Yin R. Metallurgical Process Engineering
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Preface
fleets the essence and regularities
of
movement
of
various phenomena in the real
world in the form
of
categories, laws, and theorems." In the process
of
advancing
science, it is necessary, on the one hand, to sum up the essence
of
matters and
phenomena in the form
of
theories and to establish tenets and principles that must
be observed. On the other hand, however, we must also be aware that human be-
ings are prone to unavoidable limitations in their process
of
cognition. Thus,
while attention should be paid to the theories and principles that have been
summed up, one should at the same time avoid falling into the misapprehension
that everything should proceed from existing theoretical cognitions to the exclu-
sion
of
practical considerations. For example, taking existing theories and princi-
ples as the sole criteria
of
cognition would have the effect
of
ossifying and nar-
rowing the sciences and their disciplines, and even turn already obtained results
into fetters that restrict the further development
of
science. The reason for this is
the complexity
of
the material world and the existence
of
limitless variations,
levels or possibilities, even within limited dimensions
of
time and space. That is
why scientific theories naturally generate a great many schools and branches with
different characteristics, and why different systems
of
knowledge emerge even
within one and the same disciplines
of
science and new disciplinary branches are
formed with the passage
of
time.
In fact, metallurgy and the science
of
metallic materials
-the
main sciences
that support the development
of
the metallurgical industry
-themselves
face the
issues
of
disciplinary development, extension, and innovation. The methodologies
of
metallurgy and the science
of
metallic materials have for a long time been
based on the reduction theory. True, the methodology
of
the reduction theory has
played an important role in, and still affects, contemporary science and the devel-
opment
of
the modern sciences. The conversion
of
metallurgy and the metallic
materials theories from a handicraft to a science was brought about by the use
of
such methodology, for example the thermodynamics and kinetics
of
chemical
reactions, crystallography, the theories
of
phase transformation and so forth.
However, there are a great many important and complex problems in the metal-
lurgical industry's production and construction that cannot be solved simply by
means
of
the aforementioned fundamental theories. It must also be noted that
these important and complex problems are proliferating in rapid succession in the
wake
of
current developments . This has resulted in the emergence
of
the theories
of
such applied sciences as "transport phenomena and reaction engineering" and
"controlled rolling and cooling." Toward the end
of
the twentieth century and in
the twenty-first century in particular, the development
of
modern steel enterprises
has raised the proposition
of
developing engineering science for resolving inte-
grated issues on the basis
of
the fundamental and applied sciences, in the expecta-
tion
of
resolving complex integrated problems
of
greater dimensions and higher
levels-problems
that are
of
extreme importance for the development
of
enter-
Preface
XI
prises and society. This calls for research in the macroscopic engineering science
called Metallurgical Process Engineering.
Metallurgical process engineering pertains to the category
of
macroscopic en-
gineering science.
It
studies, in the main, the physical nature, structure, and entire
operation
of
the metallurgical manufacturing (production) process. Its aim is to
clarify the driving forces
of
the flow (and storage)
of
materials (and energy) re-
lated to the metallurgical manufacturing process, and it deals with the process
cycle that starts with the acquisition
of
materials and extends through product
manufacturing, use, consumption, and recycling. The problems
of
function-
structure-efficiency in the research and manufacturing processes involve a wide
range
of
knowledge concerning spatial and planar dispositions, the ordering and
control
of
time and time sequences, and the control and optimization
of
emissions
and waste elimination (or recycling) during those processes.
Nobelist Dr. Gell-Man Murray has pointed out, for a complicated, highly
nonlinear system, the whole behavior is not connected simply with the behavior
of
its parts. It is required that the whole behavior should be concerned from dif-
ferent sides widely and courageously, not with the details
of
some facets. From
the methodological point
of
view, the above passage indicates the understanding
that complicated and integrated problems in the domain
of
engineering science
cannot be resolved simply by means
of
the methodology
of
reduction theory. This,
of
course, does not negate using the methodology
of
reduction theory for studying
complicated and integrated problems
of
engineering science, and in some cases
the strong points
of
the reduction theory are still employed to analyze complicated
problems. However, it must be pointed out that these analyses are conducted
within the framework
of
an entirty concept, and the findings
of
these analytical
studies are then integrated into the overall framework. Hence, where the research
method
of
engineering science is concerned, it is important that we learn how to
combine entirty theory with reduction theory in a flexible and skillful way.
