Metallurgical Process Engineering

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Author: Yin Ruiyu
Language: English
ISBN/ISSN: 9787502449568
Published on: 2011-01
Hardcover

The first printing of this book in Chinese edition was completed in May 2004. The book is summarized my understanding and cognitions about metallurgical engineering. 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 procedure 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 leadership, 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 readers. 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 Baosteel series of lectures demonstrated that modern steel enterprises need theoretical 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 institutions, such as the Institute of Process Engineering of the Chinese Academy of Sciences,Central Iron & Steel Research Institute (CISRI) and University of Science & Technology Beijing (USTB). Several institutions of higher learning invited me to give academic reports, and some universities even set up elective courses for postgraduates. The book also triggered interest among relevant experts at steel designing institutes, and the 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 manufacturing process, multi-factor matter “flow” (mainly ferruginous matter flow) driven by carbonaceous matter flow, operates in a dynamic and orderly manner in accordance with given “programs” and within a complex “network structure”. So, the function of steel plant should be developed as:
1. Operation function of ferruginous matter flow—the functions of steel product manufacturing.
2. Operation function of energy conversion—the functions of energy conversion and the functions of waste treatment and recycling related to surplus energy.
3. Inter-action function of ferruginous matter flow and energy flow—realizing the target of process technology and related functions of waste treatment and recycling.
Here, I would like to point out the characteristics of the book:
•It outlines a theoretical study of the energy sources and operational dynamics mechanisms of metallurgical process operations, the purpose being to reveal the essence and regularities of the whole metallurgical manufacturing process in order to optimize the flow of materials, energy, and information in the course of steel plant manufacturing.
•It presents studies of the “three elements”—flow, process network and program—metallurgical process operations, the purpose being to minimize dissipation 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 metallurgical process, the purpose being to devise quasi-continuous/continuous operations in the metallurgical process so as to raise the technical and economic indexes 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 generation of steel plants by optimizing the overall course and overall functions of 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. Qu Ying and Prof. Huang Wudi from University of Science & Technology Beijing, and Dr. Zhang Chunxia 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. Li Weili, Dr. Wang Longmei, Dr. Xu Anjun, Dr. Yi Bingxi, Mr. Pan Xinnong, Ms. Liu Yinghao, Mr. Wang Haifeng, Mr. Shangguan Fangqin, Mr. Du Xiaojian and Dr. Mao Xinping et al for their joint effort on preparing English translation. The author also wishes to express his gratitude to Mr. Wang Huimin and Mr. Chen Di 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.



Chapter1 Steel—the “Material of Choice” 1
1.1 The Position of Steel among Diverse Materials 2
1.2 Steel-an Important Basic Material in the Process of
Industrialization 7
1.3 The Rise of the Chinese Steel Industry 9
1.3.1 The traction of market demand 12
1.3.2 Correct judgments and choices and the orderly
implementation of technological progress strategies 13
1.3.3 The promotional effect of using international mineral
resources and scrap 14
1.3.4 Domestication of advanced technology and equipment 15
1.3.5 The coordinating effect of effective investments and a
technological progress strategy 16
1.4 Technological progress of the Chinese steel industry 16
1.4.1 Continuous casting technology 16
1.4.2 PCI technology 19
1.4.3 Technology for the elongation of BF campaigns 19
1.4.4 Technology for continuous rolling of long products 19
1.4.5 Comprehensive energy savings by means of production
process adjustments 20
1.4.6 Slag splashing technology for BOFs 20
1.4.7 Summary 21
1.5 Comparative Superiority, Restrictions and Prospects of the
Chinese Steel Industry 22
1.5.1 Advantages 22
1.5.2 Restrictions 23
1.5.3 Prospects of the Chinese steel industry 24
References 25

