Yin R. Metallurgical Process Engineering
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Ruiyu Yin
Metallurgical Process Engineering
Ruiyu Yin
Metallurgical Process
Engineering
With 125 figures
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IndustryPress
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Springer
Author
Ruiyu Yin
Central Iron
& Steel Research Institute (CISRI), No.76 Xueyuan Nanlu, Haidian District,
Beijing, 100081, China
E-mail: hellenz@public3.bta.net.cn
Based on an originanaI Chinese edition:
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Industry Press, 2009.
ISBN 978-7-5024-4956-8
Metallurgical Industry Press, Beijing
ISBN 978-3-642-13955-0 e ISBN 978-3-642-13956-7
Springer Heidelberg Dordrecht London New York
Library of Congress Control Number:2010928903
© Metallurgical Industry Press, Beijing and Springer-Verlag Berlin Heidelberg 2011
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Foreword
Since the birth
of
modern steelmaking technique in the middle
of
nineteenth cen-
tury, iron and steel are consistently the important basic materials for development
of
national economy and society in the world and the output
of
steel product is an
important index
of
national strength. Thus, soon after foundation
of
new China,
the development strategy
of
"taking steel as the key link" was established. In or-
der to accelerate steel production, there was a movement
of
"making steel vastly",
and in spite
of
dear cost, the result were negligible, but it was all over as a histori-
cal event. Since implementation
of
open policy in China in the middle
of
eighties
of
the twentieth century and due to rapid development
of
machinery and construc-
tion industries, the demands for steel products have been increased tremendously,
in particular, because
of
right development strategy and continuous progress in
technique, Chinese steel industry has stepped into stage
of
healthy development.
In the nineties
of
the twentieth century, Chinese steel industry boomed. In 1996,
the output
of
crude steel in China was over 100 Mt and China became the largest
steel maker in the world and the output
of
crude steel was nearly doubled from
1990 to 2000. From 1996 to 2003, the output
of
crude steel was increased by over
100%. In 2003, the output
of
crude steel in China was over 220 Mt and at the
same time, the energy consumption per ton steel was decreased greatly, such cir-
cumstance was recognized as a miracle by the world steel business circle. The
author
of
this book has worked at steel works, research institution and national
industrial department as an engineer, researcher and manager for long time, and
experienced many important technical development projects, engineering practice,
decision-making process for development, accumulated rich knowledge, and has
been investigating and thinking
oretically, and formed a theoretical frame at the
level
of
metallurgical manufacturing process
of
steel enterprises, which has been
used and popularized in the process
of
technical progress and technical modifica-
tion
of
Chinese steel industry successfully as a main direction
of
development.
Based on the practice and thorough study for more than ten years, the author
proposes an issue
of
engineering science in steel manufacture process creatively.
He proposes that in metallurgical manufacture process there would have prob-
VI
Foreword
lems to be solved by the sciences with different time-space scales, namely, fun-
damental sciences, technological science, engineering science, etc. and it is indi-
cated that metallurgical industry is a typical process manufacturing industry. That
means, manufacturing process is the "foothold to be based upon" for these indus-
tries. The manufacturing process is
of
extensive correlation and infiltration in
process industry. The manufacturing process is correlated directly with the factors
much as product quality/varieties, cost /price, input/output, efficiency/benefit,
which affect on competitive
of
the steel plant in the market. On the other hand, it
is correlated with the factors
of
sustainable development as availability
of
re-
sources and energy, the emission
of
process, environment/ecology, and circular
economy. The steel manufacturing process has been built up gradually on the ba-
sis
of
fundamental study on chemical reaction, deformation and phase transforma-
tion
of
unit procedure and knowledge
of
designing, and development
of
equip-
ment for unit procedure. Now, from a viewpoint
of
scientific perception, the steel
manufacturing process has been studied quite thoroughly as a branch
of
fundamental science on the scale
of
atom/molecule, but
of
technological science
on the scale
of
procedure, device, it can be said, only a little has been studied, and
on the scale (level)
of
process, the study in the field
of
engineering science has
just started. Nevertheless, facing such complicated and serious dual challenge
of
enhancing competitive power in the market and sustainable development, world
steel industry has to promote steel plant structure adjustment and optimization
based on engineering science as one
of
the countermeasures.
So it can be said that the development and innovation in engineering science
are the response to the calling
of
the times.
The author has investigated quite deeply the essence, attribute and connotation
of
steel manufacturing process recently and indicates that metallurgical manufac-
turing process consists
of
three elements, which are flow, process network and
program, and the attribute
of
manufacturing process is
of
dissipative structure. He
describes the theoretical frame and connotation
of
metallurgical process engineer-
ing in details, including analysis-integration
of
steel manufacturing process, con-
trol
of
multi-factorial mass flow in steel manufacturing process. At the same time,
the author emphasizes the time in the manufacturing process, the operation dy-
namics in production
of
the steel plant and "interface technique" in production,
and sums up that steel enterprise should optimize the structure, and innovate in
operation mode.
For a modem enterprise, the sustainable development and possibility
of
deve-
loping circular economy should be considered. The author has proposed the direc-
tion
of
green manufacture for steel plants and the prospect
of
extending functions
of
steel manufacturing process to a circular economy. The description
of
physical
models
of
steel manufacturing process by the author will be useful to guide
concentrated integration
of
information technique with steel manufacturing
Foreword
vn
process for total control and intellectualization
of
the latter.
Based on deep understanding
of
the domestic and foreign steel enterprises, in
combination with the development
of
modern engineering science, the author
writes this book, "metallurgical process engineering", and doubtless, it is
of
great
importance in guiding the development
of
Chinese steel industry along the health-
ier path.
In the 2Ist century, steel is still the most important basic material and has
a very important position in national economy. The publication
of
this book will
be
of
great value as a reference for researchers, designing engineers, enterprisers
and managers
of
steel industry.
Beijing
May 2010
Changxu Shi
Preface
The twentieth century was the century in which metallurgy evolved from a handi-
craft to an engineering science. In the last thirty years
of
that century and, in par-
ticular, the twenty-first century, the world's steel industry, including the Chinese
steel industry, are facing with new challenges and opportunities for development.
New propositions have been put forward mainly by developments
of
the times,
advances in science and technology, and changes in the global ecology-
environment. Where further development
of
the steel industry is concerned, these
propositions cannot be resolved simply by providing answers to such individual
issues as quality and variety. A more important and forward-looking proposition
calls for the comprehensive resolution
of
a number
of
major integrated tasks such
as the enhancement
of
market competitiveness-including such aspects as pro-
duction costs, materials consumption, energy consumption, production efficiency
and investment benefits
-and
issues
of
sustainable development, such as the
availability
of
materials and energy resources, and ecological harmony. These
propositions for the steel industry in the new century cannot be solved by focus-
ing studies simply on the fundamental sciences (such as thermodynamics, kinetics
of
chemical reactions, etc.) and the applied sciences (such as the transport phe-
nomena and reaction engineering), but have to be resolved in their entirety by
studying the functions, structure, efficiency, and other process engineering issues
of
metallurgical manufacturing.
Also, if research in the fields
of
metallurgical and metallic material sciences is
limited to the fundamental or applied sciences or remains at the level
of
science
and technology, it will probably be difficult to find a coordinated resolution for all
the many complicated and practical problems in the production and construction
of
steel plants, and the efficient integration
of
information techniques into the
entire process
of
steel manufacturing may even be negatively affected. In order to
solve the above-mentioned integrated and complicated propositions, it is neces-
sary to study and investigate the problems at the process engineering level
of
en-
gineering science.
Science is the human activity
of
cognition. It is a "knowledge system that re-