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Objectives Slag detection in steel manufacturing is essential for ensuring high product quality and process efficiency. The purpose of the accelerometer-based data is to allow for accurate monitoring and differentiation between slag and molten metal flow. This is vital to prevent equipment damage, maintain steel quality, and enhance operational effectiveness. The data is collected specifically to support the development of machine learning models for real-time monitoring in the steel production process, addressing the critical need for precise slag detection. Data description The Steel Slag Flow Dataset (SSFD) offers a comprehensive set of data obtained from a triaxial accelerometer during various stages of steel production. By leveraging this dataset, researchers can effectively analyze and classify the flow of slag versus molten metal. The dataset allows for data-driven approaches so that machine learning researchers can optimize steel manufacturing processes, ensuring high-quality steel production and minimizing the risks associated with slag contamination. The SSFD provides a valuable resource for researchers seeking to enhance predictive maintenance and monitoring in industrial applications.

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.

To elucidate the distribution law of the multiphase coupling slag discharge flow field in gas-lift reverse circulation during drilling shaft sinking, a numerical analysis model of gas–liquid–solid multiphase coupling slag discharge was established by CFD–DEM (Coupling of computational fluid dynamics and discrete element method) method, taking the drilling of North Wind well in Taohutu Coal Mine as an example. This model presented the distribution of the multiphase flow field in the slag discharge pipe and at the bottom hole, and was validated through experimentation and theoretical analysis. Finally, the impact of factors, including bit rotation speed, gas injection rate, air duct submergence ratio, and mud viscosity on the slag discharge flow field was clarified. The results indicated that the migration of rock slag at the bottom of the well was characterized by “slip, convergence, suspension, adsorption, and lifting”. The slag flow in the discharge pipe exhibited the states of “high density, low flow rate” and “low density, high flow rate”, respectively. The multiphase fluid flow patterns in the well bottom and slag discharge pipe were horizontal and axial flows, respectively. The model test of the gas lift reversed circulation slag discharge and the theoretical model of the bottom hole fluid velocity distribution confirmed the accuracy of the multiphase coupling slag discharge flow field distribution model. The rotation speed of the drill bit had the most significant impact on the bottom hole flow field. Increasing the rotation speed of the drill bit can significantly enhance the tangential velocity of the bottom hole fluid, increase the pressure difference between the bottom hole and annular mud column, and improve the adsorption capacity of the slag suction port. These findings can provide valuable insights for gas lift reverse circulation well washing in western drilling shaft sinking.

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.

The entrained flow gasification has been identified as the most promising gasification technology. Serious environmental pollution and waste of land resources are caused by the increasing amount of storage and production of coal gasification slag. The aim of this work is to explore the feasibility of high-temperature combustion and melting technology for treating coal gasification fine slag and determine the important parameters of system operation. The flow properties and molten slag structure characteristics of three fine slags from different entrained flow gasifiers were studied. Depending on the melting mechanism of melt-dissolution, the melting time of fine slags is short. Three fine slags all produce glassy slags, which is conducive to slag discharge. The degree of polymerization of silicate melt is proportionate to the amount of SiO 2 in the slag. A part of Al 3+ exist in the form of [AlO 4 ] 5− because of the effect of CaO and Na 2 O, as the network former. Finally, the degree of polymerization of the three type molten slag was calculated by considering the role of Si and Al in molten slag and the property of each one.

Combined with the advanced drilling of the central return air shaft in Kekegai Coal Mine, the distribution law of slag discharge flow field by drilling method and the influencing factors of slag discharge effect are studied. Firstly, the numerical model of gas–liquid–solid coupling slag discharge is established by CFD-DEM (computational fluid dynamics coupled discrete element method). Then, the flow field distribution law of the site slag outlet layout model and the optimization model is compared and analyzed. Finally, the influence of drilling parameters on slag discharge effect is studied. The results show that the best arrangement of slag suction ports is: the number is two, the length-diameter ratio is 0.4, the area ratio is 1, and the total area ratio is 1.94%. The fluid movement at the bottom of the well is mainly tangential flow, while the fluid in the slag discharge pipe is mainly axial flow. The construction parameters of efficient slag discharge are put forward: bit rotation speed is 8.7 r/min, gas injection rate is 4200 m 3 /h, air duct sinking ratio is 0.84, and mud viscosity is 165 MPa·s. The research results can provide useful theoretical reference for large-scale sinking construction in deep wells.

