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Vol 24, No 1 (2020)
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POWER ENGINEERING

85-96 278
Abstract
The purpose of protecting the electric power system is one of the most complicated and urgent tasks since the stability of the whole electric power system largely depends on the correct operation of relay protection and automation. The main difficulty lies in determining the settings that ensure the correct operation of relay protection in power systems. The reason for this is the lack of methods and means providing the opportunity for adequate consideration of the variation dynamics of the electric power system mode during the accident. This is confirmed by the application of the most simplified models of electric power system equipment and corresponding mathematical methods for calculating short-circuit currents used in the formation of relay protection settings, which allow a very rough estimate of the effective value of short-circuit currents at the time period t = 0 s for only one phase. To calculate the currents of remaining phases, the method of symmetric components is used. In some cases, significant discrepancy of such settings to the actual conditions of protection operation is proved by the statistics of electric power system accidents, as well as by the statistical data of incorrect relay protection actions. The authors propose a new approach to relay protection setting. Its feature is the use of detailed mathematical models describing the processes simultaneously in the totality of all elements in the relay protection circuit (including primary converters) in combination with a hybrid simulator of power systems of an all-time simulation complex of electric power system electrical equipment real-time, which implements a methodically accurate analog-digital solution of mathematical models of electric power system equipment. Using this approach, the digital differential protection of a transformer is configured using a standard four-zone tripping characteristic. Also, the authors propose a new approach to the formation of a flexible multi-zone tripping characteristic that envelopes the emergency characteristics of IД = f(IТ) of those modes in which the digital differential protection of the transformer should not be triggered. The introduction of this procedure will allow to determine relay protection settings in specific conditions of its operation as well as to avoid excessive roughening of settings, which will ensure reliable all-time operation of protection.
97-111 268
Abstract
The purpose of the article is to study the influence of distributed generation installations based on renewable energy sources using inverters on the resonance at harmonic frequencies. The function of the inverter is to convert DC voltage into AC. The inverter uses pulse width modulation (PWM) to generate a sinusoidal output current. The analysis is performed for distributed generation installations with an inverter system connected to the IEEE 13 Node Test Feeder in the Simulink graphical simulation environment. To study the phenomenon of resonance, frequency is measured during the analysis of the Fourier series expansion in order to measure voltage and current distortions at the point of general connection of the network and distributed generation. The influence of harmonics on the interaction between the distribution system and the distributed generation unit with an inverter connected to a passive LCL filter is analyzed. In order to study the effect of distributed generation integration into the distribution network, it has been decided to consider two scenarios of generating plant connection. In the first scenario, the effect of several distributed generation installations connected to different buses of the distribution network is researched. In the second scenario, the effect of several installations of the given type connected to one bus of the design circuit distribution network is studied. In addition, each of the scenarios contains four measurements with a uniform increase in the number of generating units in each measurement. The maximum permissible integration level of distributed generation units connected to the grid is assumed to be equal to 40% of the total connected load. It is based on breaking the limits of standard harmonic voltage distortion. This study also analyzes the effect of multiple distributed generators under integration and resonance at harmonic frequencies. The analysis of the influence of distributed generation installations integrated into the distribution network has been carried out with the application of an analytical comparison of the obtained (calculated) parameters of voltage non-linear distortion coefficients when modeling distributed generator operation in the network with permissible limits for these coefficients of voltage non-linear distortions in accordance with low voltage network GOST. The results of numerical experiments are presented.