It may be said that at the present moment we have attained basically clear un-
derstandings
of
the knowledge
of
metallurgy and metallic materials at the level
of
the basic sciences. However, such understandings are still somewhere between
"basic" and "approximate" at the level
of
the applied sciences, and are only just
receiving attention and overall consideration at the engineering science level.
Hence, one might say that social progress, industrial development, the spreading
of
science, and the training
of
qualified personnel depend to a large extent on the
results
of
explorations and research in the fields
of
metallurgy and metallic mate-
rials at the level
of
engineering science.
In the new century, the world's steel industry and in particular the steel indu-
saies in China, India, Brazil and other developing countries are in a period
of
de-
velopmental opportunities
-opportunities
for coordinating and harmonizing steel
plants with the environment, for coordinating the structures
of
products, materials,
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Preface
and energy resources, for upgrading the technological structure
of
steel plants as
well as for further readjusting the distribution of the world's steel industries. At a
time when opportunities and challenges exist in tandem, the steel industry and
steel enterprises in particular should carry out comprehensive optimizations and
innovations
of
their entire structures. This is especially important for new and
upcoming investors.
I, the author
of
this book, have worked many years at steel enterprises and met-
allurgical departments and have acquired some understandings and cognitions
about this rise as I look back at many events during the rapid growth
of
the Chi-
nese steel industry in the I990s. During visits to the world's main steel plants and
exchanges with many well-known experts and scholars the world over, I have
come to see, at the level
of
engineering science, that the manufacturing process
(technological process)
of
the steel industry
-as
a typical process manufacturing
industry
-has
a highly correlative and permeating nature.
It
is, therefore, most important to explore and study the substance, the structure,
and the regularities
of
the metallurgical manufacturing process. In order to inves-
tigate and study the functions, structure, and efficiency
of
the manufacturing
process, one must first
of
all have a theoretical understanding
of
that process. The
initial understanding today is that the manufacturing process consists
of
three
main elements: "flow," "process network," and "order." The manufacturing proc-
ess is a "multi-factor (multi-dimensional) flow" that moves in a dynamic and or-
derly fashion and according to certain program within a complex net structure
(process net framework) composed
of
various procedures and inter-procedural
connectors, to realize certain groups
of
objectives."
This book is written along the following train
of
thought:
• Process manufacturing industry and process engineering.
• What is metallurgical process engineering?
• Analysis and integration
of
the steel manufacturing process.
• Multi-factor mass flow control in the steel manufacturing process.
• The paramater time in the manufacturing process.
• The operation dynamics
of
steel production processes.
• The structures and models
of
steel plants.
• Steel plants and the environment.
This book is written as a reference for the leadership stratum and technicians at
steel plants, teachers and post-graduate students at relevant institutions
of
higher
learning, researchers at design and research institutes, and high-level managers at
certain administrative departments. Due time constraints, some readers may be
interested in only a few
of
the chapters, for which reason some chapters have
been written as complete and relatively independent entities.
It
is thus unavoid-
able that the contents
of
some chapters are somewhat repetitive. Some repetition
may be permissible and even necessary, since this book is not an ordinary text-
Preface
XII!
book.
I encountered many difficulties in the writing this book. One
of
these was find-
ing the proper reference books. Another was the time needed for collating and
processing all the materials. In reality, however, the biggest difficulty lay in the
crystallization
of
the concepts and the abstraction and construction
of
the models.
Hence, the decade that it took me to prepare the book was in fact a process
of
"getting into the role"
of
theoretical cognition. Even now I do not claim to have
acquired a complete understanding, and errors and mistakes are unavoidable.
Where these occur, I sincerely hope my readers will correct me.
In the writing
of
this book, I received encouragement and support from acade-
micians Changxu Shi, Xianghua Shao, Jun Ke, Kuangdi Xu, Dainzuo Wang,
Shourong Zhang and Zhongwu Lu, and
Prof
. Ying Qu. Financial support for the
book by the state fund for key scientific and technical publications was recom-
mended and obtained by Academicians Changxu Shi and Shourong Zhang. As I
recall, when I was elected academician in 1994, Changxu Shi suggested that I
write a book describing my knowledge and lines
of
thinking with regard to fer-
rous metallurgy, and I have kept this suggestion constantly in mind. Thus, in the
last ten years, I have give assiduous attention to forming theoretical conceptions
at the level
of
engineering science as I studied, worked, and taught post-graduate
students. I must admit,
of
course, that the study
of
integrated problems
of
metal-
lurgy at the level
of
engineering science in still at an initial "getting-in-the-role"
stage, and many topics, in particular those connected with information techniques
and environmental sciences, require further study and exploration and are being
carried to greater depths in the course
of
actual application.