The behaviors of the slag layers formed by the deposition of molten ash onto the wall are important for the operation of entrained coal gasifiers. In this study, the effects of design/operation parameters and slag properties on the slag behaviors were assessed in a commercial coal gasifier using numerical modeling. The parameters influenced the slag behaviors through mechanisms interrelated to the heat transfer, temperature, velocity, and viscosity of the slag layers. The velocity profile of the liquid slag was less sensitive to the variations in the parameters. Therefore, the change in the liquid slag thickness was typically smaller than that of the solid slag. The gas temperature was the most influential factor, because of its dominant effect on the radiative heat transfer to the slag layer. The solid slag thickness exponentially increased with higher gas temperatures. The influence of the ash deposition rate was diminished by the high-velocity region developed near the liquid slag surface. The slag viscosity significantly influenced the solid slag thickness through the corresponding changes in the critical temperature and the temperature gradient (heat flux). For the bottom cone of the gasifier, steeper angles were favorable in reducing the thickness of the slag layers.

Gasification of coal is gaining more popularity due to its clean operation, and its ability to generate products for various markets. However, these technologies are not widely commercialized due to reliability and economic issues. Mineral matter in coal plays an important role in affecting the availability/reliability of a gasifier. Agglomeration in the bed, slag mobility and blockage of the syngas exit section are some of the operations related concerns in fixed-bed gasifiers, while ash deposition and sudden defluidization are the major concerns in fluidized bed gasifiers. In the case of entrained flow gasifiers, syngas cooler fouling and blockage, corrosion and erosion of refractory, and slag mobility are some of the major issues affecting the operations and the reliability of the gasifier. This review is aimed at critically examining various mineral matter related issues contributing to the operation and reliability problems in three types of generic gasifiers (fixed bed, fluidized bed and entrained flow gasifiers). Based on the review, some strategies to counter the potential mineral matter related issues are presented.

A terminal Iron Age furnace threatened by suburban development in Cato Manor, Durban, was excavated in 1989. The furnace is of a type previously unknown in Natal and may represent a second Late Iron Age smelting tradition in this region. Speculation concerning the practitioners of this tradition and discussion of the relationship between this furnace and other smelting sites in the Durban area is provided. The discussion is extended to include the distribution of smelting sites in southern Natal, and suggestions concerning where concentrations of smelting sites are likely to be found south of the Mngeni River.

Increasing global cement and steel consumption means that a significant amount of greenhouse gases and metallurgical wastes are discharged every year. Using metallurgical waste as supplementary cementitious materials (SCMs) shows promise as a strategy for reducing greenhouse gas emissions by reducing cement production. This strategy also contributes to the utilization and management of waste resources. Controlled low-strength materials (CLSMs) are a type of backfill material consisting of industrial by-products that do not meet specification requirements. The preparation of CLSMs using metallurgical waste slag as the auxiliary cementing material instead of cement itself is a key feature of the sustainable development of the construction industry. Therefore, this paper reviews the recent research progress on the use of metallurgical waste residues (including blast furnace slag, steel slag, red mud, and copper slag) as SCMs to partially replace cement, as well as the use of alkali-activated metallurgical waste residues as cementitious materials to completely replace cement for the production of CLSMs. The general background information, mechanical features, and properties of pozzolanic metallurgical slag are introduced, and the relationship and mechanism of metallurgical slag on the performance and mechanical properties of CLSMs are analyzed. The analysis and observations in this article offer a new resource for SCM development, describe a basis for using metallurgical waste slag as a cementitious material for CLSM preparation, and offer a strategy for reducing the environmental problems associated with the treatment of metallurgical waste.