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2013年 20卷 9期
刊出日期：2013-09-15
Review
材料
工艺
Review
1
SUN Wen-qiang,CAI Jiu-ju,SONG Jun
Plant-Wide Supply-Demand Forecast and Optimization of Byproduct Gas System in Steel Plant
Considerable energy is consumed during steel manufacturing process. Byproduct gas emerges as secondary energy in the process; however, it is also an atmospheric pollution source if it is released into the air. Therefore, the optimal utilization of byproduct gas not only saves energy but also protects environment. To solve this issue, a forecast model of gas supply, gas demand and surplus gas in a steel plant was proposed. With the progress of energy conservation, the amount of surplus gas was very large. In a steel plant, the surplus gas was usually sent to boilers to generate steam. However, each boiler had an individual efficiency. So the optimization of the utilization of surplus gas in boilers was a key topic. A dynamic programming method was used to develop an optimal utilization strategy for surplus gas. Finally, a case study providing a sound confirmation was given.
2013 Vol. 20 (9): 1-7 [
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工艺
8
SU Bu-xin,ZHANG Jian-liang,WANG Da,SHAO Jiu-gang,REN Shan,WANG Guang-wei
Rules of Assimilation of Single Ore and Mixed Ores
Assimilation behaviors of 7 kinds of iron ores from Australia, Brazil, India, South Africa and China were evaluated and analyzed. On the basis of that, four ore blending principles were proposed, and seven groups of iron ore powder blending schemes were designed. The ores of different types or from different places are shown apparently different in assimilation. The assimilation of hematite in Australia, Brazil and India is relatively high, but the assimilation of magnetite in South Africa and China and specularite in China is relatively low. The assimilation of the ores has negative correlation with MgO content and binary basicity, while the assimilation of the ores has positive correlation with porosity, SiO2 and Al2O3 contents, and crystal water. The iron ores with smaller crystal size and microstructure looseness have relatively higher assimilation. Assimilation of mixed ores has relationship of linear, arch and “S” types to the ratio of single iron ore powder. When the charge ratio of ore is less than 25%, it possesses additivity, providing theoretical basis for optimization of ore matching.
2013 Vol. 20 (9): 8-15 [
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16
LIANG Ru-quan,YANG Shuo,YAN Fu-sheng,HE Ji-cheng
Kinetics of Oxidation Reaction for Magnetite Pellets
An experiment for the oxidation process of single magnetite pellet and theoretical analysis based on modified unreacted core shrinking (MUCS) model were carried out, and the controlling mechanisms of the initial and developing reactions were examined, respectively. From the study of the initial reaction, it was found that the chemical reaction of surface is the controlling step of the overall reaction when the temperature is up to about 750 K, while the mass transfer through the gaseous boundary layer dominates the reaction rate when the temperature is above 750 K. As the reaction developing within the pellet, the mass transfer through the produced layer becomes the controlling step. In addition, the effects of reaction conditions (such as oxygen concentration, temperature) on the fractional oxidation of magnetite pellet were determined.
2013 Vol. 20 (9): 16-20 [
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REN Zhong-shan,,HU Xiao-jun,,CHOU Kuo-chih,
Calculation and Analysis of Sulfide Capacities for CaO-Al2O3-SiO2-MgO-TiO2 Slags
The empirical models of sulfide capacity calculated by traditional optical basicity do not consider the charge compensation of alkaline metal ions to Al3+ in the molten slags, so that the deviations between the calculated values and measured ones of sulfide capacity are inevitable. The relation between sulfide capacity and the corrected optical basicity put forward by Mills considering the charge compensation was investigated. Combined with the relation between sulfide capacity and temperatures, a novel and accurate calculation model of sulfide capacity was proposed, which was applied to calculate the sulfide capacities of CaO-Al2O3-SiO2-MgO and CaO-Al2O3-SiO2-MgO-TiO2 systems, where the sum of the CaO and MgO concentrations in the slags must be not lower than the Al2O3 concentration. It was also found that the calculated values were in a good agreement with the measured values, and the mean deviations were 257% and 265%, respectively.
