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Table of Content

    28 October 2022, Volume 22 Issue 10
    Contents
    Cover and Contents
    The Chinese Journal of Process Engineering. 2022, 22(10):  0. 
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    Review
    Multiscale discrete particle simulation for iron and steel industry: progress and prospect
    Ji XU Wei GE Limin WANG Jinghai LI
    The Chinese Journal of Process Engineering. 2022, 22(10):  1308-1316.  DOI: 10.12034/j.issn.1009-606X.222276
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    To achieve the carbon peaking and carbon neutrality goals, the steel industry is currently facing an urgent need for transformation and upgrading. Due to the long development cycle and high cost of the experimental methods, simulation methods of high accuracy and high efficiency are playing an important role in realizing the intelligent and green technology of the steel industry. However, the applicable simulation toolkits are lacking due to the complexity and diversity of the iron-making and steel-making processes. This article introduces the possibility to realize a high-performance, more accurate multiscale discrete particle simulation method based on the consistency of the logic and structure between the problem, model, software, and hardware, namely the EMMS paradigm. Some preliminary applications on the optimization of apparatus structures and operating conditions in the steel industry are summarized, e.g., enhancing the iron ore raw material separation process by adding the permanent magnets, optimizing the structure of the inlet region of a sinter vertically arranged cooler for higher heat recovery efficiency, optimizing the operation of the rotating drum to enhance the throughput of dealing with the steel slag, and the operational optimization of the burden distribution in the blast furnace to reduce the coke consumption. These successful applications demonstrate that the multiscale discrete particle simulation method is becoming a powerful tool for the steel industry. Thus, the realization of the higher level tool for transformation and upgrading of the steel industry, namely virtual process engineering (VPE), is prospected, which requires integrating the multi-scale discrete particle simulation with online measurement, artificial intelligence (AI), interactive simulation, virtual reality (VR) and online control.
    Development trend for co-production of steel and chemical in the context of carbon neutrality
    Chunyan SHI Guoshuai ZHANG Yi LI Suojiang ZHANG
    The Chinese Journal of Process Engineering. 2022, 22(10):  1317-1324.  DOI: 10.12034/j.issn.1009-606X.222361
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    The by-produced gas, waste heat, and steel slag as well as the current situation on the co-production of steel and chemical in the iron and steel industry are analyzed. The developing trend of green and low-carbon technologies is discussed and the new mode from "carbon fixation by chemical" to "carbon substitution by hydrogen" in carbon-free steelmaking in the future is prospected. Suggestions and measures are put forward to the application of new technologies for steel and chemical co-production. It is expected to establish a new sustainable industrial ecosystem with the steel industry as the leader coupled with the chemical industry to support the realization of China's carbon peaking and carbon neutrality goal.
    Research progress of fluidized bed direct reduction at Institute of Process Engineering
    Chuanlin FAN Zhan DU Feng PAN Zheng ZOU Jun LI Hongzhong LI Qingshan ZHU
    The Chinese Journal of Process Engineering. 2022, 22(10):  1325-1332.  DOI: 10.12034/j.issn.1009-606X.222325
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    Under the background of carbon peaking and carbon neutrality, iron and steel industry urgently needs low-carbon reconstruction. Hydrogen direct reduction (usually called "hydrogen metallurgy") is an important research field in the domestic and overseas. Fluidized bed (FB) direct reduction has been the research direction at Institute of Process Engineering (IPE) for more than 60 years. On the occasion of commemorating the 120th anniversary of Professor Chu-Phay Yap's birth, this work reviews and summarizes a series of important achievements on basic researches and industrial applications of FB direct reduction at IPE. In the basic researches respect, the competition of adhesive force and rupturing force for particle sticking, the behaviors of agglomerate fluidization and slow defluidization, the growth mechanisms and sticking characteristics of newly formed iron with different morphologies were revealed; and a series of methods for anti-defluidization were successively established, including particle coating and iron morphology regulation to reduce the adhesive force, and enhance particle motion, particle size increase, using external field forces to increase the rupturing force. Furthermore, several pilot plants with various iron ores were constructed and operated to promote the industrial application of new technologies, including hydrogen FB direct reduction of 100 kg/d iron ore concentrate, 1 t/d vanadium bearing titanomagnetite and FB direct reduction-electric furnace smelting of 2000 t/a vanadium bearing titanomagnetite. Currently, IPE is cooperating with Ansteel Group to establish the world's first FB direct reduction pilot plant of 10 000 t-DRI/a using green hydrogen. This paper aims to commemorates Professor Chu-Phay Yap, Professor Mooson Kwauk and other scientists of the older generation, and also to propel advance of basic theory and technology in FB direct reduction, for promotion of the low-carbon development for the iron and steel industry of China.
