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Theoretical Principles of High Metallurgy Technologies Author: Prof. V.P.Bystrov, Prof. A.F.Vishkarev, Prof. V.A.Grigoryan, Prof. V.A.Romenets Publications Conferences Patents Grants and Projects Research and Development Contracts Technical-Scientific Developments Offered for Realization 1. The institute carried out investigations of properties and structure of heterophase slags, taken from different horizons of slag bath. Having studied the morphology and the structure of slag samples taken from bubbling zone of Romelt furnace, the scientists of the institute determined that the reduction of ferrous oxide dissolved in slag melt can also take place in gas bubbles, containing particles of coal coke remainders. 2. It was shown, that the nucleus and drops of cast iron generated as the result of iron reduction localize on the coal particles surface and on the interphase surface slag-gas. It was established that cast iron drops are stable on the interphase surface slag-gas and do not transfer into the volume of slag melt, at least with the dimension of the drops up to 1mm. 3. Understanding of the process of liquid-phase reduction of iron oxides in the Romelt process will improve the technology of aggregates control and will decrease the specific consumption of coal and oxygen per ton of finished cast iron. The elaborated approach to understanding of the liquid-phase reduction process of iron oxides helps to assess the sequence of coal transformation in the Romelt process. Coal particles, existing in powerful gas-slag flows, mixed in slag, create active (according to their ability to renew FeO) bubbles. Reduction of ferrous oxide dissolved in slag melt takes place on the surface gas-slag in active gas bubbles, containing coal remainders particles. Coal particles provide support to reduction of the gas phase potential as the result of carbon dioxide regeneration, discharged during FeO reduction, and carburization of the creating metal phase. 4. The institute elaborated an original investigation method of diffusion transfer of sulfur in slag melts. The scientists received experimental data on sulfur diffusion in iron-silicate industrial slags. 5. Investigation of reasons and conditions of refractory coatings destruction on the surface of cooled elements of bubbling equipment for heavy metals and alloys direct production let the scientists elaborate methods of highly effective protective coatings on the fire surface of cooled elements of the equipment. The institute elaborated also a method of assessment of layer dimensions on metal elements of bubbling equipment. 6. The scientists elaborated theoretical principles and technology of a new
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resource-saving mode of cast iron and ferrous alloys producing in oxygen reactor. These principles and technologies are based on full application of carbon heating and renewing ability inside the equipment. 7. On the basis of thermodynamic calculations it was determined that converter slags might be used to process liquid cast iron aimed at its desulfuration and its dephosphorization. The results of laboratory tests prove this possibility. Usage of converter slags to refine cast iron will give the possibility to decrease consumption of fluxing and refining materials, will decrease the amount of slag wastes, will help to save energy resources and to increase the environment ecological purity. The scientists also determined the theoretical consumption of refining materials necessary for manufacturing of steel with the content of carbon not exceeding 0,001%, the content of sulfur - no more than 0,001%, phosphorus - no more than 0,001%, nitrogen - no more than 0,001%. A special method of investigation of small (micron and submicronic) NV creation and development is elaborated in the institute as well the mode of their identification.
Publications:
Author: Vildanov S.K., Valavin V.S., Romenets V.A. Perspectives of the Romelt Technology Application in Reprocessing of Red Oxide of Iron Steel (1998), N7, p.73-77 Author: Sakir N.F. Economical Effectiveness of Iron-Containing Wastes Utilization In Metallurgical Enterprises applying the Method of Liquid-Phase Reduction Author's Abstract Of Thesis to obtain the scientific degree of Economical Science Candidate, Moscow, MISA, 1998. Author: Rostovsky A.V. Modernization of the Aggregates Blow In Technology for Cast Iron Smelting Author's Abstract of Thesis to obtain the scientific degree of Technical Science Candidate, Moscow, MISA, 1998. Author: Doskikh D.K., Zaitstev V.Ya., Kirillin I.I. and others Antimony Production Set-Up and Assimilation at Sakha-Uralsk Antimony Plant Non-ferrous Metals (1998), to be published Author: Novozhilov A. A., Fedorov A.N., Pavlov R.A. Interaction between Copper Sulfate with High Copper Ferruginous Slags Non-ferrous Metals (1998), to be published Author: Svyazhin A.G., Shakhpasov E.Kh., Romanovich D.A. Assessment of Effectiveness of Liquid Cast Iron Processing with Converter Slags Metallurgist (1998), N11, p.27-28 Author: Svyazhin A.G., Shakhpasov E.Kh., Romanovich D.A. Ferrous Metallurgy Slags Recycling Metallurgist (1998), 4, p.25-27