Chapter2 Process Manufacturing Industry and Process Engineering 27
2.1 Manufacturing Industry and its Technological Process 28
2.2 Process Manufacturing Industry and Product Manufacturing
Industry 29
2.3 Manufacturing Process and Manufacturing Process Engineering 30
2.3.1 Process and manufacturing process 30
2.3.2 Manufacturing process engineering 32
2.3.3 Manufacturing process engineering and manufacturing process 33
2.3.4 Connotation and targets of manufacturing process engineering 35
2.4 Features of Manufacturing Process 37
2.4.1 Complexity of manufacturing process 37
2.4.2 Integrity of manufacturing process 38
2.5 Classification of Manufacturing Processes 40
2.5.1 Classification according to function 40
2.5.2 Classification according to structure 41
2.5.3 Classification according to the time factor of output of
product flow 47
2.5.4 Classification according to technological features 48
References 49
Chapter3 Engineering Science in Steel Manufacturing Process 50
3.1 Transition of Theory and Engineering Practice for Metallurgical
Process 51
3.1.1 Formation and progress of the fundamental science on
metallurgy 52
3.1.2 Technical science issues in unit device and procedure level
of metallurgical process 63
3.1.3 Formation and progress of metallurgical process engineering 66
3.2 Connotation and Physical Essence of Metallurgical Process
Engineering 67
3.2.1 Multi-level analysis of science 69
3.2.2 Physical essence of manufacturing process of metallurgy 73
3.2.3 Target of the metallurgical process engineering 77
3.2.4 Research scope and methodology of metallurgical process
engineering 79
3.2.5 The influence of metallurgical process engineering on steel
enterprise 83
3.3 Ken and Topics of Fundamental Research of Metallurgical
Engineering Science 86
References 88
Chapter4 Analysis and Integration of Manufacturing Process
of Metallurgy 89
4.1 Steel Manufacturing Process Is a Complex Process System 90
4.1.1 Feature of the steel manufacturing process system 90
4.1.2 Complexity of steel manufacturing process 93
4.1.3 “Flow” and “order” of steel manufacturing process 94
4.2 Steel Manufacturing Process—a Dissipative Process 98
4.3 Essence of Steel Manufacturing Process 102
4.3.1 Basic parameters and derivative parameters for steel
manufacturing process 103
4.3.2 Operation mode of steel manufacturing process system 104
4.4 Metallurgical Process Engineering V.S. Analysis and Integration
of Steel Manufacturing Process 105
4.4.1 Evolution and structural analysis of steel manufacturing
process 106
4.4.2 Analysis-optimization of the sets of procedures’ functions 108
4.4.3 Coordination-optimization for the set of procedures’ relations
in steel manufacturing process 111
4.4.4 Restructuring-optimization of the set of procedures in steel
manufacturing process 114
4.4.5 Combination of process science and information technology 115
References 116
Chapter5 Multi-Factor Matter Flow Control for Metallurgical
Manufacturing Process 117
5.1 Some Fundamentals of Multi-Factor Matter Flow Control 118
5.1.1 Concept and elements of manufacturing process 118
5.1.2 Dynamically and orderly operating of process 120
5.1.3 Targets, contents and methodology of study on multi-factor
matter flow control 125
5.2 Multi-factor Matter Flow System Control of Steel Manufacturing
Process 126
5.2.1 Process features of steel manufacturing process 126
5.2.2 Concept of operation in steel manufacturing process 128
5.2.3 Analysis on “stimulus-response” of manufacturing process
system 137
5.3 Dynamicall Order Process Structure and Information Flux 138
5.3.1 Multi-scale, multi-level and self-organization 139
5.3.2 Information flow and model building 142
5.4 Case Study of Multi-factor Matter Flow Control in Steel
Manufacturing Process 146
References 151
Chapter6 Time Factor in Manufacturing Process 153
6.1 Function of Time in the Manufacturing Process 154
6.1.1 Connotation of time 154
6.1.2 Character of time 154
6.1.3 Time, clock and time scheduling 156
6.1.4 Time—a basic and essential parameter 156
6.2 Time Factors in Metallurgical Manufacturing Process 157
6.3 Time Factors in the Production of Steel Plant 162
