Hot metal yield optimization of a blast furnace based on constructal theory

Abstract Constructal theory is introduced into the hot metal yield maximization of the blast furnace in this paper. Generalized constructal optimization of a blast furnace is performed for a specified total raw material cost. The optimal distribution of each raw material cost in the total cost, namely “generalized optimal construct”, is obtained. Besides, the optimal charge composition of the blast furnace is also obtained. The effects of blast parameters, agglomerate ratio and pulverized coal dosage on the optimization results are analyzed. The results show that the hot metal yield after generalized constructal optimization is 1027.4 kg, and is improved by 2.64% compared with that before optimization. For actual production of the blast furnace, when the total cost is fixed, decreasing the blast oxygen enrichment, blast volume, and agglomerate and increasing pulverized coal dosage can increase the hot metal yield. Increasing blast humidity can increase the hot metal yield when the blast humidity is always under a certain value. The contribution of this paper is to optimize the hot metal yield of the blast furnace based on new methodology, which leads to a good economic performance of the blast furnace iron-making process and provides new guidelines for the design of this process.

[1]  Fengrui Sun,et al.  Constructal optimization of a sinter cooling process based on exergy output maximization , 2016 .

[2]  Hannu Helle,et al.  Optimization of Top Gas Recycling Conditions under High Oxygen Enrichment in the Blast Furnace , 2010 .

[3]  Cristobal Feliciano-Bruzual,et al.  Charcoal injection in blast furnaces (Bio-PCI): CO2 reduction potential and economic prospects , 2014 .

[4]  A. Bejan.  Constructal Law: Optimization as Design Evolution , 2015 .

[5]  Lingen Chen,et al.  Constructal optimization of twice Y-shaped assemblies of fins by taking maximum thermal resistance minimization as objective , 2010 .

[6]  Xiang Yin,et al.  A bottom-up analysis of China’s iron and steel industrial energy consumption and CO2 emissions , 2014 .

[7]  Wan Ki Chow,et al.  Constructal design of evacuation from a three-dimensional living space , 2015 .

[8]  Fengrui Sun,et al.  System dynamics analysis on characteristics of iron-flow in sintering process , 2015 .

[9]  A. Bejan,et al.  Constructal theory of generation of configuration in nature and engineering , 2006 .

[10]  LinGen Chen,et al.  “Volume-point” heat conduction constructal optimization based on entransy dissipation rate minimization with three-dimensional cylindrical element and rectangular and triangular elements on microscale and nanoscale , 2012 .

[11]  Gongnan Xie,et al.  Numerical Analysis of Constructal Water-Cooled Microchannel Heat Sinks with Multiple Bifurcations in the Entrance Region , 2015 .

[12]  Gongnan Xie,et al.  Constructal wavy-fin channels of a compact heat exchanger with heat transfer rate maximization and pressure losses minimization , 2015 .

[13]  C. Biserni,et al.  Constructal design of X-shaped conductive pathways for cooling a heat-generating body , 2013 .

[14]  Fengrui Sun,et al.  Constructal optimization for geometry of cavity by taking entransy dissipation minimization as objective , 2009 .

[15]  Adrian Bejan,et al.  Design with constructal theory , 2008 .

[16]  Fengrui Sun,et al.  Constructal entransy optimizations for insulation layer of steel rolling reheating furnace wall with convective and radiative boundary conditions , 2014 .

[17]  Sun Feng-rui,et al.  Thermal insulation constructal optimization for steel rolling reheating furnace wall based on entransy dissipation extremum principle , 2012 .

[18]  Gongnan Xie,et al.  Constructal Design Associated to Genetic Algorithm of Asymmetric V-Shaped Pathways , 2015 .

[19]  Adrian Bejan,et al.  Street network theory of organization in nature , 1996 .

[20]  N. Pardo,et al.  Prospective scenarios on energy efficiency and CO2 emissions in the European Iron & Steel industry , 2013 .

[21]  Lingen Chen,et al.  Thermodynamic optimization opportunities for the recovery and utilization of residual energy and heat in China's iron and steel industry: A case study , 2015 .

[22]  A. Bejan,et al.  Constructal law of design and evolution: Physics, biology, technology, and society , 2013 .

[23]  Semida Silveira,et al.  Capturing energy efficiency in European iron and steel production—comparing specific energy consumption and Malmquist productivity index , 2014 .

[24]  Mustafa Erdemir,et al.  Utilization and efficiency of ground granulated blast furnace slag on concrete properties – A review , 2016 .

[25]  Liércio André Isoldi,et al.  Constructal design of T-shaped assemblies of fins cooling a cylindrical solid body , 2014 .

[26]  Adrian Bejan,et al.  The Physics of Life: The Evolution of Everything , 2016 .

[27]  Dhirendra Kumar.  Optimization of Blast Furnace Parameters using Artificial Neural Network , 2015 .