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Author: Karpov Yu.A., Filimonov L.N. Metrological Aspects of Silver-containing Ash Tests Selection and Batches Preparation Plant Laboratory (1998), N4 Author: Karpov Yu. A., Andreev A.V., Makarov S.A. NG-Activation Determination of Noble Metals in Secondary Raw Materials Plant Laboratory (1998), N4 Author: Polkhovskaya T.M. The Quality of Metal Products is the Decisive Factor in Providing Competitiveness of Our Enterprises Metallurgist (1998), N6
Conferences:
The Twelfth Intern. Conf. of the Israel Society for Quality Jerusalem, Israel, December 1-3, 1998 Author: Adler Yu.P., Karabasov Yu.S., Karpov Yu.A and others Quality of Education and Education in Area of Quality Author: Karpov Yu.A. Chemical Analysis as a Specific Measurement Method Author: Adler Yu.P. A Glance into the Future: Management of the 21 Century International Conf. Autumn School Berlin-1998. Metal Clusters Berlin, Germany, November 1-6, 1998 Author: Krivolapov N.V., Pokhvisnev Yu.V., Valavin V.S. and others The SEM Method Applied to the Researching of the Liquid-Phase Reduction Processes 8th Inter. Ferroalloys Congress INFACON 8 Beijing, China, June 7-10, 1998 Author: Kossyrev K.I., Pavlov A.V., Olsen S.E. Phase Equilibria and Activities of Chromium Oxides in SiO2-CrO2-MgO-Al2O3 Slags X Intern. Scientific Conference Modern Problems of Steel Electrical Metallurgy Chelyabinsk, YuurGY, October 1998 Author: Grigoryan V.A., Pavlov A.V., Semin A.E and others New Method of Production of Original Charge for Steel Energy Smelting Manufacturing
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5th Congress Steel Smelting Enterprises Association Rybnitsa, Moldavia, November 1998 Author: Grigoryan V.A., Pavlov A.V., Semin A.E and others New Energy-saving Method of Cast Iron and Ferrous Alloys Smelting Author: Svyazhin A.G., Kindop V.E., Romanovich D.A. Mathematical Model of Nitrogen Behavior in the Oxygen-Converter Smelting Process Author: Kazakov S.V. and others Application of Monolithic Calcium during Steel Processing Outside Furnace
Patents:
Patent Application N98111524/25 (012746) dates 15.06.98 and N98108839/02 (009889) dated 06.05.98 Vildanov S.K., Romenets V.A., Balavin V.S. Patent of the Russian Federation N2109817 dated 16.10.98 Methods of Cast Iron and Ferrous Alloys Production Grigoryan V.A., Pavlov A.V., Vegman E.F. and others
Grants and projects:
Elaboration of Theoretical Principles and Practical Proposals in Modernization of the Technology and Equipment for the Liquid-Phase Reduction Process (Romelt) (1996-2000) Coordinator: Romenets V.A. Funded by: the Russian Federation Ministry of Education., EZN Elaboration of Elements Distribution Control Methods in the Liquid-phase Reduction Process (Romelt) (1996-1998) Coordinator: Valavin V.S. Funded by: the Russian Federation Ministry of Education., EZN Elaboration of Physical and Chemical Principles of Heavy Metals and Alloys Direct Production in Intensively Mixing Gas-liquid Systems (1996-1999) Coordinator: Bystrov V.P. Funded by: the Russian Federation Ministry of Education., EZN Investigation of Sulfur Diffusion Transfer in Melts (1998) Coordinator: Komkov A.A. Funded by: the Russian Federation Ministry of Education., EZN, Grant in the trend Fundamental Problems in Metallurgy Experimental Investigation and Theoretical Summary of Thermodynamic Characteristics of Metal and Slag Melts Containing Polyvalent Elements, aimed at Elaboration of a Mutually Agreed Data Base and at Solution of Specific
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Applied Problems (1996-1998) Coordinator: Stomakhin A, Ya,., Pavlov A.V. Funded by: the Russian Federation Ministry of Education., EZN Elaboration of the Theory and Methodology of Non-Standard Reprocessing of Chromium and Manganese Ores in a Furnace of a New Type (Oxygen Reactor) Aimed at Ferrous Alloys Production (1998-2000) Coordinator: Pavlov A.V. Funded by: the Russian Federation Ministry of Education., MSTE Energy and Recourse Saving Technologies in Metallurgy Elaboration of New Economically Doped Alloys of Nickel, Chromium and Vanadium, and Technology of their Melting with NEWRUMELT Aimed at Increase of Physical and Mechanical Properties of Finished Products (1998-2000) Coordinator: Pavlov A.V. Funded by: the Russian Federation Ministry of Education, MSTE Perspective Materials Elaboration of Theoretical Principles and Technology of a New Method of Cast Iron and Ferrous Alloys Production in Low-Shaft Furnaces (Trade Mark New Russian Smelting; Newrumelt) (1998-2000) Coordinator: Pavlov A.V. Funded by: the Russian Federation Ministry of Education, MSTE Energy Saving Systems and Technology of Assimilation of Non-Standard Reductive