    Analysis and thinking of low-carbon technology in non-ferrous metal industry
    Shili ZHENG Shufeng YE Qian WANG Shuhua MA Zhi WANG Zhi SUN Shan QIAO Xiaomeng ZHANG Yi ZHANG
    The Chinese Journal of Process Engineering. 2022, 22(10):  1333-1348.  DOI: 10.12034/j.issn.1009-606X.222282
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    Reduction of carbon dioxide emission in the non-ferrous metal industry is critical for realizing the carbon peaking and carbon neutrality goals in China. State-of-the-art of carbon dioxide emissions in the non-ferrous metal industry were summarized and analyzed here. Based on this, the low-carbon technology path of non-ferrous metal industry, especially the key smelting industry, was put forward. The analysis shows that the aluminum smelting industry is the core of carbon dioxide emission reduction in the non-ferrous metal industry. It is expected that the non-ferrous metal industry will achieve a peak of carbon dioxide emission in 2025 with the peak value being 750 million tons carbon dioxide. The carbon dioxide reduction technology path of the non-ferrous industry mainly includes four parts, which are, green energy substitution, advanced low-carbon technologies and equipment, metal recycling, and carbon capture and utilization (CCU). Among them, metal recycling is the key path for the non-ferrous industry to support the realization of the national carbon peaking and carbon neutrality goals.
    Research progress of chemical engineering technology in the process intensification of biohydrometallurgy
    Cailong SHEN Yan JIA Yanzhen CHEN Guangji ZHANG Chao YANG
    The Chinese Journal of Process Engineering. 2022, 22(10):  1349-1359.  DOI: 10.12034/j.issn.1009-606X.222246
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    With the depletion of high-grade minerals, traditional pyrometallurgy with high cost and serious environmental contamination is no longer suitable for the sustainable development of the economy and society of China. Biohydrometallurgy is a bacterial-assisted leaching process to solubilize or expose the metals contained in different minerals, and the main role of the bacteria is to regenerate ferric ions and protons. Since the 1980s, biohydrometallurgy including heap bioleaching and tank bioleaching has been widely used for the recovery of metals such as copper and gold from low-grade and complex minerals because of its easy operation, low cost, and environmental advantages. Up to now, about 15% of the world's copper production can be attributed to the heap bioleaching of copper ore and about 5% of the world's gold production can be attributed to the biooxidation of refractory gold ore in continuous stirred tank reactors. However, the relatively slow reaction velocity of biohydrometallurgy is the main limitation to its further development. The application of biohydrometallurgy has been promoted remarkedly by the development of chemical engineering technology in history such as chemical reaction engineering and chemical separation technology. The process intensification of biohydrometallurgy based on chemical engineering technology is still one of the most important research interests in the future. Therefore, the research progress of chemical engineering technology in the process intensification of biohydrometallurgy was reviewed in this paper to help a better understanding. The influencing factors of efficiency in heap bioleaching and tank bioleaching were discussed mainly from an industrial point of view, and future research prospects were also put forward.
    Technical consideration on the transition from "ultra-low emissions" to "reduction of pollution and carbon emissions" in China's iron and steel industry
    Tingyu ZHU Xiaolong LIU
    The Chinese Journal of Process Engineering. 2022, 22(10):  1360-1367.  DOI: 10.12034/j.issn.1009-606X.222353
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    The iron and steel industry plays an important role in China's national economy, and it is also the largest pollution-carbon emission in China. In April 2019, five ministries and commissions jointly issued the "Opinions on Promoting the Implementation of Ultra-low Emissions in the Iron and Steel Industry", leading to a beginning of ultra-low emissions for industrial flue gas, and the air pollution emissions of China's steel industry achieved a significant reduction. Since the "14th Five-Year Plan", under the background of carbon peaking and carbon neutrality, with the proposal of pollution and carbon reduction, the problem of carbon incremental effect caused by ultra-low emission technologies has gradually become prominent, which has brought new technological needs to the steel industry. This work expounds the technological progress of ultra-low emissions in China's steel industry, summarizes the development direction of pollution and carbon reduction in the steel industry, and puts forward suggestions for the green and low-carbon development of the steel industry in the future, providing a reference for promoting the high-quality green development of China's steel industry.