[28]  Luiz Alberto Oliveira Rocha,et al.  Geometric optimization of X-shaped cavities and pathways according to Bejan’s theory: Comparative analysis , 2014 .

[29]  C. Biserni,et al.  Geometric optimization of a convective T-shaped cavity on the basis of constructal theory , 2012 .

[30]  Fengrui Sun,et al.  Constructal entransy dissipation rate minimization for variable cross-section insulation layer of the steel rolling reheating furnace wall , 2014 .

[31]  Fengrui Sun,et al.  Constructal multidisciplinary optimization of electromagnet based on entransy dissipation minimization , 2009 .

[32]  Jing Li,et al.  Properties and Structural Optimization of Pulverized Coal for Blast Furnace Injection , 2011 .

[33]  Fengrui Sun,et al.  Exergy loss minimization for a blast furnace with comparative analyses for energy flows and exergy flows , 2015 .

[34]  Jinliang Xu,et al.  The optimal evaporation temperature and working fluids for subcritical organic Rankine cycle , 2012 .

[35]  Shengli Wu,et al.  Mathematical Model for Blast Furnace Burden Optimization Based on the High-temperature Reactivity , 2010 .

[36]  Adrian Bejan,et al.  Complexity, organization, evolution, and constructal law , 2016 .

[37]  Fengrui Sun,et al.  Constructal design for blast furnace wall based on the entransy theory , 2016 .

[38]  Jie Lu,et al.  A knowledge-based multi-role decision support system for ore blending cost optimization of blast furnaces , 2011, Eur. J. Oper. Res..

[39]  Fengrui Sun,et al.  Constructal entransy dissipation rate minimization for solid–gas reactors with heat and mass transfer in a disc-shaped body , 2015 .

[40]  Lingen Chen,et al.  Modeling and performance analysis of a two-stage thermoelectric energy harvesting system from blast furnace slag water waste heat , 2014 .

[41]  Lingen Chen,et al.  Thermodynamic analysis and optimization of an air Brayton cycle for recovering waste heat of blast furnace slag , 2015 .

[42]  Chao Liu,et al.  Performance Analysis and Working Fluid Selection of a Supercritical Organic Rankine Cycle for Low Grade Waste Heat Recovery , 2012 .

[43]  Ponnuthurai N. Suganthan,et al.  Modeling of steelmaking process with effective machine learning techniques , 2015, Expert Syst. Appl..

[44]  A. Bejan.  Shape and Structure, from Engineering to Nature , 2000 .

[45]  Simone Moretti,et al.  Fin Shape Thermal Optimization Using Bejan's Constructal Theory , 2011, Fin Shape Thermal Optimization Using Bejan's Constructal Theory.

[46]  Fengrui Sun,et al.  Generalized constructal optimization for solidification heat transfer process of slab continuous casting based on heat loss rate , 2014 .

[47]  Gongnan Xie,et al.  Optimization of Pin-Fins for a Heat Exchanger by Entropy Generation Minimization and Constructal Law , 2015 .

[48]  Chen Lingen.  Progress in study on constructal theory and its applications , 2012 .

[49]  Elizaldo Domingues dos Santos,et al.  Constructal design of convective cavities inserted into a cylindrical solid body for cooling , 2015 .

[50]  Zheng‐gen Liu,et al.  Mathematical Simulation on Blast Furnace Operation of Coke Oven Gas Injection in Combination with Top Gas Recycling , 2016 .

[51]  B. Sundén,et al.  Laminar thermal performance of microchannel heat sinks with constructal vertical Y-shaped bifurcation plates. , 2014 .

[52]  Hannu Helle,et al.  Multi-objective Optimization of Ironmaking in the Blast Furnace with Top Gas Recycling , 2010 .

[53]  Lynn Price,et al.  A Comparison of Iron and Steel Production Energy Use and Energy Intensity in China and the U.S. , 2014 .

[54]  Fengrui Sun,et al.  Generalized constructal optimization for the secondary cooling process of slab continuous casting based on entransy theory , 2014 .

[55]  Hong-wei Wang,et al.  Increasing Lump Ores Proportion in Blast Furnace Based on the High-temperature Interactivity of Iron Bearing Materials , 2010 .

[56]  Elizaldo Domingues dos Santos,et al.  Constructal Design of Cavities Inserted Into a Cylindrical Solid Body , 2012 .

[57]  Gongnan Xie,et al.  Constructal Theory Based Geometric Optimization of Wavy Channels in the Low Reynolds Number Regime , 2014 .

[58]  Lingen Chen,et al.  Thermoelectric power generation driven by blast furnace slag flushing water , 2014 .

[59]  Hannu Helle,et al.  Mathematical Optimization of Ironmaking with Biomass as Auxiliary Reductant in the Blast Furnace , 2009 .

[60]  Ruiyu Yin,et al.  Metallurgical Process Engineering , 2011 .