Sources of Energy Reprocessing of Iron Ore and Technogenic Raw Materials in a Furnace of a New Type - Oxygen Reactor (1998-2000) Coordinator: Pavlov A.V. Funded by: the Russian Federation Ministry of Science, SSTE Investigations and Elaboration in the Prior Trends of Civil Science and Equipment Development Investigations and Elaboration in the Prior Trends of Civil Science and Equipment Development (1998) Coordinator: Grigoryan V.A. Funded by: the Russian Federation Ministry of Science Thermodynamic and Kinetic Features of Joint Manganese and Phosphor Oxidation, and Creation of Database of Outside Blast Furnace Refining of Highly Manganese Phosphor Cast Iron (1996-1998) Coordinator: Vishkarev A.F. Funded by: the Russian Federation Ministry of Education, MSTE Export Technologies and International Cooperation Creation of Steels New Generation without the Introduction Phase (1998-2000) Coordinator: Vishkarev A.F. Funded by: the Russian Federation Ministry of Science, MSTE Perspective Materials Textbook Preparation (1998-2000) Coordinator: Adler Yu.P. Funded by: the Russian Federation Ministry of Education Institute Quality Systems Elaboration (1998-2000)
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Coordinator: Soloviev V.P. Funded by: the Russian Federation Ministry of Education Certification Center Preparation as a Body of GOST R System Certification (1998-2000) Coordinator: Polkhovskaya T.M. Funded by: the Russian Federation Ministry of Education Certification Center Preparation to its Accreditation as a Test Laboratories Accreditation Body Coordinator: Polkhovskaya T.M. Funded by: the Russian Federation Ministry of Education Formation of Information Bases and Databases of Certification of Products, Quality Systems and Personnel in Metallurgy (1998-2000) Coordinator: Grigoriev B.M. Funded by: the Russian Federation Ministry of Education
Research and Development contracts:
Customer: SIE Metekotekh Coordinator: Yatsenko-Zhuk A.D. Scientific and Technical Assistance in Implementation of Trial Smeltings at OY PZhV NLMK and its Technical Reconstruction (1998) Customer: Norilsk Mining and Metallurgy Group of Enterprise Named after R.P. Zavenyagin Coordinator: Bystrov V.P. Scientific and Technical Assistance in Implementation of Trial Smeltings at OY PZhV NLMK and its Technical Reconstruction (1998) Customer: Norilsk Mining and Metallurgy Group of Enterprise Named after R.P. Zavenyagin Coordinator: Bystrov V.P. Creation of the Collective Copper-Nickel Concentrate Smelting Technology at Rich Matte (1998) Customer: AOOT Head Scientific-Research and Project Institute of Nickel-Cobalt Industry RAO Norilsk Nickel Coordinator: Bystrov V.P. Elaboration of Technological Regulations for Industrial Aggregate PB Type Designing according to the Technology of Non-stop Converting of Copper Nickel-Containing Ore Concentrates to Produce "Raw" Rough Copper Using Recycling of Sulfur Dioxide in Furnace Blow (1997-1998) Customer: OAO Kolchugino Non-Ferrous Metals Processing Plant Coordinator: Polkhovskaya T.M. Certification Elaboration and Preparation of AO Kolchugzcvetmet Quality Systems applying to Production of Casting, Flat and Round Rolled Stock, Pressed and Stretched Products (1998-1999) Customer: OAO Avtonormal
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Coordinator: Polkhovskaya T.M. Certification Elaboration and Preparation of AO Avtonormal Quality Systems applying to Production of General Machine-building Industry Timbering Products (1998-1999) Customer: Oskolsk Electrical and Metallurgical Plant Coordinator: Zvonkova A.M. Information and Inquiry Service (1998-1999) Customer: Oskolsk Electrical and Metallurgical Plant Coordinator: Polkhovskaya T.M. Quality Management and Certification Training (1998-1999) Customer: Cherepovetsk Steel Rolling Plant Coordinator: Polkhovskaya T.M. Quality System Elaboration and its Preparation to Certification (1998) Customer: SSC RF VNIINM named after Academician A.A. Bochvar Coordinator: Grigoriev V.M. Set-up and Implementation of Step-by-step Quality Training of the Enterprise Personnel (1998-1999) Customer: SC Airtransport Flight Safety Coordinator: Grigoriev V.M. Information and Inquiry Service (1998-1999) Customer: OOO Globus-Stal Coordinator: Grigoriev V.M. Stainless Steel Samples Certification of their Chemical Composition Accordance to the RF Standards. Receipt of Official Certificates (1998-1999) The Institute together with Gipromez and JSV Romelt Sail elaborated design proposals for construction of Romelt equipment for National mining company NMDC (India); a plant in Raigar town, firm Gindal. The work is performed together with Gipromez and the firm AMET at a plant in Vietnam. A trial sample of oxygen reactor is tested at Serovsl metallurgical plant. Due to the results of the test a trial-industrial reactor with productivity of 5 ton/hour of cast iron was designed and constructed at the end of 1998.
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