Yin R. Metallurgical Process Engineering
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xx
Contents
Chapter 2 Process Manufacturing Industry and Process Engineering ······25
2.1 Manufacturing Industry and Its Technological Process 26
2.2 Process Manufacturing Industry and Equipment Manufacturing
Industry·································································································27
2.3 Manufacturing Process and Process Engineering 28
2.3.1 Process and manufacturing process·················································28
2.3.2 Process engineering ··················30
2.3.3 Process engineering and manufacturing process ·····························31
2.3.4 Connotation and targets
of
process engineering 33
2.4 Features of Manufacturing Process 35
2.4.1 Complexity of manufacturing process 35
2.4.2 Integrity of manufacturing process ······················ ················ ·····..··..36
2.5 Classification
of
Manufacturing Processes ············································38
2.5.1 Classification according to functions ··············································38
2.5.2 Classification according to structures··············································39
2.5.3 Classification according to production running modes..··················44
2.5.4 Classification according to technological features ··············· ···········45
R
ef
erences······································································································46
Chapter 3 Engineering Science in Steel Manufacturing Process ················47
3.1 Transition
of
Theory and Engineering Practice for Metallurgical
Process···································································································48
3.1.1 Formation and progress of the fundamental science on
metallurgy ·······················································································49
3.1.2 Technical science issues in unit device and procedure level
of
metallurgical process ············60
3.1.3 Formation and progress
of
metallurgical process engineering·········63
3.2 Connotation and Physical Essence
of
Metallurgical Process
Engineering 64
3.2.1 Multi-level analysis
of
science·..·····················································66
3.2.2 Physical essence
of
manufacturing process
of
metallurgy· ··············70
3.2.3 Targets
of
the metallurgical process engineering..···························73
3.2.4 Research scope and methodology
of
metallurgical process
engineering ·······························76
3.2.5 The influence of metallurgical process engineering on steel
enterprise·························································································80
3.3 Ken and Topics of Fundamental Research of Metallurgical
Engineering Science ··············································································83
Ref
erences······································································································84
Contents
XXI
Chapter
4 Analysis
and
Integration
of
Manufacturing
Process
of Metallurgy ·························87
4.1 Steel Manufacturing Process Is a Complex Process System..·················88
4.1.1 Feature
of
the steel manufacturing process system ·························88
4.1.2 Complexity
of
steel manufacturing process ························· ···········91
4.1.3 Flow and order
of
steel manufacturing process·······························92
4.2 Steel Manufacturing Proces
s-A
Dissipative Process..··························96
4.3 Essence
of
Steel Manufacturing Process··············································100
4.3.1 Basic parameters and derivative parameters for steel
manufacturing process 101
4.3.2 Operation mode
of
steel manufacturing process system················102
4.4 Metallurgical Process Engineering v.s. Analysis and
Integration
of
Steel Manufacturing Process ·········································103
4.4.1 Evolution and structure analysis
of
steel manufacturing
process ·························································································104
4.4.2 Analysis-optimization
of
the set
of
procedures' functions·············106
4.4.3 Coordination-optimization for the set
of
procedures'
relations in steel manufacturing process ..······································109
4.4.4 Reconstruction-optimization
of
set
of
procedures in
steel manufacturing process
111
4.4.5 Combination
of
process science and information technology ······· 113
Ref
erences ···································································································· 114
Chapter
5 Multi-Factor Mass Flow Control for Metallurgical
Manufacturing
Process 115
5.1 Some Fundamentals
of
Multi-Factor Mass Flow Control"···················116
5.1.1 Concept and elements
of
manufacturing process 116
5.1.2 Dynamically and orderly operating
of
process······························118
5.1.3 Targets, contents and methodology
of
study on multi-factor
mass flow control ··········································································123