2013 Vol. 20 (9): 21-25 [
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MIN Yi,,HUANG Jian,,LIU Cheng-jun,JIANG Mao-fa,YU Xue-qing
Physical Simulation of Molten Slag Granulation by Rotary Disk
A physical model of molten slag granulation by rotary disk was developed based on the mechanism of Newtonian liquid granulation. For geometrical similarity, the radius ratio of model disk to the prototype disk was chosen as 1∶1. For dynamic similarity, equality of Ohnesorge number between the model and the prototype was achieved firstly by compounding rosin and paraffin wax with mass ratio of 4∶1 as simulation liquid of molten blast furnace (BF) slag, and the simulation material can satisfy the similarity of liquid-solid transformation during falling in the medium; then equality of Reynolds number and Weber number was obtained by controlling the volumetric flow rate and the rotary speed, respectively. Model accuracy was verified by comparing the simulation data with the results reported in literature, which showed good agreement with the calculation results of empirical equation and the actual molten BF slag granulation from the view point of particle size. Furthermore, influences of disk radius, rotary speed and liquid flow rate on granulation were discussed using the developed model, and the Kitamura equation was modified according to the simulation data which can predict particle size more accurately. Using the modified equation, the operation parameters were predicted according to the flow rate of molten industrial BF slag.
2013 Vol. 20 (9): 26-32 [
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WANG Zhao-hui,GAO Quan-jie,YAN Chao,XIA Zhi-yong,ZHANG Yao-bing
Calculation and Analysis of Force in Roll System of 20-High Sendzimir Mill
The calculation of force for a roll system has significant effects on cold rolled thin strip gauge adjustment of a 20-high Sendzimir mill. According to the rolling parameters and rolling plans of a ZR-22BS-42 Sendzimir mill in a silicon steel factory, the contact force and the resultant force of each roll in the roll system were calculated both in the static state and in the rolling state through C++ programs. It was found that the contact force between the second intermediate driven roll and the back-up rolls B and C was much lower than that between the other rolls in static state. The results also demonstrated that the resultant force are 595%-62%, 377%-403%, 871%-887% and 539%-567% of the rolling force at the second intermediate driven roll, the second intermediate idler roll, the back-up rolls B and C and the back-up rolls A and D, respectively. It was also revealed that the minimum contact force generated between the first intermediate roll and the second intermediate idler roll is 2067 kN on the first rolling pass, and that on the second rolling pass, the minimum contact force generated between the second intermediate driven roll and the back-up roll C is 4707 kN.
2013 Vol. 20 (9): 33-39 [
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K S Abdel Halim
Theoretical Approach to Change Blast Furnace Regime With Natural Gas Injection
The operation of blast furnace using natural gas and oxygen enriched blast (composite blast technology) is considered in many countries to be standard operation for a modern blast furnace particularly in certain countries with cheap and stable supply of natural gas. The theoretical flame temperature (TFT) of combustion and the degree of direct reduction of iron oxides (rd) are considered as the main controlling parameters of composite blast technology. The calculated values of these parameters are mainly dependent on the amount of air blast consumption. This amount of air blast is measured before entering into blast stoves. Actually, some of air blast is lost through valves of air stoves. Consequently, the real volume of air blast in the furnace is less than the recorded value by amounts of 5%-15% which is not considered in the estimation of rd and TFT. The purpose is to analyze the different methods for estimation of air blast inside the blast furnaces and develop a theoretical model to calculate air blast consumption with high accuracy. Based on the calculation of air blast consumption, a complete roadmap is demonstrated to change the operation regime parameters of blast furnaces working on composite blast technology.
2013 Vol. 20 (9): 40-46 [
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FAN Jian-jun,,QIU Guan-zhou,JIANG Tao,GUO Yu-feng,MU Ke-lang
Improvement of Sinter Properties With Ultra Fine-Sized Iron Concentrate by HPRG
The experiments were conducted on the changes of sintering performance of one kind of ultra fine-sized iron concentrate with or without being processed by high pressure roll grinding (HPRG). The experimental results indicate that the specific surface area increases from 17230 to 22016 cm2/g when the iron concentrate is processed by HPRG. The permeability of sintering mix increases and the iron concentrate becomes easy to react with CaO reagent at high temperature. The effect gets intensified when iron concentrate and lime are processed together by HPRG. The further studies indicate that compared with the base case, the sinter quality also gets improved, in which the yield of sinter increases from 6724% to 6952% and further to 7168%, the tumble index (TI) increases from 6038% to 6213% and further to 6445%, and the productivity increases from 142 to 157 t/(m2·h) and further to 162 t/(m2·h) when the iron concentrate is processed by HPRG or is processed with lime together. The metallurgical properties of sinter also get improved when the iron concentrate is pretreated by high pressure roll. The results indicate that it is conducive to the increase of sinter quality and productivity when the iron concentrates are processed by HPRG.