    Research progress of biomass application in EAF steelmaking
    Chengjin HAN Rong ZHU Guangsheng WEI
    The Chinese Journal of Process Engineering. 2022, 22(10):  1368-1378.  DOI: 10.12034/j.issn.1009-606X.222321
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    In the current context of carbon peaking and carbon neutrality, the steel industry is under tremendous pressure to reduce carbon emissions in the long term, which is a major emitter of CO2. Therefore, developing electric arc furnace (EAF) steelmaking with lower carbon emissions will be an effective measure for the steel industry to achieve carbon emission reduction. However, although the carbon emission of EAF steelmaking is greatly lower than that of the traditional "Blast furnace-Converter" long-process steelmaking, it still needs to use a large number of coal resources to meet the smelting requirements. Therefore, using a suitable carbon source to replace coal as a carburizing and foaming agent in EAF steelmaking is of great significance to further reduce carbon emissions from EAF steelmaking. Biomass resources as the only renewable carbon source will be the first choice of alternative carbon sources. In this work, a series of studies on the application of biomass in EAF steelmaking conducted by domestic and international scholars had been introduced and the existing research results were also presented. On this basis, the future research direction of biomass application in domestic EAF steelmaking was prospected.
    Prospect on high ratio pellet utilized in blast furnace under the background of carbon peaking and carbon neutrality
    Xindong WANG Yonglong JIN
    The Chinese Journal of Process Engineering. 2022, 22(10):  1379-1389.  DOI: 10.12034/j.issn.1009-606X.222239
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    Carbon peaking and carbon neutrality are important measures taken by China to shoulder its responsibility as a major country in addressing climate issues and promote ecological progress and high-quality development. High carbon emissions are a key factor limiting the steel industry's ability to achieve carbon peaking and carbon neutrality goals. In order to achieve the goal of low-carbon development, on the one hand, breakthrough low-carbon metallurgical processes should be developed and applied, or enough high-quality scrap resources be supplied. On the other hand, the merits of existing blast furnace process, i.e., mature, high efficiency, high quality and low cost, etc., will be brought to full play to. And combining with the condition of iron ore resources, making full use of pellets' excellent metallurgical performance, low energy consumption and low emissions advantages of the production, developing blast furnace optimized burden structure and the related operation system by using high percentage of pellets, the best energy consumption and carbon emissions in the system level will be achieved. The overall competitiveness of existing processes will be improved. Significant progresses have been made in the research, development and application of technologies related to the use of high proportion of pellets in blast furnace at home and abroad. In China, some enterprises have certain resource advantages, and a large number of preliminary studies have been carried out. The future development will have a positive effect on China's steel industry to achieve the goal of low carbon emission.
    Research progress on high efficiency metallurgy and clean extraction of vanadium-titanium magnetite ore in Panxi area
    Chenguang BAI Xuewei LÜ Guibao QIU Shengfu ZHANG
    The Chinese Journal of Process Engineering. 2022, 22(10):  1390-1399.  DOI: 10.12034/j.issn.1009-606X.222302
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    The vanadium-titanium magnetite ore is an important characteristic resource in Panxi area of China, but it is difficult to smelt because of its high TiO2 content and complex mineral phase. As early as June 1958, Mr. Chu-Phay Yap issued a written opinion on "urgent problems of iron ore bearing titanium in Panzhihua". Among them, the "urgent problem" is to break through some foreign scholars' judgment: "smelting this ore with blast furnace has little hope of success", and rely on domestic scientific research to overcome the problems of smelting vanadium-titanium magnetite ore with blast furnace in Panxi area. With the cooperation of related industries and research forces in China, it has been successfully broken through that difficult problem of smelting of vanadium-titanium magnetite ore with blast furnace in Panxi region, and further improved the level of smelting, reaching the world higher level in whole. In recent years, in addition to the continuous improvement of smelting level, the level of comprehensive utilization of that kind ore has also carried out a lot of original research work. Chongqing University is one of the earliest research institutes on comprehensive utilization of vanadium-titanium magnetite ore smelting. Over the years it has always took the vanadium-titanium magnetite smelting and its efficient utilization as the primary of metallurgical science research topic in the Chongqing University, and the unique processes of blast furnace smelting vanadium-titanium magnetite ore are studied systematically in the theory and technology, that has formed distinctive research features. In recent years, it has also been made that breakthroughs in theoretical and experimental research methods and made good progress in close cooperation with enterprises on smelting technology of high ratio vanadium-titanium magnetite ore in blast furnace, titanium extraction from titanium-containing blast furnace slag and titanium slag smelting technology in large electric furnace, as well as efficient and clean extraction technology of vanadium resources. This review gives a brief introduction on the clean metallurgy and efficient extraction research progress on Panxi vanadium-titanium magnetite ore in Chongqing University, to commemorate the contribution of Chu-Phay Yap and Yanxian Lin et al. scientific workers for the development and utilization of Panxi vanadium-titanium magnetite ore, and uphold their feet on the ground, as well as the innovation of scientific spirit. To promote the development of green and intelligent metallurgy and resource efficient utilization of vanadium-titanium magnetite ore in Panxi region under the carbon peaking and carbon neutrality goals.