5.2 Multi-factor Mass Flow System Control
of
Steel Manufacturing
Process·································································································124
5.2.1 Process features
of
steel manufacturing process ···························124
5.2.2 Concept
of
operation in steel manufacturing process ····················126
5.2.3 Analysis on "stimulus-response"
of
manufacturing process
system ····································· 135
5.3 Dynamic-Orderly Structure and Information Flux in Process ··············136
5.3.1 Multi-scale, multi-level and self-organization"·····························137
5.3.2 Information flow and model building ··········································· 140
XXII
Contents
5.4 Case Study
of
Multi-factor Mass Flow Control in Steel
Manufacturing Process 144
References ···································································································· 149
Chapter
6 Time
Factor
in
Manufacturing
Process ····································151
6.1 Function
of
Time in the Manufacturing Process""""""""""""""""'"152
6.1.1 Connotation
of
time ················152
6.1.2 Character
of
time ····················152
6.1.3 Time, clock and time scheduling..············································ 154
6.1.4 Time-
-a
basic and essential parameter 154
6.2 Time Factors in Metallurgical Manufacturing Process """""""""""'"155
6.3 Time Factors in the Production
of
Steel Plant 160
6.3.1 The importance
of
time factors 160
6.3.2 Forms and connotation
of
time in steel manufacturing
process ·························································································161
6.3.3 Statement
of
expression
of
time factors ········································ 162
6.4 Continuation Degree
of
Steel Manufacturing Process ··························165
6.4.1 Theoretic continuation degree·······················································165
6.4.2 Actual continuation degree ·····166
6.5 The Analysis for Time Factor
of
Thin Slab Casting-Rolling
Process·································································································169
References ··············································175
Chapter
7
Operating
Dynamics in the Production Process of
Steel
Plant
·····························177
7.1 Evolution
of
Production Operation in Steel Enterprises since
1990s ············································· 178
7.1.1 Guiding idea for production operation in steel enterprises
in the first half
of
the 20
th
century ················································179
7.1.2 Guiding idea for production operation in steel enterprises
in the second half
of
the
zo"
century············································ 180
7.1.3 Tendency
of
guiding idea for production operation
of
modem steel plants beyond the
zo"
century""" "" "" """" "" "" '"181
7.2 Dynamic Features
of
Production Process Running
of
Steel
Plants--Operation
Form and Essence ··············································182
7.3 Operating Mode
of
Different Procedures and Devices in Steel
Production Process ························ 185
7.4 Running Strategy for Steel Production Process····································186
7.4.1 Section division
of
running strategy for production
process
of
steel plant 186
Contents
xxm
7.4.2 Pushing force and pulling force in up-stream
of
steel
manufacturing process ··········· 187
7.4.3 Pushing force and pulling force in downstream
of
steel
manufacturing process ·································································188
7.4.4 Strategy
of
the continually running
of
mass flow for
steel manufacturing process ···190
7.5 Interface Techniques
of
Steel Manufacturing Process 199
7.5.1 The meaning
of
interface technique ..············································ 199
7.5.2 Interface techniques
ofBF
-BOF
section ····································200
7.5.3 Interface technique between steelmaking furnace and caster ········206
7.5.4 Interface technique
of
section between caster and rolling
mill ··············· ························· 211
7.6 Influence
of
Steel Plant Structure on the Operation Dynamics
of
Steel Manufacturing Process 214
References ····································································································215
Chapter
8
The
Structure
and
Mode of Steel
Plant
Process ·······················217
8.1 Relation between Process Functions' Evolution and the Process
Structure in a Steel Plant ···············218
8.1.1 Positions and functions
of
procedures in a process ·······················218
8.1.2 Evolution
of
procedures' functions
of
steel manufacturing
process·························································································219
8.1.3 The optimization for the distribution and combination
of
procedural functions in the steel manufacturing process ··············230
8.2 Transportation in the Production
of
Steel Plant 231
8.3 General Layout
of
a Steel Plant ·····233
8.3.1 "Flow" is the corpus in the operation
of
a steel production
process 233
8.3.2 The importance
of
general layout 234