2013 Vol. 20 (9): 47-52 [
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53
ZHANG Fu-ming
Design and Operation Control for Long Campaign Life of Blast Furnaces
At the beginning of 1990s, Shougang blast furnaces (BFs) No2, No4, No3 and No1 were rebuilt sequently for new technological modernization in succession. The campaign life of BFs No1, No3 and No4 reaches 164, 176 and 156 years, respectively, and the hot metal output of one campaign reaches 338, 3548 and 2637 Mt, respectively; the hot metal output of BF effective volume of one campaign reaches 13328, 13991 and 12560 t/m3, respectively, which reaches the international advanced level of BF high efficiency and long campaign life. In BF designing, several advanced BF long campaign technologies were adopted. BF proper inner profile was optimized, reasonable inner profile was adopted, and closed circulating soften water cooling technology was applied in 4 BFs. Double row cooling pipe high efficiency cooling stave was developed which could prolong the service life of bosh, belly and stack. Hot pressed carbon brick and ceramic cup hearth lining structure were applied and optimized. BF operation was improved continuously to ensure stable and smooth operation of BF. Hearth working condition control was strengthened, burden distribution control technology was applied to achieve reasonable distribution of gas flow, and heat load monitoring was strengthened to maintain BF reasonable working inner profile. Proper maintenance at the end of BF campaign was enhanced. Hearth and bottom service life was prolonged by adding titaniferous material and enhancing hearth cooling. Gunning of lining was carried out periodically for the area above tuyere zone.
2013 Vol. 20 (9): 53-60 [
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材料
61
HE Tong,LIU Yan-dong,SUN Wei,ZUO Liang
Formation of Nuclei With {111}<110> and {111}<112> Orientations of IF Steel at Early Stage of Recrystallization Using EBSD Analysis
The excellent deep drawability of interstitial free steel (IF steel) is closely related to its texture formed during recrystallization. The nucleation process of cold rolled IF steel at the early stage of recrystallization was investigated by electron back scattered diffraction (EBSD). The characteristics of the microstructure after deformation and the orientation of nucleation were observed. The results show that the deformed microstructure with 80% reduction could be subdivided into two groups. These two types of microstructure were characterized by their orientation and internal local misorientations. The nuclei with γ-orientation preferred to form in deformed bands with γ-orientation and at the boundaries between deformed grains with different orientations. The recrystallized grains with {111}<110> orientation appeared firstly in deformed matrix with {111}<112> orientation and consumed the matrix with {111}<112> to grow up, while the recrystallized grains with {111}<112> orientation were observed secondly in deformed matrix with {111}<110> orientation and consumed matrix with {111}<110> to grow up.
2013 Vol. 20 (9): 61-66 [
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ZHU Yuan-zhi,,LI Bing-liang,LIU Ping
Effect of Annealing and Hot Rolling on Grain Boundary Segregation of Arsenic in an Mn-Steel Microalloyed by Ti,Cr and Nb
Steel samples with size of 10 mm×10 mm×5 mm were cut down from a hot-rolled Mn-steel microalloyed by Ti, Cr and Nb and produced by compact strip production (CSP) technology. The samples were annealed at 950 ℃ for different time firstly, and then hot rolled or cooled in the air, in water and in furnace, respectively. Auger electron spectroscopy (AES) was used to study the effects of annealing and hot rolling on the segregation of arsenic at grain boundary (GB) in the steel. The results indicated that a higher content of arsenic was found at grain boundaries than in the matrix when the steel was annealed at 950 ℃ for 2 h and then cooled to room temperature by water quenching. But the content of arsenic at grain boundaries was similar to that in the matrix when the steel was annealed at 950 ℃ for 2 h and then cooled to room temperature by furnace cooling. A longer holding time, such as 12 h and 36 h at 950 ℃, resulted in a similar arsenic content at grain boundaries to that in the matrix of the steels. Hot rolling led to a similar content of arsenic at grain boundaries and within grains in the steels as well.