    Thermal simulation technique for solidification process of continuous casting and its application
    Huazhi YUAN Honggang ZHONG Qijie ZHAI
    The Chinese Journal of Process Engineering. 2022, 22(10):  1400-1413.  DOI: 10.12034/j.issn.1009-606X.222310
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    Solidification is an important process governing the quality of metallurgical products, but the study of solidification process under continuous casting condition is extremely difficult result from the high temperature, opaque, large-scale and continuous production. The current research methods mainly include numerical simulation, physical simulation and thermal simulation, among which thermal simulation method is of great interest because the experimental data similar to the production conditions can be directly obtained. This work systematically introduces the methods of thermal simulation for continuous casting solidification. The principles of thermal simulation techniques are briefly described, and the applications of the mold thermal simulation method and the characteristic unit thermal simulation method are summarized. Among them, the thermal simulation methods for dendritic growth of continuous casting billet and hot tearing based on the heat conduction similarity have successfully "condensed" the solidification process of a dozen tons of cast billet into a laboratory study with 100 grams of steel. Both the methods can not only reveal the influences of composition, pouring and cooling conditions on solidification process, microstructure and solute distribution, but also can observe the morphology of solid-liquid interface, diffusion of solute, evolution of inclusions, and the possibility of hot tearing formation, that are regarded as extremely important issues in metallurgy filed but cannot be obtained by other means.
    Viewpoint
    Prospect of resource recycling technology frontier of metallurgical industry with carbon peaking and carbon neutrality strategy
    Huiquan LI Yufeng WU Yunfa CHEN
    The Chinese Journal of Process Engineering. 2022, 22(10):  1414-1417.  DOI: 10.12034/j.issn.1009-606X.222360
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    Resource recycling is an important way for the metallurgical industry to ensure the safe supply of key metal resources and achieve carbon peak and carbon neutrality. From the perspective of carbon peaking and carbon neutrality strategy, this work outlines the overall status and the development trend of green low-carbon transformation in the resource recycling of metallurgical industry, prospects the development frontier of resource recycling technology in the metallurgical industry from multiple perspectives such as the scientific basis of material recycling, the revolutionary technology of "waste free metallurgy", the coupling of resource recycling and carbon cycle, the high-quality recycle of secondary metal resources, and the reconstruction of intellectual property rights based on digital technology. A series of view points is proposed to be useful reference for the green and low-carbon transformation and development of metallurgical industry.
    Secondary resources utilization, problems and countermeasures of the domestic and oversea steel industry
    Daqiang CANG Lingling ZHANG Yang LIU Zhaohou CHEN Bingyang HE
    The Chinese Journal of Process Engineering. 2022, 22(10):  1418-1424.  DOI: 10.12034/j.issn.1009-606X.222345
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    In order to improve the steel industrial secondary resources utilization level (steel slag as an example), the different gas, liquid, and solid phase secondary resources (wastes) from the steel industry are introduced first, and then the recent situation of the solid phase secondary resources is introduced. The problems and the relevant countermeasures are put forward for steel slag future utilization. So far steel slag is one of the most difficult proposals and utilization of solid secondary resources, and has become a hot topic in the world steel industry. So new steel slag technologies and product development are urgently needed for high efficiency, cleaner, and high value-added utilization for steel slag utilization.So new steel slag technologies and product development are urgently needed for high efficiency, cleaner, and high value-added utilization for steel slag.
    The technical development for water saving and pollution control in iron and steel industry under carbon peaking and carbon neutrality background
    Yongbing XIE Di ZHANG He ZHAO Yuehong ZHAO Fengqiang LIU Hongbin CAO
    The Chinese Journal of Process Engineering. 2022, 22(10):  1425-1428.  DOI: 10.12034/j.issn.1009-606X.222357
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    The iron and steel industry plays an important role in Chinese economic development. It is a pillar industry of our country, but also an industry with high energy and water consumption, high pollution, and high carbon emissions. Under the new situation that China has formulated the carbon peaking and carbon neutrality goal, the end treatment of wastewater pollution in the iron and steel industry is still disconnected from the production process, and the efficiency of water and energy usage still needs to be improved. It is difficult to meet the control needs of low-carbon development of the industry, so it is urgent to promote the overall planning of pollution control and carbon emission reduction. This work puts forward the research ideas for the development of water-saving and pollution-reduction technology in the iron and steel industry under this background, which concludes the comprehensive planning of water supply, water use, wastewater treatment, and water recycling, low-carbon collaborative control of water pollution across different mediums, the whole process control and intelligent optimization of wastewater pollution, the common prosperity and collaborative development of steel enterprises and local cities. It is expected to further enhance the scientific and technological support for water conservation and pollution reduction in the iron and steel industry in the future, and help the green and low-carbon development of the industry.