8.4 Issues about Structure Optimization in Steel Plants ·····························240
8.4.1 Background and driving power
of
structure optimization in
steel plants ·····························240
8.4.2 Connotations of steel plant structure and the trend of steel
plant restructuring 242
8.4.3 Engineering analysis
of
steel plant structural optimization ···········243
8.4.4 Resources, energy and steel plant manufacturing process ············· 244
8.5 Steel Plant Structure Optimization and Engineering Design ················247
8.5.1 The importance
of
process engineering design ·····························247
8.5.2 Trend
of
technological progress in steel plants ·····························249
8.5.3 Principles about engineering design in optimizing steel plant
process structure 281
XXIV
Contents
8.6 Modem Steel Plant Models..································································283
8.6.1 Large integrated steel plants 283
8.6.2 Steel plants with small or medium BF ··········································285
8.6.3 EAF process steel plants 285
8.6.4 Steel plant and consolidated steel corporation (group) ··················287
8.6.5 Issues about investment 288
Ref
erences····································································································289
Chapter 9 Steel Plants and the Environment Issues ··································291
9.1 Issues on Sustainable Development 292
9.1.1 Put forward
of
the topic ··········292
9.1.2 Manufacture linkage and evolution
of
the values
of
commodity ······························293
9.1.3 Features and multi-levels
of
the influence of steel plants on
environment ····························294
9.2 Progress
of
Environment Protection in Steel Enterprises
Worldwide···························································································294
9.3 Green Manufacturing in Steel Plants..··················································296
9.3.1 Concept and connotation of green manufacture ····························296
9.3.2 Philosophy and technical route for green manufacture..················297
9.3.3 Key role
of
manufacturing process in the course
of
greenization
of
steel plants ······299
9.3.4 Technologies
of
green manufacture of steel plants..······················299
9.4 Steel Plants and Industrial Ecology 301
9.4.1 About industrial ecology..·····························································301
9.4.2 Research view
of
industrial ecology ..···········································303
9.4.3 Steel plants and eco-industrial chain 304
9.5 Function Extension of Steel Plants and Circular Economy Society······308
9.5.1 Function extension
of
manufacturing process and eco-
oriented transforming
of
steel plants ·············································309
9.5.2 Steel plants in circular economy society ·······································315
References ··········································322
Index ····325
List
of
Figures
Fig. 1.1 Trend in world steel output since 1870 2
Fig. 1.2 Evaluation
of
the characteristics
of
materials vital to industry
(Total points: 100)
2
Fig. 1.3 Future requirements in terms
of
materials and industrial
technology
3
Fig. 1.4 Prices
of
various materials since 1974 (Price indices for 1974 =
100)
3
Fig. 1.5 Changes in the prices
of
steel and its downstream processed
products (Price indices for 1974
= 100) 4
Fig. 1.6 Recycling rate (%)
of
various materials 4
Fig. 1.7
Evolution
of
China's industrial structure from 1970 to 2006
(Yin, 2008)
6
Fig. 1.8 Development
of
world stainless steel output from 1984 to
2006 (China Steel Yearbook)
7
Fig. 1.9 Crude steel output over the years in China 8
Fig. 1.10
Increases in China's steel output since 1990
9
Fig. 1.11 Increases in the number
of
Chinese steel plants with annual
outputs
of
over
1 million tons since the 1990s
9
Fig. 1.12 Regional distribution
of
crude steel output
of
mainland China
in 2005 10
Fig. 1.13
Impact
of
investment increase on China's apparent consumption
of
steel products 12
Fig. 1.14 Increases in the ratios
of
continuous casting, argon bubbling &
wire feeding, and secondary refining in the Chinese steel
industry 16
Fig. 1.15 Changes in specific energy consumption at China's key steel
plants from 1990 to 2005 19
Fig. 2.1 Concept
of
manufacturing industry and manufacturing process 26
Fig. 2.2 Schematic
of
concept
of
process engineering in the
manufacturing process 32
XX
VI
List
of
Figures
Fig. 2.3 Relational grade and comprehensive influence power
of
manufacturing process for process manufacturing industry 34
Fig. 2.4 The schematic diagram
of
the series connection
39
Fig. 2.5 The schematic diagram
of
the concurrent connection 40
Fig. 2.6 The schematic diagram
of
the counter current connection 40
Fig. 2.7
The flow chart
of
the gas-based process
of
direct reduction iron
40
Fig. 2.8 The schematic diagram
of
the concurrent jumping connection 41
Fig. 2.9 The schematic diagram of the counter currentjumping connection 41
Fig. 2.10 The schematic diagram
of
the parallel connection mode 42
Fig. 2.
