bluuebunny/crossref_metadata_2025 huggingface dataset:
Development of a steel health monitoring device based on anisotropic magnetoresistance sensors
Authors: Stamou Georgia , Angelopoulos Spyridon , Hristoforou Evangelos
Published: November 2023

This paper presents a portable device based on an Anisotropic Magnetoresistance (AMR) sensor for Steel Health Monitoring. The system operates by detecting magnetic anomalies in ferromagnetic materials caused by strain, corrosion, etc. This sensor can have various applications in the transportation, building, and aerospace fields for safety and maintenance monitoring of ferromagnetic materials. In this work, a low-cost device, that combines a high-sensitivity AMR sensor, a microcontroller, and supporting electronics has been designed and implemented. This sensor allows the contactless measurement of the magnetic flux density along three axes, when placed above the material under test, while the microcontroller and the required electronics enable real-time analysis and monitoring of measurements. In order to house and protect the sensor under various circumstances, a 3D-printed enclosure has also been created. This device can be used along with rehabilitation techniques for treatment of defective areas of an under-test material. Its versatility allows it to be employed in a variety of testing conditions for both single-point and scanning mode monitoring. The device’s portability, ease of use and applicability to on-site measurements make it accessible to a wide range of users, requiring only a personal computer to display the measurements. Finally, measurements are presented to prove the device’s accuracy for steel health monitoring.
Improving maternal update rates within the first hour of NICU admission
Authors: Manzar S. , Cole S.R. , Bhat R.
Published: November 2023

BACKGROUND:

Timely communication is essential in attaining maternal satisfaction, developing an excellent physician-patient rapport, and increasing trust. This study reports a significant improvement in maternal communication rates through the quality improvement method.

METHODS:

An educational module was developed, and NICU staff was presented with the slides, followed by a performance questionnaire to demonstrate understanding. The first phase was completed by obtaining feedback from mothers through a questionnaire. The first plan-do-study-act (PDSA) cycle, carried out for eight weeks looking at the rates of the maternal update provided within an hour of admission of their neonates to the NICU, was followed by the second PDSA cycle, carried out for ten weeks. The improvement was calculated using conventional statistics and a statistical process control chart.

RESULTS:

During the first phase of the study, thirty-six percent of the mothers were updated within an hour of admission of their neonates to the NICU. During the first PDSA cycle, we did not notice a special cause variation or process change. A significant shift, eight consecutive points above the mean, was noted on the control chart during PDSA cycle 2. The mean±SD of the weekly update rate increased significantly during PDSA cycle 2 (76.8±11) compared to PDSA cycle 1 (47.5±14), p-value = 0.0002.

CONCLUSION:

We improved the maternal update rates through the educational module following the QI improvement model using the PDSA cycles.
Clinical determinants of intestinal failure and death in preterm infants with surgical necrotizing enterocolitis
Authors: Garg P.M. , Denton M.X. , Talluri R. , Ansari M.A.Y. , Riddick R. , Ostrander M.M. , McDonald A.G. , Premkumar M.H. , Hillegass W.B. , Garg P.P.
Published: November 2023

OBJECTIVE:

We sought to investigate the clinical determinants of intestinal failure and death in preterm infants with surgical NEC.

METHODS:

Retrospective comparison of clinical information between Group A = intestinal failure (Parenteral nutrition (PN) >90 days) and death and Group B = survivors and with PN dependence < 90 days in preterm infants with surgical NEC.

RESULTS:

Group A ( n = 99/143) had a lower mean gestational age (26.4 weeks [SD3.5] vs. 29.4 [SD 3.5]; p = 0.013), lower birth weight (873 gm [SD 427g] vs. 1425 gm [894g]; p = <0.001), later age of NEC onset (22 days [SD20] vs. 16 days [SD 17]; p = 0.128), received surgery later (276 hours [SD 544] vs. 117 hours [SD 267]; p = 0.032), had cholestasis, received dopamine (80.6% vs. 58.5%; p = 0.010) more frequently and had longer postoperative ileus time (19.8 days [SD 15.4] vs. 11.8 days [SD 6.5]; p = <0.001) and reached full feeds later (93 days [SD 45] vs. 44 [SD 22]; p = <0.001) than Group B. On multivariate logistic regression, higher birth weight was associated with lower risk (OR 0.35, 95% CI 0.15–0.82; p = 0.016) of TPN > 90 days or death. Longer length of bowel resected (OR 1.76, 95% CI 1.02–3.02; p = 0.039) and longer postoperative ileus (OR 2.87, 95% CI 1.26–6.53; p = 0.011) were also independently associated with TPN >90days or death adjusted for gestational age and antenatal steroid treatment.

