Slag-hanging capacity numerical simulation and analysis of blast furnace copper cooling plate

ZHANG Zhen, TANG Jue, CHU Mansheng, SHI Quan, WANG Chuanqiang

Iron and Steel ›› 2024, Vol. 59 ›› Issue (11) : 54-64.

PDF(4707 KB)
Welcome to visit Iron and Steel, July 23, 2025
PDF(4707 KB)
Iron and Steel ›› 2024, Vol. 59 ›› Issue (11) : 54-64. DOI: 10.13228/j.boyuan.issn0449-749x.20240154
Raw Material and Ironmaking

Slag-hanging capacity numerical simulation and analysis of blast furnace copper cooling plate

Author information +
History +

Abstract

In the middle and late stage of the blast furnace, the slag layer was mainly used to protect the furnace body. Reasonable operation of the furnace type helped the blast furnace to maintain uniform distribution of gas flow and smooth operation of the furnace. However, there were some problem in the blast furnace with cooling plate, such as incomplete research on slag hanging mechanism and unreasonable calculation method of slag layer. Based on ANSYS "life and death unit" technology, 3D slag hanging mechanism model of the cooling plate had been constructed, designed an iterative method of slag cycle in the cooling plate model, it helped to solve the above problems. The influence of working conditions on slag-hanging ability was analyzed emphatically. The analysis result showed, the gas temperature increased from 1 200 ℃ to 1 600 ℃, the slag layer decreased from 56 mm to 8 mm. When the gas temperature was 1 550 ℃, the copper cooling plate would exceeded safe operating temperature (120 ℃). The thermal conductivity increased from 1.2 W/(m2·℃) to 2.2 W/(m2·℃), and the slag layer was able to be thickened by 76%-85%, however the slag layer would became non-uniform. When the temperature of slag-hanging increased by 50 ℃, the slag layer increased by about 6.9-7.6 mm, and the uniformity of slag layer increased by 10%. The maximum temperature of cooling plate could reduced by 5-10 ℃ when the cooling water speed increased by 1 m/s. The cooling water temperature was reduced by 10 ℃, and the maximum temperature of cooling plate and the measuring point temperature could reduced about 10 ℃. Comprehensive mechanism model analysis and the actual situation on site, it was recommended that the slag skin thermal conductivity coefficient was maintained at 1.6 W/(m2·℃) or less, the slag hanging temperature was maintained at 1 100-1 150 ℃, the cooling water speed was at 1.5-2.5 m/s, and the cooling water temperature was at 25-35 ℃, the cooling plate hanging slag was more reasonable, and the blast furnace could maintain a more uniform operation of the furnace type. The above analys was provided theoretical basis and foundation for the blast furnace to extend furnace service and keep smooth operation.

Key words

blast furnace / cooling plate / slag-hanging capacity / heat transfer / ANSYS "birth-death" element / numerical simulation

Cite this article

Download Citations
ZHANG Zhen, TANG Jue, CHU Mansheng, et al. Slag-hanging capacity numerical simulation and analysis of blast furnace copper cooling plate[J]. Iron and Steel, 2024, 59(11): 54-64 https://doi.org/10.13228/j.boyuan.issn0449-749x.20240154