11
The schematic diagram of the circumambulatory (bypass)
connection 43
Fig. 2.12 The simple schematic diagram
of
the feedback connection 44
Fig. 2.13 The diagram
of
the feedback connection
of
iron resource
among units in steel manufacturing process 44
Fig. 2.14 The feedback connection
of
energy/material in steel
manufacturing process 44
Fig. 3.1 Flowsheet
of
manufacturing process
of
blast furnace-
converter-continuous casting-rolling 48
Fig. 3.2 Relationship between standard Gibbs energy
of
formation
of
oxides flGoand temperature
52
Fig. 3.3 Standard Gibbs energy
of
oxidation
of
elements in liquid iron 54
Fig. 3.4 Development schema
of
metallurgical process engineering
65
Fig. 3.5 Process engineering: business model 66
Fig. 3.6 Correlativity and permeability
of
the steel manufacturing process 80
Fig. 4.1 Relationship analysis among basic parameters and derivative
parameters in the system
of
steel manufacturing process 102
Fig. 4.2 Evolution
of
steel manufacturing process 104
Fig. 4.3
Schematic
of
concept
of
analysis-integration
of
steel
manufacturing process 106
Fig. 4.4 The block diagram
of
analysis-integration model
of
steel
manufacturing process
107
Fig. 4.5 Schematic
of
the relationship between steel manufacturing
process structure and information system 113
Fig. 5.1 Sketch
of
conceptions and elements in manufacturing process 117
Fig. 5.2
Schematic diagram
of
matter state-matter property-mass flow
in steel production process 125
Fig. 5.3 Schematic diagram
of
multi- factor mass flow trajectory in
different steel plants 131
Fig. 5.4
EAF process route, steady syntonic state
of
elastic chain/
semielastic chain and its different types 132
Fig. 5.5 Evolution
of
the manufacturing process and critical-
Fig. 5.6
Fig. 5.7
Fig. 5.8
Fig. 5.9
Fig. 5.10
Fig. 5.11
Fig. 5.12
Fig. 5.13
Fig. 5.14
Fig. 5.15
Fig. 5.16
Fig. 5.17
Fig. 5.18
Fig. 5.19
Fig. 5.20
Fig. 5.21
Fig. 6.1
Fig. 6.2
Fig. 6.3
Fig. 6.4
Fig. 6.5
Fig. 6.6
Fig. 6.7
Fig. 6.8
Fig. 6.9
Fig. 6.10
List
of
Figures
XXVII
compactness-continuation effect 134
Relation between critical value
of
slab thicknesses and number
of
rolling stands (Flick, Schwaha, 1993) 135
Multi-level structure in the steel manufacturing process system 139
Self-reproduce for main procedure running in steel
manufacturing process (Electric furnace steelmaking) 140
Self-reproduce and self-growth (evolving-coupling on level or
scale) in steel manufacturing process (BF-BOF route) 141
Relationship between physical-mathematical model and
integrated model 142
Schematic diagram
of
control in steel manufacturing process 143
Distribution
of
tap-to-tap time
ofEAF
144
Distribution
of
tapping temperature in EAF 145
Distribution
of
time-interval from EAF tapping to LF arrival 145
Distribution
of
temperature drop value from EAF tapping to
LF arrival 146
Distribution
of
refining time in LF 146
Distribution
of
temperature variation in LF refining 146
Distribution
of
casting time
of
one heat steel on thin slab caster 147
Distribution
of
slab surface temperature change from entering to
exiting tunnel furnace (as few grade in statistical samples only
on low carbon steel and middle carbon steel, so deviation is
more obvious) 147
Distribution
of
time from slab entering stand FI to leaving
stand F6
of
rolling mill 147
Distribution
of
time from leaving last stand to closing coiling 148
The coupling-running course
of
multi-factor mass flow at time
axis in electric arc furnace steel plant with fully continuous
casting 157
The sketch
of
important factors
of
different procedures coupled
with time axis in integrated steel manufacturing process 158
The schematic diagram
of
time-point 162
The schematic diagram
of
time-order 163
The schematic diagram
of
time-interval in procedure 163
The scheme
of
time-position 164
The composition
of
time-cycle 164
Scheme
of
time- rhythm 165
Convergence analysis
of
temperature in steelmaking process
(Yin,I998) 170
Time analysis and integration in thin slab casting-rolling process
(Yin, 1998) 171
XXVIll
List
of
Figures
Fig. 7.1
Fig. 7.2
Fig. 7.3
Fig. 7.4
Fig. 7.5
Fig. 7.6
Fig. 7.7
Fig. 7.8
Fig. 7.9
Fig. 7.10