CONCLUSION:

In preterm infants with surgical NEC, clinical factors such as lower birth weight, longer bowel loss, and postoperative ileus days were significantly and independently associated with TPN >90 days or death.
FORECASTING OF INDUSTRIAL COKE QUALITY AT JSC EVRAZ NTMK BASED ON DATA OF PASSIVE INDUSTRIAL EXPERIMENT
Authors: ZOLOTUKHIN YU. A. , BERKUTOV N. A. , KUPRYGIN V. V. , KUPRIYANOVA S. N.
Published: November 2023

A methodological approach to the processing of data of a passive industrial experiment on charge coking at the coking plant of EVRAZ NTMK JSC using a sample (general) matrix, rather than the entire data array, which takes into account various multilevel values of the factor of influence on M25 and M10 of coke ‒ a complex indicator of charge coking capacity (CCIVo) is presented, which provides sufficiently wide changes in the response functions (M25/M10) with a symmetric matrix, excluding the predominance of any one range of values of the CCIVo and М25/М10 indices. On the basis of the proposed approach to the processing of the actual reporting data of industrial coking of charges on batteries No. 5‒6 (wet quenching) and No. 9‒10 (dry quenching) (passive industrial experiment), adequate mathematical models were obtained for predicting the quality of industrial coke for wet and dry quenching (M25/M10) on the properties of coal charges (CCIVo) under the existing modes of their preparation and coking in batteries No. 5‒6 and No. 9‒10. Verification of the accuracy of the obtained mathematical models for predicting the quality of wet and dry quenched coke (M25/M10) on a large actual material of industrial coking in batteries No. 5‒6 (62 coking operations) and No. 9‒10 (58 coking operations) showed high enough for practical use accuracy of the forecast of indicators M25 and M10 of industrial coke of wet and dry quenching.
ON THE CLASSIFICATION OF COLD RESISTANT MATERIALS
Authors: KUPRIYANOVA О. А.
Published: November 2023

Low-temperature technologies are increasingly used in various industries. Cold-resistant materials have gained particular popularity in the field of creating low-temperature machinery. The need for a special approach when choosing cold-resistant materials used in the production of machines, equipment and structures, whose operation is carried out under extreme conditions [low temperatures, dynamic/static loads and (or) intense wear], caused the need to systematize them according to a complex of mechanical properties. Despite the fact that a wide variety of products is produced from new cold-resistant materials in Russia and abroad, neither the scientific literature nor the regulatory documentation provides a common unified classification, which covers a wide range of their categories. Research was carried out for shipbuilding cold-resistant steels, which is reflected in the Russian National Standard R 52927–2008 “Steel rolled for shipbuilding from normal, increased and high strength steel”, however, this classification is incomplete and covers strength categories from 265 to 735 MPa. This article presents comprehensive systematization of scientific data of new structural cold-resistant steels of various leading industries of strength category up to 1550 MPa with corresponding characteristics of plasticity and cold resistance. The article considers and summarizes various criteria used to classify cold-resistant materials, as well as preferred classification features, determines numerical ranges of constituent properties. The article develops a classification system of structural steels according to groups of strength, cold resistance and hardness. The use of the proposed classification of structural alloys makes it possible to select material of certain category (class) of strength depending on operational loads of structural elements, machines and equipment of leading industries in conditions of low temperatures, and also to predict their reliability life depending on interval of low-temperature operating threshold
STUDY OF THERMOSTRESSED STATE AND THERMOSTABILITY OF SLAG CARRIAGE BOWLS
Authors: RAKHMANOV S. P. , EMELIN М. V. , DRAGOMERETSKII YU. A.
Published: November 2023

Impact of high temperatures on slag bowls causes considerable elastoplastic deformations resulted in appearance of cracks in them. To prevent destruction of the bowls casing, it is necessary to undertake measures for stabilization of thermostressed state of slag carriage bowls and increasing their thermostability. Results of experimental and computer studies of temperature fields and thermostressed state of slag carriage bowls of various design presented. The study of the thermostressed state of slag carriage bowls was carried out by a tensometric method based on standard equipment. The measuring of temperature and thermal stresses was carried out in the most critical bowls sections. To study the thermostressed state of bowls, a methodology of computer simulation and engineer analysis based on Solid Works/Cosmos Works software was proposed. Results of comparative evaluation of the thermostressed state and thermostability of the forming bowl casing, used in the domestic industry and abroad presented. Basic measures to stabilize the thermostressed state of slag carriage bowls and ways of their thermostability increasing were proposed. Reliability of the results obtained was confirmed by results of experimental studies.
THERMODYNAMIC MODELING OF PHASE EQUILIBRIA DURING DEOXIDATION OF THE LOW AND MEDIUM CARBON STEELS BY SILICOMANGANESE
Authors: SAMOILOVA O. V. , MAKROVETS L. A. , MIKHAILOV G. G.
Published: November 2023

To create digital twins of steelmaking production, it is necessary to develop programs for calculating all stages of smelting and secondary treatment of steel and alloys, including the process of deoxidation. The aim of this work was to construct a phase stability diagram in the form of a surface of solubility of components in a metal (SSCM) of the Fe–Si–Mn–O–C system for carbon concentrations [C] = 0; 0.1; 0.4 wt. % and a temperature of 1600 °C. SSCM will make it possible to establish the stability boundaries of non-metallic inclusions (NI) formed during deoxidation and the degree of deoxidation of low- and medium-carbon steel, depending on the introduced concentrations of silicon and manganese. It is noted that in the system under study, during absence of carbon ([C] = 0 wt. %) an oxide melt of variable composition (FeO, MnO, SiO2) with a minimum concentration of iron oxide prevails as nonmetallic inclusions. With the appearance of carbon in the melt, the region of equilibrium of the liquid metal with the gas phase {CO, CO2} was established, and with an increase in the concentration of carbon, this region increased. For low-carbon steels ([C] = 0.1 wt. %) at industrially significant concentrations of silicon (0.1–0.3 wt. %) and manganese (about 1.0 wt. %), NI in steel also represent oxide melt. In medium-carbon steels ([C] = 0.4 wt. %) at the same silicon and manganese concentrations, the deoxidation product is in the gas phase. In the course of modeling, the isotherms of oxygen solubility in the system under study were also constructed. The simulation results are in good agreement with the literature data. The constructed SSCM can be used to create a digital twin of the deoxidation process of steels.
APPLICATION OF METHODS FOR DETERMINATION OF THE VOLATILE CORROSION INHIBITORS CONTENT IN COMBINED PACKAGING MATERIALS
Authors: TARASYUK E. V. , KOLYADA L. G. , PONOMAREV A. P.
Published: November 2023