As I wrote this book, chapter by chapter, I revised and corrected it several times.
Prof. Ying Qu checked the drafts and gave me specific and considerate assistance.
Prof. Qu was my teacher when I was a student fifty years ago. We have kept up
contact for more than forty years, exchanging academic opinions from which I
derived a great deal
of
benefit. Seventy years old at this time, he checked my draft
line by line, and furnished many suggestions for modifications which helped to
bring this book to fruition. In the past ten years, Prof. Naiyuan Tian has constantly
supported me in my work, helped me with the teaching
of
post-graduates for doc-
toral degrees, and done much to enrich the theoretical and practical contents
of
the book. I must also mention a group
of
young Ph.D partners
ofmine
-
-Bingxi
Yi, Anjun Xu, Yingqun Wang, Xiaodong Wu, Jian Cui, Maolin Liu, Honghua
Tang, Qichun Peng, Qing Liu, Jian Qiu, and Xinping Mao. Studies and discus-
sions with them have done much to amplify and enrich the theoretical framework
of
this book. A few chapters in this book were checked and corrected by Acade-
mician Shourong Zhang. Some
of
the information was provided by Mr. Taichang
Wang, Zhixiang Yu, Jie Fu, Jian Cui, and Zhongbing Wang. I must also mention
Dr. Chunxia Zhang who contributed a great deal
of
effort in terms
of
collating,
compiling, proofreading and revising after she joined the research on this subject
XlV
Preface
in 1998. Mr. Xuxiao Zhang, who became my assistant in recent years, undertook
the work
of
sorting, arranging, and printing the draft. I wish to express my deep
gratitude to all the persons mentioned above for the help they have rendered.
Beijing
December 2009
Ruiyu Yin
Preface for the English Edition
The first printing
of
this book in Chinese edition was completed in May 2004.
The book summarizes my understanding and cognitions about metallurgical engi-
neering. Since 1990, I have come to see that the analyzing-optimization
of
the
functions
of
many procedures at steel plant has been occurred, which has been
resulted the coordinating-optimization between upstream and downstream proce-
dure and the restructing-optimization
of
whole steel manufacturing process has
been brought. It has been led to the changes
of
dynamic-operation mechanism and
the mode
of
steel plant by above evolution and optimization. Analysis-integration
method should be used for studying the contents.
Thanks to support from the Baoshan Iron & Steel Co., Ltd. (Baosteel), the first
distribution took place in Shanghai on May 28, 2004, a memorable event that
remains fresh in my mind. Thereafter, the Baosteel management, which had
evinced close concern for the contents
of
the book, specially organized a study
class voluntarily attended by about a hundred engineers and technicians. Starting
in July 2004 and ending in May 2005, I gave a total
of
twelve lectures at the rate
of
approximately one per month. On May 12 and 13, a summing-up seminar was
held at which eight experts at Baosteel delivered a number
of
vivid and variegated
academic reports, supported by visual displays, in connection with the production,
construction, and technological reforms at Baosteel. All these reports were
of
a
high caliber and quite stimulating. On the following day I gave a summing-up
discourse.
These lectures held by Baosteel helped me shed two misgivings that had been
bothering me before the book's publication. One was an apprehension that the
book's contents were too difficult to understand, that some
of
its readers might
not be well-grounded enough to accept certain views and arguments since these
had never been touched upon during their college educations, and because in-
depth comprehension requires a broad range
of
knowledge on the part
of
the read-
ers. The other was that readers would not be interested, as the book often places
emphasis on physical fundamentals, on analyses and integration, rather than on
the resolution
of
individual matters confined to specific issues. However, the
XVI
Preface for the English Edition
Baosteel series
of
lectures demonstrated that modem steel enterprises need theo-
retical knowledge regarding flow process engineering, or in other words, that
such knowledge is necessary for the modernization and revamping
of
the steel
industry.
The publishing
of
this book also drew the attention
of
a number
of
research in-
stitutions, such as Institute
of
Process Engineering, Chinese Academy
of
Sciences, Central Iron & Steel Research Institute (CISRI) and University
of
Sci-
ence
& Technology Beijing (USTB). Several institutions
of
higher learning in-
vited me to give academic reports, and some universities even set up elective
courses for postgraduates. The book also triggered interest among relevant experts
at institutes
of
projection and consultation, and Capital Engineering & Research
Incorporation Limited repeatedly invited me to deliver special-topic reports.