References

[1] 鞠贵冬, 吴俐俊, 陆祖安. 基于CFD模拟和热态实验的高炉冷却壁传热分析[J].钢铁研究学报,2016,28(2):9.(JUN G D, WU L J, LU Z A. Heat transfer mechanism study of blast furnace cooling wall based on hot CFD simulation and model experiment[J]. Journal of lron and Steel Research, 2016, 28(2):9.)
[2] 李晨晓, 姚鑫, 林岩, 等. 高炉渣余热回收数值模拟研究进展[J]. 钢铁, 2024, 59(5):12.(LI C X, YAO X, LIN Y, et al. Progress in numerical simulation of waste heat recovery of high furnace slag[J]. Iron and Steel, 2024, 59(5):12.)
[3] 李佳,陈帅,罗石元, 等. 高炉冷却壁冷却水管破损处理与数值模拟[J]. 中国冶金, 2023, 33(6):122.(LI J, CHEN S, LUO S Y, et al. Treatment and numerical simulation for cooling water pipe damage of blast furnace cooling stave[J]. China Metallurgy, 2023, 33(6):122.)
[4] 王旭, 姚灏, 陈卉婷, 等. 高炉炉缸炉底热应力模拟[J]. 钢铁, 2023, 58(12):23.(WANG X, YAO H, CHEN H T, et al. Simulation of thermal stress at hearth and bottom of a blast furnace[J]. Iron and Steel, 2023, 58(12):23.)
[5] 陈畏林, 李熠, 宋钊, 等. 武钢8号高炉投产11年生产实践[J] .中国冶金, 2021, 31(10):62.(CHEN W L, LI Y, SONG Z, et al.Practice of No.8 blast furnace put into production in WISCO for 11 years[J] .China Metallurgy, 2021, 31(10):62.)
[6] CUI K K, WANG J, WANG H, et al.Erosion behavior and longevity technologies of refractory linings in blast furnaces for ironmaking: A review[J]. Steel Research International, 2022, 93(11): 2200266.
[7] 孙瑞靖,康月,丁洪玲,等.喷吹工艺参数对高炉渣粒化成珠效果的影响[J].钢铁,2024,59(7):159.(SUN R J, KANG Y, DING H L, et al. Effect of injection process parameters on the effect of high slag[J]. Iron and Steel,2024,59(7):159.)
[8] YANG W C.Structure and casting process optimization of inclined copper cooling stave for HIsmelt furnace using process simulation based on Taguchi method[J]. International Journal of Metalcasting, 2024, 18:1012.
[9] SHI Q, TANG J, CHU M S.Numerical simulation of slag layer and its distribution on hot surface of copper stave based on ANSYS birth-death element technology[J]. Journal of Iron and Steel Research International, 2021, 28:507.
[10] SHI Q, TANG J, CHU M S.Key issues and progress of industrial big data-based intelligent blast furnace ironmaking technology[J].International Journal of Minerals, Metallurgy and Materials, 2023, 30(9):1651.
[11] ZHANG Z, TANG J, CHU M S, et al.The amount prediction and optimization of the returned ore generated from sintering process based on SHAP value and ensemble learning[J]. Steel Research International,2023, 94(9):2300114.
[12] 李宏扬, 李欣, 刘小杰, 等. 基于FEA和DNN的高炉炉缸侵蚀状态监测模型[J]. 钢铁, 2023, 58(12):41.(LI H Y, LI X, LIU X J, et al. Based on FEA and DNN blast furnace hearth erosion state monitoring model[J]. Iron and Steel, 2023, 58(12):41.)
[13] JIAO K X, ZHANG J L, LIU Z J, et al.Cooling phenomena in blast furnace hearth[J]. Journal of Iron and Steel Research International, 2018, 25(10):1010.
[14] 王国栋, 刘振宇, 张殿华, 等. 钢铁企业创新基础设施及研究进展[J]. 钢铁, 2023, 58(9):2.(WANG G D, LIU Z Y, ZHANG D H, et al. Steel enterprise innovation infrastructure(SEll) and its research development[J]. Iron and Steel, 2023, 58(9):2.)
[15] DENG Y, JIAO K X, WU Q, et al.Damage mechanism of copper stave used in blast furnace[J]. Ironmaking and Steelmaking, 2018, 45(10):886.
[16] 伍积明, 邹忠平, 许俊. 高炉冷却板的传热分析[J]. 四川冶金, 2008(3):56.(WU J M, ZONG Z P, XU J. Heat transfer analysis of the blast furnace cooling plate[J]. Sichuan Metallurgy, 2008(3):56.)
[17] 杨为国,吴启常. 高炉冷却板及炉衬温度场数值分析[C]// 2001中国钢铁年会论文集(上卷).北京:冶金工业出版社,2001:4.(YANG W G, WU Q C. Numerical analysis of temperature field of blast furnace cooling plate and furnace lining[C]//Proceedings of 2001 China Steel Annual Conference (Volume 1). Beijing:Metallurgical Industry Press, 2001:4.)
[18] 吴桐, 程树森. 高炉铜冷却壁炉衬侵蚀挂渣模型及工业实现[J]. 炼铁, 2011, 30(5):26.(WU T, CHENG S S. Modeling and industrial realization of slag hanging from blast furnace copper cooling wall lining erosion[J]. Ironmaking, 2011, 30(5):26.)
[19] 钱亮, 程素森, 李维广, 等. 铜冷却壁炉墙内型管理传热学反问题模型[J]. 炼铁, 2006(2):18.(QIAN L, CHENG S S, LI W G, et al. Inverse problem model of copper cooled fireplace wall interior management[J]. Ironmaking, 2006(2):18.)
[20] WU T, CHENG S S.Model of forming-accretion on blast furnace copper stave and industrial application[J]. Journal of Iron and Steel Research International, 2012, 19(7):1.
[21] 吴桐, 程树森. 高炉铜冷却壁合理操作建议[J]. 钢铁, 2010, 46(10):11.(WU T, CHENG S S. Suggestions for reasonable operation of copper cooling stave of blast furnace[J]. Iron and Steel, 2010, 46(10):11.)
[22] 程素森, 孙磊, 杨天钧. 正常炉况下炉衬和冷却板稳态温度场的研究[J].钢铁, 2004, 39(2):14.(CHENG S S, SUN L, YANG T J. Study on the steady-state temperature field of furnace lining and cooling plate under normal furnace condition[J]. Iron and Steel, 2004, 39(2):14.)
[23] CHOI S W, KIM D.On-line ultrasonic system for measuring thick of the copper stave in the blast furnace[J]. AIP Conference Proceedings, 2012, 1430(1):1715.
[24] LIU D L, ZHANG W, XUE Z L, et al.Simulation and validation of thickness of slag crust on the copper stave in the high-temperature area of blast furnace[J]. Metals, 2023, 14(1): 19.
[25] GANGULY A, REDDY A S, KUMAR A.Process visualization and diagnostic models using real time data of blast furnaces at tata steel[J]. ISIJ International, 2010, 50(7): 1010.
[26] YEH C P, HO C K, YANG R J.Conjugate heat transfer analysis of copper staves and sensorbars in a blast furnace for various refractory lining thickness[J]. International Communications in Heat and Mass Transfer, 2012, 39(1): 58.
[27] ATRI S, KUMAR A, GAUTUTAM S, et al.Microscale modelling of electret filters using disordered 2-D domains[J]. Powder Technology, 2024, 431: 119094.
[28] LI Z, ZHENG Q, ZHAN L, et al.Numerical simulation of H2-intensive shaft furnace direct reduction process[J]. Journal of Cleaner Production, 2023, 409:137059.
[29] 焦克新, 张建良, 刘征建, 等. 关于高炉炉缸长寿的关键问题解析[J]. 钢铁, 2020,55(8):193.(JIAO K X, ZHANG J L, LIU Z J, et al. Analysis of key issues on longevity of blast furnace hearth[J]. Iron and Steel, 2020, 55(8):193.)
[30] LIU W, SHAO L, ZOU Z, et al.Asymptotic model of refractory and buildup state of the blast furnace hearth[J]. Metallurgical and Materials Transactions B, 2022, 53:320.
PDF(4707 KB)

83

Accesses

0

Citation

Detail

Sections
Recommended

/