One of the modern means of corrosion protection of metal products during transportation and storage is packaging materials containing volatile corrosion inhibitors. The efficiency of the metal protection is highly dependent on their content in the packaging materials. Present study considers the peculiarities of practical application of Synchronous Thermal Analysis method and Walki Wisa (Finland) method for determination of the corrosion inhibitor content in packaging combinations. The packaging materials used in the study were the crepe paper laminated with thermoplastic polymer on one side, onto which the water solutions of inhibitors Koring 501, 505 (Cortec, USA) and UNI (a mixture of sodium nitrite and urotropine in relation 1:1, Russia) containing 5 % (mas.) of active substance were applied with a roller. After application of the solution the paper was subjected to drying at 80 °C for 35 min. The residual content of inhibitors was determined by two methods: thermogravimetric analysis using STA 449 F3 Jupiter and the method of washout according to the Walki Wisa method. It was shown that washout method requires preliminary isolation of inhibitor from packing material in the form of its aqueous extract. It was found that the inhibitor content indices obtained by the washout method have higher values compared to the initial samples which is probably caused by the water extraction of other components from combined material together with the inhibitor. The content of the inhibitor in the materials under study and the temperature of the maximum rate of inhibitor volatilization were determined by the thermogravimetric analysis. The sample with UNI inhibitor had the highest inhibitor content (13 %) and a higher maximum volatilization temperature compared to the other samples. This may be due to the overlapping processes of urotropin removal and cellulose fibers decomposition. The method of thermogravimetric analysis can be applied for determination of the inhibitors removing up to 200 °C. It is noted that both considered methods have certain limitations and can be used for approximate determination of the inhibitor content in paper-based composite packaging materials.
MORPHOLOGICAL FEATURES OF THE AYAT IRON ORE DEPOSIT
Authors: SULEIMEN B. , SALIKHOV S. P. , ROSHCHIN V. E.
Published: November 2023

Due to decrease in the resources of high-quality iron ore with a low phosphorus content, the iron ores with an increasingly complex mineralogical composition, as well as oolitic deposits, in particular, the deposits with an increased phosphorus content are involved in the production. The morphology of the oolite ore of the Ayat deposit (Kazakhstan), which is close to the iron content of the oolite iron ore of the world's largest Kerch deposit was studied. The results of the study of the morphology of the iron ore of the Ayat deposit and the influence of oxidative firing on the process of transformation of its structural components are presented. The general analysis of the composition of the initial ore before and after oxidative firing was carried out by chemical methods. It is shown that firing leads to an increase in the iron content from 39.3 to 48.1 wt. %. The mineral composition was determined by XRD phase analysis using a diffractometer. The initial iron-containing phase goethite dissociates with formation of hematite during firing. The experiments were carried out to study the decomposition of brown ironstone in an oxidizing atmosphere with continuous control of the temperature and mass of the sample. The two peaks were revealed on the graph of the mass rate change depending on temperature. At a temperature of 220 °C the rate of mass loss during the removal of crystallohydrate moisture reacheda maximum and it was 1.38 %/min, and at a temperature of 380 °C the maximum mass loss rate was 1.18 %/min, which was associated with the dissociation of carbonates. The total mass loss during firing was almost 24 %. A map of the distribution of elements in the initial ore is presented. It confirms that oolites are mainly formed by the iron oxides, there are phases of waste rock consisting mainly of silicon oxides, in addition, there are complex oxide phases where several elements (Fe, Si, Al) are present. The sulfur and phosphorus are distributed almost evenly not being attributed to any particular phase. The structural components of the initial and fired ore were evaluated using an electron microscope. The obtained data generalizes the results of the study of morphological features of the oolite ore of the Ayat deposit and can be used in the development of theoretical and technological bases for processing the oolite ores.
IRON ORE BLENDING AT PJSC MMK’s SINTER PLANT No. 5
Authors: CHUKIN D. M. , ANDRYUSHECHKIN A. A. , FROLOV YU. A. , KOTYSHEV V. Е. , KOTYSHEVA N. I.
Published: November 2023

