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煉鋼過程反應熱力學與動力學及其在數值模擬仿真的應用研究進展

Advances in the thermodynamics and kinetics of the steelmaking process and their application in numerical simulation

  • 摘要: 煉鋼過程需要完成鋼液的脫碳、脫硫、脫磷、脫氧等一系列操作,是一個復雜的多因素控制過程,反應器內溫度高且不均勻,多相化學反應同時發生,相際之間質量、動量和熱量傳輸相互耦合,準確預報和控制煉鋼過程一直是鋼鐵冶煉的難點和冶金工作者的研究熱點. 本論文總結了近年來煉鋼過程反應熱力學和動力學以及其在數值模擬仿真方面的研究進展. 在反應熱力學方面,鋼液活度計算模型主要有Wagner相互作用系數模型、統一相互作用系數模型和締合物模型,在現階段,Wagner相互作用系數模型仍是應用最為廣泛的鋼液活度計算模型,但隨著新鋼種的開發,這一模型的普適性遇到了挑戰,鋼液活度的計算亟需開發新模型、補充新數據;熔渣活度計算模型主要有分子理論模型、離子理論模型、正規離子溶液模型、修正的準化學模型和共存理論模型. 通過反應動力學模型,煉鋼過程鋼液、渣和非金屬夾雜物隨時間的變化能夠被較為準確的預報出來,如多組分耦合反應模型、有效平衡反應區模型和未反應核模型等,但反應動力學模型中的傳質系數多是通過經驗公式確定,無法準確表征不同反應器內的動力學. 通過將反應動力學與三維數值模擬仿真相耦合,揭示了Kambara reactor鐵水預處理脫硫過程和Ruhrstah-Hereaeus精煉鋼液脫碳過程反應器內鋼液成分的三維分布及其隨時間演變,但綜合考慮鋼、渣、夾雜物、耐火材料、合金等多相多元反應的三維數值模擬仿真尚沒有較為成熟的模型,仍需要進一步深入研究.

     

    Abstract: The steelmaking process involves a series of operations, including decarburization, desulfurization, dephosphorization, and deoxygenation. Therefore, this process is controlled by complex multifactors such as high and inhomogeneous reactor temperatures, simultaneous multiphase chemical reactions, and mutual coupling between phases in terms of mass, momentum, and heat transfer. Accurate prediction and control of the steelmaking process has always been a difficult problem in the ironmaking and steelmaking industries and a popular topic in metallurgy. The reaction thermodynamics and kinetics are theoretical bases for controlling the steelmaking process. Recent advances in reaction thermodynamics and kinetics and their application in numerical simulation are summarized in the present study. In terms of reaction thermodynamics, the main models for calculating the activity of liquid steel are the Wagner interaction parameter formalism (WIPF), the unified interaction parameter formalism, and the associate model. At present, the WIPF model is still the most widely used model for calculating liquid-steel activity, but with the development of new steel grades, the universality of the WIPF model has been challenged. An urgent need exists to develop a new model for liquid-steel activity calculations and to supplement it with new data. The main models for calculating slag activity are molecular theory, ionic theory, the regular ionic solution model, the modified quasi-chemical model (MQM), and ion and molecular coexistence theory (IMCT). The MQM and IMCT models are the most widely used for calculating slag activity. Reaction kinetic models such as the multicomponent coupled reaction model, the effective equilibrium reaction zone model, and the unreacted nucleus model can accurately predict changes in the molten steel, slag, and nonmetallic inclusions during the steelmaking process. However, the mass transfer coefficients in these kinetic models are mostly determined using empirical equations, which cannot accurately characterize the kinetics in different reactors. To address this problem, the three-dimensional distribution of the molten steel composition and its time evolution during the iron desulfurization process in Kambara reactor and the steel decarburization process in Ruhrstah-Hereaeus reactor were revealed by coupling the reaction kinetics with three-dimensional numerical simulations. However, no mature three-dimensional numerical simulations are available for multiphase and multidimensional reactions with the integrated consideration of molten steel, slag, inclusions, refractory materials, and alloys, which requires further in-depth study.

     

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