Process Simulation and Control Optimization of a Blast Furnace Using Classical Thermodynamics Combined to a Direct Search Algorithm

Several numerical approaches have been proposed in the literature to simulate the behavior of modern blast furnaces: finite volume methods, data-mining models, heat and mass balance models, and classical thermodynamic simulations. Despite this, there is actually no efficient method for evaluating quickly optimal operating parameters of a blast furnace as a function of the iron ore composition, which takes into account all potential chemical reactions that could occur in the system. In the current study, we propose a global simulation strategy of a blast furnace, the 5-unit process simulation. It is based on classical thermodynamic calculations coupled to a direct search algorithm to optimize process parameters. These parameters include the minimum required metallurgical coke consumption as well as the optimal blast chemical composition and the total charge that simultaneously satisfy the overall heat and mass balances of the system. Moreover, a Gibbs free energy function for metallurgical coke is parameterized in the current study and used to fine-tune the simulation of the blast furnace. Optimal operating conditions and predicted output stream properties calculated by the proposed thermodynamic simulation strategy are compared with reference data found in the literature and have proven the validity and high precision of this simulation

Thermophysical properties of 22 pure metals in the solid and liquid state – The pulse-heating data collection

The workgroup of subsecond thermophysics in Graz has a long tradition in performing fast pulseheating experiments on metals and alloys. Thereby, wire-shaped specimens are rapidly heated (108 K/s) by a large current-pulse (104 A). This method provides thermophysical properties like volume-expansion, enthalpy and electrical resistivity up to the end of the liquid phase. Today, no more experiments on pure metals are to be expected, because almost all elements, which are suitable for pulse-heating so far, have been investigated. The requirements for pulse-heating are: a melting point which is high enough to enable pyrometric temperature measurements and the availability of wire-shaped specimens. These elements are: Co, Cu, Au, Hf, In, Ir, Fe, Pb, Mo, Ni, Nb, Pd, Pt, Re, Rh, Ag, Ta, Ti, W, V, Zn, and Zr. Hence, it is the correct time to present the results in a collected form. We provide data for the above mentioned quantities together with basic information on each material. The uniqueness of this compilation is the high temperature range covered and the homogeneity of the measurement conditions (the same method, the same laboratory, etc.). The latter makes it a good starting point for comparative analyses (e.g. a comparison of all 22 enthalpy traces is in first approximation conform with the rule of Dulong-Petit which states heat capacity – the slope of enthalpy traces – as a function of the number of atoms). The data is useful for input parameters in numerical simulations and it is a major purpose of our ongoing research to provide data for simulations of casting processes for the metal working industry. This work demonstrates some examples of how a data compilation like this can be utilized. Additionally, the latest completive measurement results on Ag, Ni, Ti, and Zr are described