Considers the factors that determine the efficiency of iron ore raw materials blending and the variability in the chemical composition of the sinter. The characteristics are provided for the areas of receiving and blending iron ore raw materials at PJSC MMK’s Sinter Plant No. 5. It is shown that an autonomous dosing department for iron ore raw materials with lime in front of the blending warehouse is used for the first time at sinter plants in Russia; the closed blending warehouse is equipped with the most modern technology. The method for determining the efficiency of blend-ing iron ore raw materials by chemical composition for the operation of a warehouse in certain periods (summer, winter, with and without a drum-mixer, various concentrates) has been clarified using several piles. The distribution of iron ore raw materials along the length of the newly installed drum-mixer in front of the warehouse was measured, and the mathematical model of its operation was adapted. The operating modes of the drum, including those critical in terms of the raw material consumption were studied using the model. The samples of iron ore raw materials were taken at the inlet and outlet of the drum and an assessment was made for the efficiency of blending raw materials. It was found that the coefficient of uniformity at the input was 82.5% and at the output 92.4%. It is shown that, despite the significantly different conditions, the preliminary dosing of raw materials and modern equipment in the warehouse provide high uniformity of the iron ore raw materials in terms of the chemical composition. The subsequent dosing with high accuracy of raw materials, fuel and limestone, and the use of modern mixer and granulating drums at Sinter Plant No. 5 provide favorable conditions for obtaining stable sinter properties, including high cold strength (average 82%) and fines content of fraction 0‒5 mm up to 6‒7%.
Viscosity, crystallization temperature, phase composition, and structure of the low-basicity СаО–SiO2–B2O3–Cr2O3–Аl2O3–МgO slag system
Authors: Babenko A. A. , Shartdinov R. R. , Upolovnikova A. G. , Lobanov A. D. A. , Smetannikov A. N.
Published: November 2023

The influence of B2O3 on viscosity, crystallization temperature, phase composition, and structure of fluorine-free slags of the СаО–SiO2–B2O3–2 % Cr2O3–3 % Аl2O3–8 % МgO system in the range of boron oxide content from 0 to 6% and basicity (B = CaO/SiO2 ) equal to 1.0 is studied by vibrational viscometry, phase composition thermodynamic modeling in combination with raman spectroscopy. It is found that boron oxide-free slag has the simplest structure, as indicated by the average amount of bridging oxygen BO equal to 0.73, and has a higher viscosity compared to boron-containing slags of 0.85‒0.60 Pa•s in the temperature range of 1400‒1450°C, and crystallization temperature of 1402°C. This is due to the high proportion of high-temperature compounds in the formed slag. The introduction of 2 to 6% boron oxide complicates the structure of the slag, which is accompanied by an increase in the average amount of bridging oxygen BO to 0.98 and 1.28, respectively. The resulting four-coordination structural elements [BO4], [CrO4] and [AlO4] are embedded in the silicon-oxygen lattice of the slag and complicate it, which increases the degree of polymerization. However, the formation of low-melting eutectics CaO•B2O3 and 2CaO•B2O3 after introduction of 2 and 6% boron oxide, despite the complexity of the structure of the formed slags, leads to a decrease in crystallization temperature to 1346 and 1265°C, an increase in the degree of slag superheating and a decrease in its viscosity to 0.9 and 0.55 Pa•s already at 1350°C. Thus, the addition of boron oxide to slag, despite the structure complication of the formed oxide system, leads to an increase in the liquid mobility of the slag due to the formation of a high proportion of low-temperature phases and a decrease in the proportion of medium- and high-temperature phases and a lower binding energy of boron with oxygen compared to silicon
Current state of the ferroalloy industry in Russia and prospects for its development in the Asian part of the country
Authors: Petrov S. P.
Published: November 2023

Ferrous metallurgy, as a supplier of metal products and a major consumer of energy and engineering products, is an industry that can act as one of the source for Asian Russia complex development impulse. The different ferroalloys and ligatures have used in the process of steelmaking to ensure the required range of steel products. Therefore, it is necessary to conduct an audit of the current state of the Russian ferroalloy industry and its Asian part in order to identify possible growth points of the industry to ensure the development of ferrous metallurgy and sustainable socio-economic growth of the Asian Russian space. In the article it is shown that Asian part is one of the ferroalloy industry centers in Russia, which, as in the industry as a whole, has a high dependence on imported supplies of ore which neces-sary for ferroalloys production. Its own raw materials provided only for production of silicon alloys. In the issue of oth-er alloys and ligatures production, the existing conservative approach in the organization of the ferroalloy industry does not allow the use of poor domestic ore in production. The growth in demand for silicon alloys can be achieved by reori-enting export flows to domestic consumption but the most important alloys for the development of Asian Russia based on manganese, chromium, vanadium and niobium may have difficulties in providing ferrous metallurgy with them. The solutions of such problems are implementation of new technologies for raw materials processing, development of non-standard types of alloys, introduction of technogenic waste processing. This will contribute to the realization of Russia’s desire for import substitution, including the provision of metallurgy with its own raw materials.
EFFECT OF LIME SIZE AND IRON ORE MOISTURE CONTENT ON BLENDING STORAGE IN WINTER AND SUMMER FOR THE OPERATION OF SINTERING MACHINES OF SINTER PLANT No. 5 OF MAGNITOGORSK IRON AND STEEL WORKS
Authors: CHUKIN D. M. , GRISHIN I. A. , FROLOV YU. A. , ANDRYUSHECHKIN A. A. , KOTYSHEV V. E.
Published: November 2023