6.3.1 The importance of time factors 162
6.3.2 Forms and connotation of time factors 163
6.3.3 Statement of expression of time factors 164
6.4 Continuation Degree of Steel Manufacturing Process 167
6.4.1 Theoretic continuation degree 167
6.4.2 Actual continuation degree 168
6.5 The Analysis for Time Factor of Thin Slab Casting- Rolling
Process 171
References 177
Chapter7 Operating Dynamics in the Production Process of
Steel Plant 178
7.1 Evolution of Production Operation in Steel Enterprises since
1990s 179
7.1.1 Guiding idea for production operation in steel enterprises
in the first half of the 20th century 180
7.1.2 Guiding idea for production operation in steel enterprises
in the second half of the 20th century 181
7.1.3 Tendency of guiding idea for production operation of
modern steel plants beyond the 20th century 182
7.2 Dynamic Features of Production Process Running of Steel
Plants—Operation Form and Essence 183
7.3 Operating Mode of Different Procedures and Devices in Steel
Production Process 186
7.4 Running Strategy for Steel Production Process 187
7.4.1 Section division of running strategy for production process
of steel plant 187
7.4.2 Pushing force and pulling force in up-stream of steel
manufacturing process 188
7.4.3 Pushing force and pulling force in downstream of steel
manufacturing process 189
7.4.4 Strategy of the continually running of matter flow for steel
manufacturing process 191
7.5 Interface Technigues of Steel Manufacturing Process 200
7.5.1 The meaning of interface technique 200
7.5.2 Interface techniques of BF-BOF section 201
7.5.3 Interface technique between steelmaking furnace and caster 207
7.5.4 Interface technique of section between caster and rolling mill 212
7.6 Influence of Steel Plant Structure on the Running Dynamics
of Steel Manufacturing Process 214
References 216
Chapter8 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 232
8.3 General Layout of a Steel Plant 234
8.3.1 “Flow” is the corpus in the operation of a steel plant’s
production process 234
8.3.2 The importance of general layout 235
8.4 Issues about Structure Optimization in Steel Plants 241
8.4.1 Background and dynamics behind structure optimization
in steel plants 241
8.4.2 Connotations of steel plant structure and the trend of steel
plant restructuring 243
8.4.3 Engineering analysis of steel plant structural optimization 244
8.4.4 Resources, energy and steel plant manufacturing process. 245
8.5 Steel Plant Structure Optimization and Engineering Design 248
8.5.1 The importance of process engineering design 248
8.5.2 Trend of technological progress in steel plants 250
8.5.3 Principles about engineering design in optimizing steel plant
process structure 283
8.6 Modern Steel Plant Models 285
8.6.1 Large integrated steel plants 285
8.6.2 Steel plants with small or medium BF 287
8.6.3 EAF process 288
8.6.4 Steel plant and steel corporation (group) 290
8.6.5 Issues about Investment 290
References 292
Chapter 9 Steel Plants and the Environment 294
9.1 Issues on Sustainable Development 295
9.1.1 Put forward of the topic 295
9.1.2 Manufacture linkage and evolution of the values of goods 296
9.1.3 Features and multi-levels of influence of steel plant on
environment 298
9.2 Progress of Environment Protection in Steel Enterprise
Worldwide 299
9.3 Green Manufacturing in Steel Plants 300
9.3.1 Concept and connotation of green manufacture 300
9.3.2 Philosophy and technical route for green manufacture 302
9.3.3 Key role of manufacturing process engineering in the
course of greenization of steel plants 303
9.3.4 Technologies of green manufacture of steel plants 304
9.4 Steel Plants and Industrial Ecology 305
9.4.1 About industrial ecology 306
9.4.2 Research view of industrial ecology 307
9.4.3 Steel plants and eco-industrial chain 308
9.5 Function Extension of Steel Plants and Circular Economy
Society 312
9.5.1 Function extension of manufacturing process and
eco oriented transforming of steel plants 313
9.5.2 Steel plants in circular economy society 319
References 326
Index 328


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