Use of Model Systems for Solving New Technological Problems in Blast-Furnace Production

Possibilities are considered for a model-based decision support system developed and put into pilot operation at the Magnitogorsk Metallurgical Combine (MMK) for appraisal of operation and prediction of process situations in blast furnaces. The main model blocks make it possible to calculate material and heat balances; model heat, slag and gas dynamic conditions of blast furnace operations; select burden composition; calculate the viscoplastic iron-ore materials zone; and predict process situations. The model system is implemented as a complex of program modules and integrated into the MMK information system. A module for calculating melting material and heat balances includes both fulfilment of overall generally accepted balances, and calculation for balances of iron, sulfur, manganese, and titanium. A Slag Regime program module makes it possible to determine the most important properties of melted slag for implementation of normal slag conditions of smelting, to find the ratio of iron-ore materials providing slag of required viscosity and viscosity gradient, and to produce cast iron with required sulphur content. A Gas Dynamics of Blast-Furnace Smelting program module accomplishes calculation and visual display of gas dynamic characteristics of a burden layer as well as assessment of the change in pressure drop and degree of burden balancing in separate zones of the furnace in the design period with the change of burden parameters. A program module built into a balanced model of the UrFU–MMK blast-furnace process makes it possible to find iron ore compositions providing preparation of slag of the required properties with respect to viscosity and viscosity gradient, and makes it possible to prepare cast iron of the quality required with respect to sulfur content. A Viscoplastic Iron-Ore Materials Zone of Blast Furnace program module performs model calculation of a set of parameters specifying radial nonuniformity of charge and gas flow distribution in blast furnaces. The module includes calculation of temperature characteristics of iron-ore materials used for smelting, which makes it possible to display the shape and position of the cohesive zone in the profile of the furnace in question. Some results are provided of practical application of the system developed, and recommendations are given for certain aspects of resolving production tasks using the model-based decision support system.