The efficiency of lime use, which is supplied to the sintering mix, is significantly affected by the lime size, the duration of interaction with iron ore raw materials (IORM), as well as the difference in iron ore moisture content in the blending store in winter and summer time. The aim of the research is to determine the effects of lime size, the duration of interaction in the stacks of IORM and lime on the degree of dispersion and slaking of the latter, as well as the moisture content of IORM in winter and summer time in the blending store on the operation of sintering machines of sinter plant No. 5 of MMK PJSC. The results of modeling in laboratory conditions of slaking lime of different sizes in piles of IORM with lime in a blending storage in winter and summer are presented. It has been established that the slaking of lime with a particle size of 0‒10 mm in summer conditions is satisfactory only when the IORM stays in a pile for at least 6‒7 days, while at the same time “whitewash” (a large fraction of lime that has not been subjected to slaking) in IORM with fraction lime 3‒10 mm does not disappear even after 7 days of keeping the material. The deepest slaking occurs at a lime size of 0‒3 mm. The large fraction of lime segregates in height and in the volume of the pile, which leads to significant fluctuations in the basicity of IORM and sinter. It is shown that the transfer of operation of sintering machines from the “summer” pile of iron ore with an average moisture content of 5.4% to the “winter” one with a moisture content of 2.3% is accompanied by a decrease in the specific productivity of sintering machines to 8% due to the low efficiency of using lime for the mix granulation. It is recommended to carry out additional crushing of lime to a fraction of 0‒3 mm with its separate supply both to the blending store and to the SP-5 dosing department, as well as to install a mixer drum in front of the blending store with moistening of IORM with lime in winter.
EFFECT OF BASICITY ON COMPLEX METALLURGICAL PROPERTIES OF SINTER
Authors: ISAENKO G. E. , KOVALEV D. A. , NECHKIN G. A. , CHERNAVIN D. A. , KOBELEV V. A.
Published: November 2023

Metallurgical properties of sinter have a significant influence on its basicity. The dependence of cold and hot strength, softening point, reducibility and other physical and chemical properties of sinter on basicity was established by studies of many domestic and foreign scientists. However, taking into account essential increase of iron content in concentrate during decrease in silica content as a result of modernization of production in JSC Stoilensky GOK, the estimation of basicity influence on complex properties of sinter produced with the silica usage is actual. The results of laboratory research at Novolipetsk Iron and Steel Works with the purpose of study of sinter basicity influence on sintering process indexes, strength and high-temperature properties, including filterability of smelting products through the coke baffle are presented. The sinters of different basicity were produced in the laboratory conditions by sintering based on concentrate of Stoilensky GOK with iron content 68,0 %. The basicity of the charge CaO/SiO2 was varied in the range of 1.2‒2.0 units in steps of 0.2 units. In the process of research we selected the optimum rate of solid fuel for each charge from the condition of maximum vertical speed of sintering and sintering strength of sinter. It was found that increasing the basicity of sintering material leads to increasing cold and hot strength, narrowing interval of plastic-viscous state. The maximum vertical sintering rate and maximum specific capacity are reached at basicity 1.6. At basicity of 1.4 the minimum strength of sinter was obtained. It was established, that the sinter reducibility sharply increases at basicity of 1.6 units. With increase in basicity the temperature softening-melting interval (TSMI) of sinter decreases, which characterizes the cohesion zone. The widest TSMI is in sinter with basicity of 1.2, the narrowest – with basicity of 2.0. With increasing basicity of sinter the characteristics of the melt flow through the coke packing increases. The mixture of 55% of sinter with 2.0 basicity and 45% of unfluxed pellets from Stoilensky GOK had the best flow characteristics of the melt products and slag.
THE INSTITUTE OF MINING ENGINEERING OF THE URAL BRANCH OF THE RUSSIAN ACADEMY OF SCIENCES IS 60 YEARS OLD: STATE OF THE ART AND PROSPECTS FOR DEVELOPMENT
Authors: SOKOLOV I. V. , GLEBOV А. V.
Published: November 2023

On February 24, 2022 the Institute of Mining Engineering of UB RAS turned 60 years old. The aim of this paper was to show its role as a leading research organization in the field of development of theoretical bases of strategy of effective and safe development and complex use of mineral raw materials resources, methods of geoinformation support of georesources and geosystems of a mining enterprise, creation of innovation technologies of development of deeply buried deposits based on modern knowledge of laws of geological structure and formation of the stress-strain state of massif of rocks, deformation of minerals and geological processes. The information about innovation activity and results of fundamental and applied scientific researches, personnel policy and publication activity is provided.
THE PRACTICE AND APPLICATIONS OF PHYSICAL MODELLING IN FLOW DYNAMICS RESEARCH IN CONTINUOUS CASTING
Authors: ERON’KO S. P. , TKACHEV M. YU. , OSHOVSKAYA E. V.
Published: November 2023

The importance of physical modeling as one of the effective methods of scientific research is noted. The practical features of modeling the hydrodynamics of flows in continuous casting of steel are considered, concerning the scale, design and material of equipment models that are part of continuous casting machines. Attention is paid to the choice of modeling fluids, methods of visualization and control of their flow rates. Methods and results of modeling studies are presented, devoted to the development of technical means for shielding a steel jet from the surrounding atmosphere in order to provide protection against secondary oxidation of the metal supplied to the tundish; regulation of the direction of movement of the layers of the melt from the place of entry into the receiving part and to the outlet channels of the tundish to increase the duration of the steel casting in it and remove the non-metallic inclusions; decrease in the degree of dynamic impact of metal flows on the lining of the tundish bottom; reducing the duration of the destabilization of the velocity field of metal flows in the upper part of the mold, which occurs during the replacement of submersible nozzles. The obtained data of modeling studies served as the basis for creation of new types of equipment that allow the implementation of technological operations, the implementation of which will increase the technical and economic efficiency of modern high-speed continuous casting machines.
SEVERSKY PIPE PLANT – THE LEADER IN THE ENVIRONMENTAL ACTIVITIES IN RUSSIA – 2021
Authors: OZORNIN V. E.
Published: November 2023