2013 Vol. 20 (9): 67-72 [
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YAN Peng,,LIU Zheng-dong,LIU Wei,BAO Han-sheng,WENG Yu-qing,
Hot Deformation Behavior of a New 9%Cr Heat Resistant Steel G115
The hot deformation behavior of a new heat resistant steel G115 designed for 650 ℃ ultra-supercritical (USC) power plants was experimentally studied. Hot compression test was carried out in the temperature range of 900-1200 ℃ and the strain rate range of 01-20 s-1 by using Gleeble-3800 thermal-mechanical simulator, and the corresponding flow curves were obtained. Experimental results show that the flow stress increases with the decrease of deformation temperature and the increase of strain rate. The hot deformation activation energy of G115 steel was determined to be 494 kJ/mol and the constitutive equation was also obtained. For convenience of the practical application, a good approximate equation was obtained for calculating the peak stress values of G115 steel under different deformation conditions. At the strain value of 09, natural logarithm of the critical Zener-Hollomon parameter Zc of G115 steel was determined to be in the scope of 4967 and 5065, above which there will be no dynamic recrystallization (DRX). And natural logarithm of the critical Zener-Hollomon parameter Zs of G115 steel was determined to be in the scopes of 4558 and 4627, below which full DRX may occur. Then, the status diagram of dynamic microstructures of G115 steel was established. In addition, the strain rate sensitivity of G115 steel is not constant during the test temperature range and it increases linearly from 900 to 1200 ℃. Therefore, hot deformation at higher temperatures would obtain better workability.
2013 Vol. 20 (9): 73-79 [
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YU Hai-yan
Microscopic Response of TRIP Steels to Prestrain During Plastic Deformation
In order to uncover the mechanism of elastic modulus degradation during plastic deformation, uniaxial tensile test of transformation-induced plasticity (TRIP) steels under different prestrain levels was carried out. The real elastic modulus unloaded at each prestrain was calculated by linearly fitting. The microstructure evolution with plastic strain and the fracture morphology were monitored by using a scanning electron microscope (SEM). Dislocation density and its distribution were detected under a transmission electron microscope (TEM). Microscopic mechanism of the elastic modulus degradation of TRIP steels was discussed in detail. Experimental results indicated that the investigated TRIP600 steel was of severe elastic modulus degradation during plastic deformation. The new-born martensite distributed among the retained austenite, resulting in the combination of good ductility and high strength for TRIP steels. It was the change of dislocation movement that induced the variation of atomic binding force and finally led to the variation of elastic modulus.
2013 Vol. 20 (9): 80-85 [
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CHEN Jun,SHEN Xin-jun,JI Feng-qin,TANG Shuai,LIU Zhen-yu,WANG Guo-dong
Effect of Annealing Time on Microstructure and Mechanical Properties of Cold-Rolled Niobium and Titanium Bearing Micro-alloyed Steel Strips
Effects of annealing time on microstructure of cold-rolled niobium-titanium bearing micro-alloyed steel strips were investigated by optical microscopy, scanning electron microscopy, electron back-scatter diffraction (EBSD) and transmission electron microscopy. The complete recrystallization annealing temperature of 670 ℃ and complete annealing time of 9 min were determined using Vickers-hardness testing and EBSD analysis. The ferrite microstructure with spheric cementite particles and nano-scale precipitates of Nb(C,N) in matrix was obtained. The kinetics of the ferrite grain growth is lowered due to ferrite grain boundaries pinned by the cementite particles, so the ferrite grain size of 55 μm remains unchanged among the annealing time ranging from 9 to 30 min. In addition, the strength of tested steel also keeps unchanged with the increase of annealing time. The higher yield strength of approximately 420 MPa can be obtained by grain refinement and precipitation hardening and the higher elongation of approximately 40% and work-hardening exponent of approximately 02 can be gained due to grain refinement and presence of cementite particles, indicating that the balance of strength, ductility and forming property is realized.
2013 Vol. 20 (9): 86-92 [
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WANG Hai-ren,,JIANG Yan,QU Jun-e,CAO Zhi-yong,LIU Shao-bo,GUO Xing-peng
Adsorption and Corrosion Inhibition Performances of 1-Tetradecylphosphonic Acid Self-Assembled Monolayers on 430 Stainless Steel Surface
The self-assembled monolayers (SAMs) of 1-tetradecylphosphonic acid (TDPA) formed on the 430 stainless steel (SS430) were studied. Surface and morphological characterizations were studied by Fourier transformed infrared spectroscopy (FTIR), water contact angle measurement and atomic force microscopy (AFM). And the electrochemical study on the corrosion inhibition of the SAMs was performed by polarization curve and electrochemical impedance spectroscopy (EIS) for evaluating the corrosion protection of the SAMs. The results show that TDPA was able to form a film spontaneously on the SS430 surface and the hydrophobic SAMs could protect SS430 from corrosion effectively. In addition, the oxide surface formed by the heat pretreatment could accelerate the rate of adsorption, but had little effect on improving the inhibition efficiency.