112-122 267
Abstract
The purpose of the paper is to develop a coordination methodology for the settings of automatic controllers of generator excitation and generator rotor speed of distributed generation steam turbine plants. The methods of digital signal processing under controller noise isolation and obtaining of spectral characteristics for complex transfer coefficient calculations are used to achieve the set purpose. A genetic algorithm is used as an optimization tool for the tuning coefficients of automatic excitation and speed controllers. The power supply system with a controlled distributed generation steam turbine has been simulated in the MATLAB software environment using Simulink, SimPowerSystems packages and a specialized software package for coordination of controller setting coefficients. The results of the study show that coordination of controller settings and application of predictive algorithms improve the damping properties of the system making frequency and voltage control faster and smoother. The conducted research and computer modeling allow to derive the following conclusions: a small constant inertia of the distributed generation plant generator rotors requires coordination of settings of automatic excitation and speed controllers; the use of an auto predictive automatic speed controller can significantly improve the damping properties of the regulator when controlling the turbogenerators of distributed generation plants connected to static and dynamic loads; the auto predictive automatic speed controller of the synchronous generator can be recommended to improve the efficiency of rotor speed regulation and controlling of steam turbine control valves. Practical use of the proposed algorithms for setting automatic excitation and speed controllers will improve the reliability of distributed generation plant operation and the quality of control processes.
123-134 222
Abstract
The purpose is to analyze the heat supply subsidizing dynamics in the Arctic zone of the Sakha Republic (Yakutia). To achieve the purpose, the methods of statistical, comparative and factor analysis of heat production cost based on statistical data and information from energy supply companies in Yakutia are used. The authors have collected and analyzed the information on heat generation, structure of the cost of fuel used for heat production including the cost of purchase from suppliers, delivery via mainline and intra-settlement transport as well as storage costs. The regions with the most complicated fuel delivery scheme are identified: they are Verkhoyansky, Ust-Yansky and Momsky uluses. The necessary average annual amounts of subsidies for all Arctic uluses are calculated considering the area and number of floors of the housing stock with central heating. The factor analysis of the structure of the produced heat energy cost is carried out. Having revealed the variation dynamics of heat tariff subsidized part, the forecast of changes of heat supply tariffs is made for the period up to 2023. The subsidizing amount is estimated. It is determined that the observed average annual increase in fuel supply transport costs by 13% leads to 6% growth in the cost of heat production in the Arctic zone of Yakutia. As a result, the expected annual growth rate of subsidies will be 4.4%, and by 2030, the amount of heat energy subsidies will increase by 1.5 times compared to 2018. If most of the factors affecting the growth of heat tariffs change the coverage of the subsidized part of population, as well as the amount itself, may increase. This is due to the low per capita income in the North and another indirect factor is the annual increase in the final cost of fuel.
135-144 265
Abstract
The purpose of the paper is to control and improve the efficiency and reliability of low-voltage distribution networks as these are the most important tasks of the modern energy sector, since such networks account for a significant share of losses and costs in electric energy transmission. Distribution networks should be modeled as three-phase networks, while information about power consumption, losses, and flow distribution should be determined independently for each phase. In this case, in addition to the information about the parameters of the feeder replacement scheme, the data on active and reactive loads represented as nodal capacities or currents, as well as knowledge of phase distribution of these loads are required. The necessary information on low-voltage feeder loads, which is proposed to be the basis for solving the problem of phase identification can be obtained from the smart meters installed in a low-voltage network. Measurement data of the smart meters are recorded in the reports of the automated information and measurement system for commercial electricity metering. Knowledge of the load connection phase is necessary for further analysis of network topology, branch parameters, calculation of flow distribution, power losses, and, if there are enough measurements and they are synchronized - for evaluating the state of distribution networks. This paper solves the problem of phase identification for one of the feeders of the Irkutsk region low-voltage distribution network using the measurements of instantaneous and average values of voltage modules, which are obtained from the smart meters and registered in the protocols of the automated information and measurement system of commercial electricity metering. The identification results of single- and three-phase meter connection phases are obtained based on the estimation of mutual correlation of voltages in the power supply node with the known phases, and in the network load nodes for a certain period of time. The load connection phase is determined by the maximum positive values of the cross-correlation coefficients for a number of measurement samples. Coincidence of the phase identification results for all measurement samples confirms the validity of the obtained solution and proves the effectiveness of the used correlation analysis.
