ajay kumar shukla2 1m. Pdf a process model for eaf steelmaking semantic scholar. Multiphase and turbulent fluid flow and within each vessel in the process, incorporating the effects of gas stirring oxygen. Using steel mill wastes as feedstock will assist steelmakers to achieve zero waste status.
The scheduling of steelmaking continuouscasting scc processes is of major importance in iron and steel operations, since it is often a bottleneck in iron and steel production. Semantic scholar extracted view of a process model for eaf steelmaking by jens wendelstorf et al. To learn about our use of cookies and how you can manage your cookie settings, please see our cookie policy. Simulation and modelling of metallurgical processes in steelmaking. Dec 26, 2018 in the paper flow sheet, modeling based approach with coupled application of metsim is demonstrated for modeling of blast furnace ironmaking, bof steelmaking and ladle furnace processes.
Marr applications technology group baker refractories york, pa 174051189 abstract this paper attempts to illustrate the benefits of using slag models based on the thermodynamics of steelmaking reactions and the multidimensional modeling of phase equilibria. Professor, department of metallurgical and materials engineering, iit madras, chennai, 600036, india abstract. A primary steelmaking process refers to the actual process of taking the raw materials and converting them to steel steelmaking. Therefore, this research is motivated to verify the suitability of potential applications of rf. Modeling of steelmaking processes meets that everpresent demand and provides a solid knowledge base on which to build. Although there have been several studies on the applications of rf, ann, denfis and svm for modeling the inputoutput parameters of different complex processes, modeling using these techniques especially on prediction of output yield of the steelmaking process was not reported in the literature. Pdf in a steelmaking shop, the output yield is considered as an important performance measure while producing a specific amount of steel. Principles and applications 344 pages 2000 ahindra ghosh 1420042319, 97814200423 the steelmaking industry and its customers have benefited enormously from the many significant technological advances of the last thirty years. Synthesizing the science and its technology, the author examines the relevant reactions and phenomena, presents an integrated picture of clean steel manufacture, and provides an. Chapter 1 steelmaking, modeling,andmeasurements 1 1. It is the objective of management to maintain a high percentage of the yield.
Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets electric arc furnace steelmaking continuous casting design by cover photo. In the field of experiment, theory, modeling and simulation, the most noteworthy progressions applicable to steelmaking technology have been closely linked. Decarburization in impact zone neslihan dogan, geoffrey alan brooks and muhammad akbar rhamdhani faculty of engineering and industrial science, swinburne university of technology, hawthorn, vic 3122 australia. Understanding of underlyingbasic principles of steelmaking helps to design, optimize and control the large scale industrial. In the past, the kinetics of reactions as affected by mixing energy were emphasized. Steelsim 2021 9th international conference on modeling. The use of these personal computer based programs has become an indispensable tool for the optimization of steelmaking processes.
Steelmaking problems scope of proposed work proposed research method industry needs problem formulation multiscale modeling model lab experiments data industrial trialsvalidation process, product optimization studies industry dataparameters modeling tools for steel processes thermodynamic metsim cfd 0 20 40 60 80 100 0 50. Pdf development and application of models for steelmaking and. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. In principle, steelmaking is a melting, purifying, and alloying process carried out at approximately 1,600 c 2,900 f in molten conditions. Analyzes mechanistic, aibased, and macroscopic models, to provide a holistic view of steelmaking process modeling. In the paper flow sheet, modelingbased approach with coupled application of metsim is demonstrated for modeling of blast furnace ironmaking, bof steelmaking and ladle furnace processes. A secondary steelmaking process refers to operations that refine the crude steel before converting the liquid steel into a solid. However, these processes are highly complex with large variations in time and length, and this makes the systems extremely demanding to. Optimal scheduling of scc processes can increase profit, minimize production cost, reduce material and energy consumption, and improve customer satisfaction. Control of melt flow in steelmaking processes is important for technology optimization and product quality.
It represents the operational efficiency of the steelmaking shop. The programs are either used online to control the. Then, the engineers and plant operators are in search of simple models which represent with reasonable accuracy the bof decarburization and the thermal phenomena. Ann modeling of a steelmaking process springerlink. This is done by adding or removing certain elements andor manipulating the temperature and production environment. With content designed to serve professionals and students, this book starts with an overview of steelmaking and develops into a. Continued development and installation of these processes will help relieve pressure on future prime scrap supplies and lessen domestic dependence on imported cold pig iron. The development of a global model for oxygen steelmaking and its validation against industrial data has been reported in part 1 of this paper. Contents preface xu1 authors xvii nomenclature xix chapter 1 steelmaking,modeling,andmeasurements 1 1. Thermodynamicsbased modeling of iron and steelmaking. Continuous steelmaking has the potential to use energy more efficiently, lower production costs, lessen environmental impact, and increase steel quality and consistency. Most shops have incorporated computer modeling which is very reliable for determining many of the elements recovered from a scrap.
Numerical simulation of decarburization in a topblown. Designing a new scrapbased continuous steelmaking process. Apr 28, 2020 new method for estimating the economic penalties of ferrous scraps in the steelmaking industry due to material degradation during its storage in scrap yards vicente et al. Addresses fundamental principles of physical and mathematical modeling in steelmaking processes modeling of steelmaking processes meets that everpresent demand and provides a solid knowledge base. Over the last few decades, a number of cfd models have been dedicated to increasing the understanding of the decarburization processes in steelmaking. Evans from the prediction of complex weather patterns to the design of swimsuits, modeling has, over the years, quietly but steadily become an essential part of almost every field and industryand steelmaking is no exception.
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