Seversky Pipe Plant (STZ) is one of the oldest metallurgical enterprises in Russia and one of the most hightech pipe plants in the world. A Strategic program for the technical revamping of the plant has been developed and implemented, within the framework of the Strategic Program for the development of the TMK enterprises (STZ became its part in 2002). The environmental measures in this program are considered as the biggest priority. The total investments included 35 billion rub., and 5.5 billion rub. of this amount were assigned for the implementation of measures directed to the environmental safety. As a result of its implementation, 19 significant sources of hazardous emissions into the atmosphere were decommissioned, including four open-hearth furnaces. Eight newly commissioned facilities are equipped with modern gas treatment equipment. These measures contributed to 4 times reduction in the specific emissions of steelmaking production. Ten new recirculation cycles of water supply were introduced during the revamping. The water intake for technical water supply was reduced by 4 times, the volume of effluents decreased in more than half. The introduction of the best available technologies made it possible to bring the border of the sanitary protection zone very close to the border of the enterprise territory. The effluents discharged by the plant have several times lower hazardous substance concentration than the background ones on a number of components. In 2021, STZ became the winner of the XVII All-Russian competition “The leader in the environmental activities in Russia-2021” in the nomination of “The best environmentally responsible town-forming enterprise”.
TO THE QUESTION OF SINTER BINDER FORMATION AND IMPROVEMENT OF THE SINTER STRENGTH
Authors: ISAENKO G. E. , BAKANOVA E. A. , NECHKIN G. A. , CHERNAVIN D. A. , KOBELEV В. A.
Published: November 2023

The higher share of unfluxed pellets in blast furnace burden determines the increase of sinter basicity (CaO/SiO2) up to 1.7‒2.2 units. Study of the microstructure formation peculiarities of such sinters is an urgent challenge. Recently, the mining enterprises have been increasing the iron content in the concentrate and use concentrate grades with iron content of 68‒70% in sintering. In this regard, it is interesting to study the microstructure of sinters with high iron content and the influence of mineral composition of the binder on the sinter strength. The schemes of formation of mineral composition of sinter with low basicity and high SiO2 content and with high basicity and low SiO2 content are given. The role of hedenbergite, ferrites and alumoferrites in the formation of the melt and the formation of the sinter structure is shown. It has been established that the structure of sinter with a basicity of 1.8 units and iron content of 57.1% consists of phases of partially oxidized magnetite, calcium monosilicate and glass of variable composition. In 1.8 basicity sinter with iron content of 59.4% the structure consists of phases of magnetite, calcium ferrite and glass of variable composition. The large amount of glass and pores in the binder does not allow the sinter hardening to be fully realized. The increase in strength is achieved by increasing the basicity of the sinter up to 2.1 units. The crystal structure of ferritic binder is needleshaped, which provides high strength of sinter. The amount of glass is reduced and it fills the gaps between the crystals of ferrite isolated from ore grains.
ENERGY-SAVING TECHNOLOGY FOR PROCESSING HIGH-MOISTURE IRON-CONTAINING SLUDGE
Authors: BLUDOVA D. I. , IBRAEV I. K. , IBRAEVA O. T. , MAMYANCHIKOV S. V.
Published: November 2023

The existing methods of iron briquettes production from metallurgical sludge are based on their preliminary dewatering, multistage and energy-consuming technologies of pelletizing. The importance of solving the problem of dewatering of high-moisture fine iron sludge for creating resource-saving metallurgical processes is shown. The research results present the combined process of chemical dewatering of high-moisture iron-containing sludge with pulverized waste lime and dolomite and their hardening and pelletizing by pressing in a single technological cycle. In the process of laboratory study the following parameters were controlled: temperature, weight, rate of dewatering, chemical composition, moisture of the mixtures, appearance of produced briquettes and mechanical strength of the briquettes. A kiln-free method has been developed to produce iron-containing briquettes from sludge, which combines the processes of dewatering and self-hardening of the mixture and the process of pelletizing in a single technological cycle. The proposed technology does not require slime drying and briquette firing. The strength of briquettes increases as they cool in the air during 1 day. The proposed technology would allow organizing the production of iron-containing material for melting cast iron and steel from iron-containing slime and finely ground waste of limestone and dolomite firing.
CARBON FOOTPRINT OF SODA ASH PRODUCTION
Authors: LISIENKO V. G. , CHESNOKOV YU. N. , LAPTEVA A. V.
Published: November 2023