Fig. 7.11
Fig. 7.12
Fig. 7.13
Fig. 8.1
Fig. 8.2
Fig. 8.3
Fig. 8.4
Fig. 8.5
Fig. 8.6
Fig. 8.7
Combination
of
the matter state transforming, the matter
property controlling and the mass flow controlling in the
production process
Scheme
of
compactness, continuation and intermittence in
the steel production process
The scheme
of
the running dynamics
of
steel production
process
Diagram
of
pushing force, buffering loop and pulling force
in the running
of
steel production process
The relation between steel product type and the reasonable
tonnage
of
converter
Hot metal transport from blast furnace via iron ladle-
mixer-charging
ladle, into smaller converter
Different types
of
the hot metal shifting and transporting via
iron ladle
Desulphurization pretreatment
of
hot metal between smaller
BF and smaller converter
Transportation via torpedo between large BF and large
converter
Hot metal pretreatment
of
desiliconization, desulphurization
and dephosphorization in torpedo and its transportation
between BF and BOF
Step by step pretreatment
of
desiliconization, desulphuri-
zation and dephosphorization
of
hot metal between large
BF and large BOF
Step by step pretreatment
of
desiliconization, desulphuri-
zation and dephosphorization
of
hot metal in large scale
BF-BOF
route without torpedo
Simplified step by step pretreatment
of
desulphurization,
desiliconization and dephosphorization
of
hot metal in large
BF and BOF route without torpedo
Functions
of
procedures and devices
Development
of
modern EAF smelting technologies
Relation between casting speed and slab surface temperature
Layout
of
newly designed steelmaking workshop and hot
rolling mill in a steel plant in China
Schematic layout
of
a thin slab continuous casting and
rol1ingline
Layout
of
an EAF mini-mill for long products with
optimized design
Logic block diagram
of
steel plant structure
183
184
187
191
191
200
201
201
202
203
204
205
205
219
224
228
237
238
239
244
List
of
Figures
XXIX
Fig. 8.8 Evolution
of
relation between steel manufacturing process
and resources & energy 245
Fig. 8.9 Block diagram
of
investment decision-making and efficiency 250
Fig. 8.10 Bar production (semi-endless rolling) line layout
of
a steel
plant abroad 255
Fig. 8.11
Total hot metal desulphurization, desiliconization and
dephosphorization pretreatments 258
Fig. 8.12 Influences
oflarge
BOF's shortened smelting 259
Fig. 8.13 Change
of
manufacturing process and technologies in large
steelmaking plants 261
Fig. 8.14 Critical lifetime
of
BOF and continuation
of
manufacturing
process 263
Fig. 8.15 Influences
of
turnover rate
of
BOF ladles (280 t) on ladle wall
temperature 265
Fig.8.16 Influences
of
different ladle turnover rate on liquid steeltemp.drop
in the course
of
BOFtapping in a steelplant(280 t ladle,aluminum
killed steel) 265
Fig. 8.17 Layout
of
a newly built steelmaking workshop (with total hot
metal pretreatment) in a steel plant abroad
268
Fig. 8.18 Schematic layout
of
3 sorts
of
EAF steelmaking workshops 269
Fig. 8.19 Slag ratio
of
some European BFs 272
Fig. 8.20 Relation between the basicity
of
sinters and their strength
and reduction degree 273
Fig. 8.21
Relation
of
BF hearth area, effective height with volume
274
Fig. 8.22 Ratio
of
active zone
of
with different BFs 275
Fig. 8.23 Relation between BF volume and furnace hearth diameter 275
Fig. 8.24 The height indexes and smelting intensity with different
BF volumes 276
Fig. 8.25 Calculation ways comparison between two kinds
of
utilization
coefficient
of
BFs with different volumes 278
Fig. 8.26 Comparison
of
unit investment cost for integrated steel plant,
compact integrated plant and EAF mini-milI
289
Fig. 9.1 Connotation
of
environmental problems and relationships
among d
iff
erent types
of
environmental problems 292
Fig. 9.2
Connotation
of
Steel Products' Life Cycle
294
Fig. 9.3 The Sketch
of
progress
of
environmental protection around
steel enterprises worldwide 295
Fig. 9.4 The relationship between expanding scale
of
resources and
funds with knowledge chain 306
Fig. 9.5 The ecologic development
of
enterprise grading picture
(Wang and Yang, 2002b)
308