It
is pointed out that from the viewpoint
of
physical essence
of
steel manufac-
turing process, multi-factor mass "flow" (mainly ferruginous mass flow) driven
by carbonaceous mass flow, operates in a dynamic and orderly manner in accor-
dance with given "programs" and within a complex "network structure". So, the
function
of
steel plant should be developed as:
I. Operation function
of
ferruginous mass
flow-the
functions
of
steel product
manufacturing.
2. Operation function
of
energy
conversion-the
functions
of
energy conver-
sion and the functions
of
waste treatment and recycling related to energy.
3. Interaction function
of
ferruginous mass flow and energy flow
-realizing
the
target
of
process technology and related functions
of
waste treatment and recy-
cling.
Here, I would like to point out the characteristics
of
the book:
•
It
outlines a theoretical study
of
the energy sources and operation dynamic
mechanisms
of
metallurgical process operations, the purpose being to reveal the
essence and regularities
of
the whole metallurgical manufacturing process in or-
der to optimize the flow
of
materials, energy, and information in the course
of
steel manufacturing.
•
It
presents studies
of
the "three
elements"-flow,
process network and or-
der
-of
metal1urgical process operations, the purpose being to minimize dissipa-
tion in the course
of
such operations so as to enhance the market competitiveness
of
steel plants and their ability to maintain sustainable development.
• It lays theoretical emphasis on dynamic and orderly operations in the metal-
lurgical process, the purpose being to devise quasi-continuous/continuous opera-
tions in the metallurgical process so as to raise the technical and economic in-
dexes
of
steel plant operation.
• It outlines a theoretical study
of
the integrated structure
of
the metallurgical
manufacturing process, the purpose being to enable the setting up
of
a new gen-
eration
of
steel plants by optimizing the overall course and overall functions
of
Preface for the English Edition
XVII
the metallurgical process through integrated innovations.
The author is indeed honored by the English edition
of
this book. By the time
of
issuing the English version
of
this book, the author would like to make grateful
acknowledgement to Prof. Ying Qu and Prof. Wudi Huang from University
of
Science & Technology Beijing, and Dr. Chunxia Zhang from Central Iron & Steel
Research Institute for their great support and earnestly proofreading the English
manuscript
of
the book. The author would like to thank
Prof
. Weili Li, Dr. Long-
mei Wang, Dr. Anjun Xu, Dr. Bingxi Yi, Mr. Xinnong Pan, Ms. Yinghao Liu, Mr.
Haifeng Wang, Mr. Fangqin Shangguan, Mr. Xiaojian Du and Dr. Xinping Mao et
al for their joint effort on preparing English translation. The author also wishes to
express his gratitude to Mr. Huimin Wang and Mr. Di Chen for their dedication in
proofreading my English manuscript
of
the book into fine English. I must express
my deep gratitude to above all because their contributions are involved in the
English version
of
the book.
Beijing
May 2010
Ruiyu Yin
Contents
Chapter 1
Steel-the
"Material
of
Choice"····················································1
1.1 The Position
of
Steel among Diverse Materials ·······································2
1.2 St
eel-An
Important Basic Material in the Process
of
Industrialization ································5
1.3 The Rise
of
the Chinese Steel Industry ····················································8
1.3.1 The traction
of
market demand ·················································..··.. 11
1.3.2 Correct judgments and choices and the orderly
implementation
of
technological progress strategies ·······················12
1.3.3 The promotional effect
of
using international mineral
resources and scra
p·
········································································13
1.3.4 Domestication
of
advanced technology and equipment ·················· 14
1.3.5 The coordinating effect of effective investments and a
technological progress strategy 14
1.4 Technological Progress
of
the Chinese Steel Industry..··························15
1.4.1 Continuous casting technology ·15
1.4.2 PCI technology 17
1.4.3 Technology for the elongation
ofBF
campaigns "···························17
1.4.4 Technology for continuous rolling
of
long products..······················ 18
1.4.5 Comprehensive energy savings by means
of
production
process adjustments ·················18
1.4.6 Slag splashing technology for BOFs···············································19
1.4.7 Summary························································································20
1.5 Comparative Superiority, Restrictions and Prospects
of
the
Chinese Steel Industry 21
1.5.1 Advantages ·······························21
1.5.2 Restrictions· ····················································································22
1.5.3 Prospects
of
the Chinese steel industry ···········································22
Ref
erences ······································································································24