Greenhouse gases such as carbon dioxide, methane and others are believed to have a significant impact on global climate warming. Emissions of carbon-containing gases are commonly referred to as carbon footprint which reflects their formation and emission into the atmosphere in the full production cycle. The questions of definition of emission (carbon footprint) of carbon dioxide at soda ash production are considered. The differences of transit (indirect) and end-to-end emissions are shown. The calculations of through emission (carbon footprint) of soda ash and quicklime production are given. Based on chemical and thermochemical equations analysis and peculiarities of technological processes it was determined that the carbon dioxide net carbon footprint emission in soda ash production is 975 kg/t soda. The endto-end carbon dioxide emission in lime (calcium oxide) production is 1180 kg/t.
SIMULATION OF DUPLEX-PASS ROLLING OF RAILWAY RAILS
Authors: NOVOZHILOV I. S. , RUBTSOV V. YU. , POLUEKTOV D. A. , SHEVCHENKO O. I. , NEPRYAKHIN S. O.
Published: November 2023

As one of the options for increasing the production of rails and improving their quality, the method is proposed for simultaneous rolling of two rails on rail and beam mill with group of tandem universal stands. The two rolling schemes were considered. According to the first scheme, rolling is carried out in two parallel swaging stands, in which rails are rolled according to symmetrical arrangement of roll passes with their simultaneous feeding into the rolls of tandem mill groop. According to the second scheme, one crimping stand is used. After rolling, the rail workpiece is cut into two parts; one of them is turned over, and after that the both parts of the rail workpiece are set simultaneously in a tandem stands group. To test the operability of the second scheme, modeling was carried out using the Dedorm-3D software package. The process of strip capture in each stand of the tandem group with simultaneous symmetrical feeding into the rolls was considered in detail; the stresses created during rolling on horizontal and vertical rolls were analyzed. The problems that arise when using this rolling scheme were identified, which include the possible sagging of the strip between auxiliary and second universal stand, as well as appearance of dynamic shocks in vertical rolls. As solution to this problem, a rational high-speed mode was proposed, including the capture of the both workpieces in the first universal stand at a linear rolling speed of 1 m/s; after the capture, the acceleration of strip is up to 2 m/s, and only after the complete capture of the both workpieces by the second universal stand, the linear speed acelerates up to 5 m/sec.
DESIGN FEATURES OF THE HEATING CHAMBER OF THE MILL BALL TEMPERING FURNACE AND CALCULATED THERMAL MODES OF ITS OPERATION
Authors: KALGANOV M. V. , ZAINULLIN L. A. , KALGANOV D. V. , DZYUBAILO R. V.
Published: November 2023

The article considers the design of the heating chamber consisting of single sections equipped with the same type of block-type devices. Heating of the metal in the block is carried out by the jet blowing the surface of the balls with a heated gas flow circulating inside its body using a high-temperature fan. On the basis of the proposed method, a computational analysis of several thermal modes of operation of the heating chamber, consisting of five sequentially installed single sections, was carried out. The section consists of housing and a jet heating unit placed inside. The unit is a sheet steel structure, inside which, by means of a nozzle system and a high-temperature fan, a circulation circuit is organized, which is necessary for the movement of the heat carrier. The heat carrier is heated by a burner. The balls are stacked in one row and move inside the furnace body by means of a conveyor. The effect of changing the performance of the circulation fan on the parameters of the furnace has been studied. An analysis of the obtained calculated data showed that with a constant furnace performance, the heating mode of the balls is determined by the ratio of the coolant temperatures and the fan performance. Doubling the performance of a fan of a single section from 14,000 m3/h to 28,000 m3/h leads to a decrease in the required coolant temperature by 30% from 572 °C to 434 °C, while the efficiency of the heating chamber remains unchanged equal to 0.71. An increase in performance of a fan leads to a decrease in the temperature of the pumped gas, which contributes to an increase in the reliability of its operation by maintaining the normal thermal regime of the running gear. The materials presented in the article can be useful in the development and design of convective furnaces.
TRADITIONS AND INNOVATIONS IN THE TECHNOLOGICAL HISTORY OF DONETSK METALLURGICAL PLANT
Authors: KUKOVINETS G. V. , EGOROV A. N. , BIRYUKOV A. B. , SIDOROV V. A.
Published: November 2023

The paper considers the general historical outline of the Donetsk Metallurgical Plant (DMZ) development, which began 150 years ago with mass production of metal, as well as the process of introducing and mastering innovations, primarily within the framework of the blast furnace and steelmaking industries. The presented data considers implementations which at that time were of a pioneering nature within the framework of the Soviet, and in some cases the world metallurgy. The contribution to the development of DMZ by such metallurgists and scientists as M.K. Kurako, I.P. Bardin, A.N. Tsaritsyn, N.S. Shchirenko, V.F. Basantsov, I.M. Ektov, S.L. Yaroshevsky, V.I. Machikin, A.M. Zborshchik, E.N. Skladanovsky, D.A. Dyudkin, K.V. Baranov, P.G. Glazkov is mentioned. The particular attention is focused on the technologies of steel continuous casting and injection of pulverized coal into the hearth of a blast furnace, which were first introduced at industrial scale at the DMZ. At present, these technologies, the impetus for the development of which was given at the DMZ, are an integral part of the set of advanced modern technologies of ferrous metals production. The issues of introducing the new technologies and equipment in the post-Soviet period up to 2014 are also considered. Some examples are also provided, which illustratie the effective and practically trouble-free use of equipment created more than a hundred years ago. The role of the Donetsk National Technical University (DonNTU) in the history of the DMZ is considered. For more than a century it consists in preparing highly qualified engineering personnel and
scientific support of all innovations.
PROMISING DIRECTIONS FOR THE USE OF NATURAL THERMOANTHRACITE IN METALLURGICAL PROCESSES
Authors: STRAKHOV V. M. , KRYLOV S. A.
Published: November 2023

