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Fuel and combustion systems safety : what you don't know can kill you!
\"There are code books and there is manufacturer literature but prior to this book nothing brings it all together and explains the basics in a comprehensive yet simple manner. If you own or operate any kind of boiler, oven, furnace, or large heating equipment you need to read this book and understand the issues. Topics included in the book include case studies of explosions through the years, top combustion systems hazards, and hazard recognition and abatement issues. The book also provides an introduction to combustion and combustion equipment followed by fuel trains and safety systems\"-- Provided by publisher.
Book
Research and Application of Improving Temperature Uniformity During Tempering for Gas Heat Treatment Furnace
In order to meet the needs of high-temperature uniformity during tempering, based on the chamber gas heat treatment furnace, the influence factors were studied. A new structure combined homogenizing tray was designed. The technical path of combining high-speed burner, micro pulse combustion technology and Fuzzy PID temperature intelligent control was adopted to solve the problem of uniform heating, and a good application effect of [+ or -] 5 [degrees]C was achieved.
Journal Article
Development and progress on hydrogen metallurgy
Hydrogen metallurgy is a technology that applies hydrogen instead of carbon as a reduction agent to reduce CO
2
emission, and the use of hydrogen is beneficial to promoting the sustainable development of the steel industry. Hydrogen metallurgy has numerous applications, such as H
2
reduction ironmaking in Japan, ULCORED and hydrogen-based steelmaking in Europe; hydrogen flash ironmaking technology in the US; HYBRIT in the Nordics; Midrex H
2
™ by Midrex Technologies, Inc. (United States); H
2
FUTURE by Voestalpine (Austria); and SAL-COS by Salzgitter AG (Germany). Hydrogen-rich blast furnaces (BFs) with COG injection are common in China. Running BFs have been industrially tested by AnSteel, XuSteel, and BenSteel. In a currently under construction pilot plant of a coal gasification-gas-based shaft furnace with an annual output of 10000 t direct reduction iron (DRI), a reducing gas composed of 57vol% H
2
and 38vol% CO is prepared via the Ende method. The life cycle of the coal gasification—gas-based shaft furnace—electric furnace short process (30wt% DRI + 70wt% scrap) is assessed with 1 t of molten steel as a functional unit. This plant has a total energy consumption per ton of steel of 263.67 kg standard coal and a CO
2
emission per ton of steel of 829.89 kg, which are superior to those of a traditional BF converter process. Considering domestic materials and fuels, hydrogen production and storage, and hydrogen reduction characteristics, we believe that a hydrogen-rich shaft furnace will be suitable in China. Hydrogen production and storage with an economic and large-scale industrialization will promote the further development of a full hydrogen shaft furnace.
Journal Article
Study of the Influence of the Thermal Capacity of the Lining of Acid Melting Furnaces on Their Efficiency
First of all, the smelting equipment is the most important component of a foundry’s main production process and therefore requires constant reproduction. This is ensured by timely and high-quality maintenance and repair, the cost of which is 8–12% of the total costs. The technical and economic conditions of the enterprise itself depend on this, as the productivity of workers during production is directly related to the technical condition of the equipment and its downtime for repairs. An important factor in ensuring a melting furnace’s reproduction is a replacement of the worn lining, which leads to downtime of the smelting furnace and reduces the efficiency of its operation. The amount of torque required depends directly on the compound used. The quality of the manufacturing and sintering process of the lining, which provides the necessary durability, is affected by the heat capacity of the materials used when they are affected by the melting temperature of the alloys. In the present work, using the BRUKER D8 ADVANCE diffractometer, the Shimadzu XRF-1800 spectrometer and the STA 449 F1 Jupiter synchronous thermal analyzer, we probed the changes in the heat capacity of quartzite and PKMVI-3 under the action of temperatures of 200–1550 °C. This technology allows the manufacture of a lining that maintains high stability during operations at 1550–1600 °C melting modes.
Journal Article
Applications and Developments of Thermal Spray Coatings for the Iron and Steel Industry
The steel making processes involves extreme and harsh operating conditions; hence, the production hardware is exposed to degradation mechanisms under high temperature oxidation, erosion, wear, impact, and corrosive environments. These adverse factors affect the product quality and efficiency of the steel making industry, which contributes to production downtime and maintenance costs. Thermal spray technologies that circumvent surface degradation mechanisms are also attractive for their environmental safety, effectiveness and ease of use. The need of thermal spray coatings and advancement in terms of materials and spray processes are reviewed in this article. Application and development of thermal spray coatings for steel making hardware from the molten metal processing stages such as electric arc and basic oxygen furnaces, through to continuous casting, annealing, and the galvanizing line; to the final shaping process such as cold and hot rolling of the steel strips are highlighted. Specifically, thermal spray feedstock materials and processes that have potential to replace hazardous hard chrome plating are discussed. It is projected that novel coating solutions will be incorporated as awareness and acceptance of thermal spray technology grows in the steel making sectors, which will improve the productivity of the industry.
Journal Article
Increased Use of Natural Gas in Blast Furnace Ironmaking: Mass and Energy Balance Calculations
In blast furnace ironmaking, coke can be partially replaced by injected natural gas. Tuyère injection of cold natural gas is commonly practiced in North America. In this work, limits to the tuyère injection rate have been quantified with mass and energy balances. The fundamental origin of the limits is the endothermicity of methane injection. In principle, shaft injection of preheated and partially combusted methane would obviate the endothermic effect. However, the thermal and chemical energy parameter indicates that the energy requirement in the lower part of the furnace—to melt hot metal and slag—might not be met in the case of shaft injection. Tuyère injection of preheated methane might be a feasible alternative. Calculated combustion kinetics support the feasibility of partial combustion of preheated methane (with sub-stoichiometric oxygen) before injection.
Journal Article
Fluxing Options and Slag Operating Window for Metso's Sustainable DRI Smelting Furnace
Decarbonization of the steel industry has recently been the focus of many research and technological development tasks. Most of the developments are targeting the replacement of the highly C02 emissive blast furnace (BF), which has been the main primary smelting furnace in the ironmaking step of steel production. However, replacement of the BF has been a challenging task because of BF's many established capabilities over the years, especially its flexibility in using low-grade iron feed. In this regard, Metso has been developing an advanced furnace technology, Metso's Outotec direct reduced iron (DRI) smelting furnace. The recently developed 6-in-line electric furnace for DRI smelting can be used for primary smelting of DRI from blast furnace grade iron ore. Compared to the electric arc furnace (EAF), the DRI smelting furnace can handle larger slag volumes that emanate from the high gangue in BF-grade DRI. Therefore, slag fluxing plays an important role in operating the DRI smelting furnace. This paper presents fluxing options and proposes operating temperature windows for the DRI smelting furnace. The optimal operating temperature range is found to be between 1300 C and 1600 C. For the examined slag compositions, viscosity at 1500 C is <0.35 Pa s. Additionally, the effect of slag chemistry on the corrosion resistance of the MgO-based refractory materials has been experimentally investigated, and mag-nesia-chromite was observed to be more compatible for the studied slag composition and temperature ranges.
Journal Article