2013 Vol. 20 (9): 93-98 [
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99
YIN Shi-ke,A Rong,Mitsuru Tanino
Effects of Austenizing Temperature on Reprecipitation of BN
Most of BN was precipitated around the spherical MnS and formed the compound of MnS and BN during the isothermal treatment at 850 ℃ after austenizing at 950-1050 ℃. Most of MnS was transformed into polygon when austenized at 1150 ℃ or above, which could not be the nuclei of BN anymore. During the insulation process at 850 ℃, MnS kept the state of monomer. The compound of MnS and BN at earlier time was of fine polycrystalline in spherality and BN was formed as a plate-like monocrystal on a certain part of the polycrystalline when its dimension reached 06 μm.
2013 Vol. 20 (9): 99-104 [
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105
HUO Xiang-dong,MAO Xin-ping,L Sheng-xia
Effect of Annealing Temperature on Recrystallization Behavior of Cold Rolled Ti-Microalloyed Steel
In order to develop cold rolled Ti-microalloyed steel strips, the effects of annealing temperature on recrystallization behavior of experimental steel were researched by optical microscopy (OM), transmission electron microscopy (TEM) and Vickers hardness test. The annealing treatment could be divided into three distinct stages: recovery, recrystallization and grain growth. Recrystallization took place from 933 to 1033 K, during which a large number of recrystallized grains appear and hardness drops sharply. The morphology and size of TiN particles nearly remained unchanged at different stages of processing. With increasing annealing temperature, nanometer precipitates coarsened and the dislocation density was significantly reduced. In comparison with annealing time, annealing temperature was more crucial for recrystallization of cold rolled Ti-microalloyed steel. It could be concluded that the pinning force of nanometer particles on dislocations increased the recrystallization temperature. At higher annealing temperature, recrystallization took place because of precipitates coarsening caused by Ostwald ripening.
2013 Vol. 20 (9): 105-110 [
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111
G Banaszek,S Berski,H Dyja,A Kawaek
Theoretical Modelling of Metallurgical Defect Closing-Up Processes During Forming a Forging
Computer modelling using an FEM-based program, ie Forge 2008, was carried out. Laboratory modelling of the process of free hot forging in shaped anvils was conducted to close up metallurgical defects. Results obtained from the simulation modelling were processed by using a commercial statistical package, ie Statistica 60 PL. The influence of the anvil shape and main parameters of the forging process on closing up metallurgical defects were determined. On the basis of the investigation carried out, the optimal values of main forging technological parameters and suitable groups of anvils to be used in particular forging stages are proposed for the elimination of metallurgical defects.
2013 Vol. 20 (9): 111-116 [
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ZHOU Jian,MA Dang-shen,CHI Hong-xiao,CHEN Zai-zhi,LI Xiang-yang
Microstructure and Properties of Hot Working Die Steel H13MOD
Compared with H13 steel, the influences of different heat treatment process on the microstructure and properties of the new type of hot working die steel H13MOD were studied. The results show that the complete austenitizing temperature of H13MOD is around 1030 ℃ and the quenching hardness achieves the maximum value at this temperature. While for H13, the complete austenitizing temperature is above 1100 ℃ and the quenching hardness rise constantly with the quenching temperature increasing. In quenching process, the undissolved MC carbides can prevent the coarsening of grain in both steels. With the rise of quenching temperature, when MC carbides dissolve completely, the grain grows quickly. The hardness and strength of H13MOD at higher tempering temperature (above 570 ℃) are nearly the same as those of H13, but its toughness is higher than that of H13. Mo2C carbide is the main strengthening phase in H13MOD, which is attributed to the higher content of Mo. The quantity of VC eutectic carbides is reduced because of lower content of V in H13MOD, which plays an important role in enhancing the impact toughness of H13MOD. Under a certain strength condition, H13MOD steel can be used in the environment that higher toughness is required and the service life of die casting mold can be improved.
2013 Vol. 20 (9): 117-125 [
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S Narayan,A Rajeshkannan,K S Pandey,S Shanmugam
Workability Behaviour of Fe-C-Mo Steel Preforms During Cold Forging
A systematic method to construct the workability diagram for powder metallurgy (P/M) materials has been proposed. Preforms of Fe-08%C, Fe-08%C-1%Mo and Fe-08%C-2%Mo were prepared to the relative density of 086 with two different geometries through primary operations of P/M processes. Each sintered preform was cold upset forged with incremental compressive loading of 004 MN under three different lubricant conditions till a visible crack appeared at the free surface. Oyane′s fracture criterion was used to develop a theory to study P/M products. The least square method was used to determine the constants in fracture criteria and these equations were eventually used to construct workability diagram. It is found that the proposed method was well in agreement with the experimental results.
2013 Vol. 20 (9): 126-131 [
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