Natural thermoanthracite (NTA) from the Bulur deposit of the Omsukchan coal basin, in terms of its material and mineral composition, physicochemical and thermomechanical properties, is a unique carbonaceous raw material for technological use in many industries and, above all, in metallurgical industry. The quality of the NTA classes 75‒50, 50‒25, 25‒13, 13‒6 and 6‒0 mm was studied in a wide range of indicators. Based on experimental data on the quality of individual classes of NTA, on the degree of its compliance with the requirements of individual industries and using a system of industrial analogues, the promising areas for the use of NTA in metallurgy have been determined for:
‒ foundry production as a fuel for iron smelting in cupola furnaces;
‒ blast furnace production in lump form and as a mixture for a pulverized coal fuel;
‒ steelmaking as a carbonizing agent to improve the performance of converter smelting and to obtain special steels with a reduced nitrogen content;
‒ ferroalloy production as a carbonaceous reducing agent for smelting ferroalloys, especially in slag processes;
‒ production of thermoanthracite as a carbon raw material for the production of electrode mass and the production of electrodes for various purposes;
‒ to obtain briquettes (from small classes) with their subsequent use in a number of metallurgical industries;
‒ the agglomeration of iron and non-ferrous ores as a process fuel.
THE CHROMIUM AND COBALT DISTRIBUTION IN THE DIFFUSION LAYER OF STEEL X35CrNi2-3 DURING THERMОDIFFUSION SATURATION
Authors: SHABUROVA N. A. , PASHKEEV I. YU.
Published: November 2023

For parts of machines and equipment operating under the influence of aggressive media, abrasive, high temperatures, the creation of a hard, wear-resistant surface is an urgent task. Cobalt is used as a binder to create hard alloy materials that work under these conditions. It was of interest to evaluate the possibility of using cobalt as an additive in complex thermal diffusion chromium plating of structural steel. The article describes the features of thermal diffusion saturation of steel X35CrNi2-3 with chromium and cobalt at a temperature of 1000°C. A technique for analyzing the obtained coating is presented, based on the possibilities of X-ray spectral microanalysis of the diffusion layer on transverse microsections of the obtained samples. The elemental composition of the diffusion layer was monitored using the JEOL JSM-6460 LV universal scanning (scanning) electron microscope. The microstructure was studied using the optical metallographic microscope Axio Observer D1.m. The X-ray phase analysis was carried out with the Rigaku Ultima IV diffractometer. The hardness measurement was carried out with the FM-800 microhardness tester at a load of 50 g. Data were obtained on the distribution of chromium and cobalt in the surface layer of steel. It is shown that the resulting thermal diffusion coating consists mainly of a substitutional solid solution based on Cr‒Fe‒Co with bcc lattice and chromium carbides. The average diffusion coefficients of chromium in the α-phase of chromium were determined to be DCr = 3,22·10‒15 м2/с; in the γ-phase of iron DCr = 9,41·10‒15 м2/с. The diffusion coefficient of cobalt in the γ-phase of iron DCo = 7,89·10‒15 м2/с. The depth of the outer coating on the sample was about 15–20 µm, the depth of the diffusion layer of chromium in the base metal was about 70 µm, and that of cobalt was about 40 µm. The maximum hardness of the outer surface layer was 1740 HV, the diffusion layer in the base metal was 900–560 HV, and the base metal was about 510 HV.
COMPREHENSIVE WASTE-FREE PROCESSING TECHNOLOGY OF COPPER SMELTING SLAGS
Authors: ADILOV G. , POVOLOTSKII A. D. , ROSHCHIN V. E.
Published: November 2023

More than 140 million tons of slag have been accumulated in the dumps of copper smelting enterprises of the Russian Federation. Maintaining dumps require significant expenses, which makes it necessary to dispose these production wastes as completely as possible. At the same time, these slags contain valuable elements, in particular, iron, copper, zinc, selenium, arsenic and some others; their extraction can make disposal cost-effective. Among these elements iron has the highest cost, which content is at the level of more than 40%; it is almost at the level of some iron ores used in ferrous metallurgy. However, the use of this iron-containing material in conventional ferrous metallurgy processes is complicated by the high (up to 0.6%) copper content. In addition, the extraction of iron by conventional methods does not solve the problems of disposal of newly formed slag. In this work, the technological methods of processing copper-smelting slags by solid-phase reduction of iron in the Tamman reduction furnace, smelting of reduction products in induction furnaces with the production of metallic iron and propants from the slag residue are proposed and worked out in laboratory conditions. The slags and slurries of the Karabash Copper Smelting Plant, where the main component of is iron, were used as the research material. The properties of cast iron grinding media, as well as ceramic proppants for the use in the oil industry, were investigated. As a result, the influence of elements passing into metal (silicon, carbon, copper and sulfur) on the hardness of grinding balls and the influence of the chemical composition of the slag on the strength of the obtained propants was clarified. A technological scheme of complex slag processing has been developed and a set of serially manufactured equipment has been selected. The economic efficiency of the organization of production is estimated.