    Research Paper
    Study on technology of super gravity step separation of rare earth elements in Bayan Obo rare earth ore
    Xi LAN Jintao GAO Zhancheng GUO
    The Chinese Journal of Process Engineering. 2022, 22(10):  1429-1437.  DOI: 10.12034/j.issn.1009-606X.222303
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    The rare earth reserves of Bayan Obo mine in China rank first in the world, and its rare earth minerals are mainly light rare earth, of which cerium, lanthanum, praseodymium and neodymium account for more than 97% of the total rare earth oxides, which has important industrial value. Since the rare earth elements have extremely similar physical and chemical properties, it is difficult to realize the separation of different rare earth elements from each other in the current treatment process. In this work, a green and efficient method was proposed for respectively recovering rare earth elements under supergravity from rare earth concentrate. Based on the evolution of mineral phases and elemental migration laws of the rare earth concentrate, it was found that different rare earth phases would be precipitated in different temperature intervals during the melting and cooling precipitation process. It could be concluded that the rare earth elements (REEs: Ce, La, Pr, Nd) were discovered to be precipitated as the rare earth oxide, rare earth ferrate and britholite phases respectively at various temperature ranges of 1400~1500, 1200~1400, and 1100~1200℃, respectively. However, the rare earth phases were intimately intertwined with each other in the normal gravity. Consequently, the respective separation of REEs (Ce, La, Pr, Nd) at their corresponding precipitation temperatures was conducted under the supergravity. 98.38% of Ce was firstly enriched into the rare earth oxide and separated from the concentrate as driven by the supergravity, 97.70% of La was enriched into the rare earth ferrate and separated subsequently, and the Pr and Nd were precipitated further into britholite and separated from the system. Accordingly, the high purity of rare earth oxide, rare earth ferrate, and britholite phases were attained respectively, and the stepwise separation of Ce, La, Pr and Nd in the rare earth concentrate were achieved, achieving the green and efficient recovery of REEs (Ce, La, Pr, Nd) from the Bayan Obo rare earth concentrate with no additives, no hazardous waste, and no secondary pollution.
    The jet characteristics of post combustion oxygen lance in a 250 t converter
    Shuguo ZHENG Miaoyong ZHU
    The Chinese Journal of Process Engineering. 2022, 22(10):  1438-1446.  DOI: 10.12034/j.issn.1009-606X.222281
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    Supersonic jet characteristics of oxygen lance nozzles have a significant influence on smelting. The three-dimensional model of a 250 t steelmaking converter was established by Fluent software. The jet characteristics of a conventional 6-hole oxygen lance with five holes around and one hole in the center and a post combustion (PC) oxygen lance with a single flow channel were compared and analyzed. The interaction between gas-liquid-slag three phases was simulated by VOF multiphase flow model. The results show that the inflow of the left-side secondary hole flow unit quickly converges into the center hole jet, which has a larger radial cross-sectional area; while the right-side secondary hole flow unit converges into the peripheral 5-hole main flow unit. Due to the supplement of the second hole flow unit, the velocity under the oxygen lance is evenly distributed, and the low-velocity area is reduced, slowing down the decay of the center hole jet, resulting in a large center hole jet velocity. Therefore, the post combustion oxygen lance has a larger impact area and impact depth. Therefore, it can efficiently decarbonize and phosphoresce, giving full play to the secondary combustion effect, and is conducive to slagging. Through the three-phase simulation study of gas-liquid-slag, it can be seen that the cavity profile and interface of steel-slag-gas remain unstable due to the propagation of surface waves, and the slag layer at the furnace wall is calmer with time, indicating that there is no scouring of the furnace wall by either the conventional oxygen lance or the secondary combustion oxygen lance. The maximum impact diameter and impact depth of the secondary combustion oxygen lance is 2461 mm and 358 mm, which are 1.16 times and 1.19 times than the conventional oxygen lance, respectively. The industrial tests have shown that the use of secondary combustion oxygen lances increases the furnace temperature and significantly reduces the oxygen supply time, while the post combustion oxygen lance increases the converter temperature by 27.2°C, and shortens the oxygen supply time by 78 s.