145-163 260
Abstract
The purpose of this article is to present the analysis of modern methodology and software for assessing the wind energy potential and consider the features of the developed Wind-MCA program. The article provides a brief overview of the current state and development prospects of wind energy in the world and in Russia. Description is given to the methodical approaches and existing software for assessing the wind energy potential. Advantages and disadvantages of the sources of initial information (satellite observation data, meteorological station data, climate reference data) for assessing the wind energy potential are considered. Description is given to the Wind-MCA software features for assessing the wind energy potential. The program uses statistically unprocessed data from meteorological stations. This enables the solution of a number of problems requiring estimation of the wind energy potential with differentiation in wind directions, as well as the hourly wind energy potential in combination with other climatic data. The application of Wind-MCA is discussed for solving these types of problems. The methods of accounting a terrain relief effect on the wind speed depending on its direction is presented. Assessment results of the wind energy potential for the area of the Ayan settlement, Khabarovsk Territory are given. An approach to assessing the options for the distributed location of network wind farms to reduce the effect of short-term variability of wind speed on station power fluctuations is described. The simulation results of electric energy generation by wind power plants under their concentrated and distributed siting in the Kabansky district of the Republic of Buryatia are given. A new Wind-MCA-implemented approach to accounting the effect of blade icing on power generation by wind power plants is presented. The results of the wind energy potential calculation for various regions of eastern Russia are provided. The average annual electricity losses in the studied areas due to icing vary from 6.2 to 23.7%.
164-182 259
Abstract
The purpose is to develop a methodology for selecting the parameters of the main components of a stand-alone photovoltaic station: a step-down voltage inverter and a maximum power point search controller, which ensure the most efficient conversion and use of solar energy. The analysis of modes and energy characteristics of solar cells under different lighting conditions and temperature is carried out using equations describing physical processes in the equivalent electrical circuit of a photoelectric converter. The dynamic modes of a stand-alone photovoltaic station are simulated in the MatLab/Simulink software package. The main energy characteristics are analyzed and mathematical models of the components of a stand-alone photovoltaic station are developed in order to study the tracking modes of the maximum power point. The necessary conditions for matching solar battery and voltage inverter parameters to track the maximum power point are determined. An original methodology and an algorithm for calculating and selecting parameters of the main elements of a photovoltaic station are developed. Consideration is given to the practical example of calculating and selecting parameters of a voltage inverter and maximum power digital controller of a stand-alone photovoltaic station. The simulation results of dynamic modes of the photovoltaic station show that the voltage inverter and the maximum power controller with the parameter values selected according to the proposed methodology provide reliable and effective tracking of the maximum power point in all five considered test cases of sudden changes in solar cell illumination. The tracking accuracy is at least 98.2%, and the inverter efficiency in all the modes considered is at least 93.2%. The operating ranges of energy characteristic variation of the main elements of a photovoltaic station correspond to the calculated values obtained under their design.
183-194 236
Abstract
The purpose of the paper is a hybrid simulation of 4 type wind power plants, which allows to obtain a fairly complete and reliable information about the processes taking part in the wind power plants of the specified type, as well as to evaluate the effect from their implementation in power systems as a whole. Today renewable energy is developing rapidly in the world mainly due to the use of wind power plants. To solve most of the problems of study, design and operation of wind power plants as the components of the electric power system we need complete and reliable information about the single continuous spectrum of normal and abnormal quasi-established and transient processes in the equipment under investigation and in the electric power system as a whole. Mathematical modeling becomes the only way of obtaining such information since full-scale experiments are inadmissible in real electric power systems (especially emergency ones) and physical modeling of such systems has significant limitations. At the same time, there is a certain problem of obtaining reliable information via mathematical modeling due to the need to solve rigid systems of large order differential equations describing the processes in the elements of wind power plants and electric power systems as a whole. This problem is characteristic of all software, computing and hardware-software systems designed for calculating modes and processes in electric power systems. They inevitably use numerical integration methods as a result the reliability of such calculations is low or unsatisfactory. The article describes an alternative integrated approach to 4 type wind turbine modeling. This approach is implemented by means of the developed specialized hybrid processor of type 4 wind power plants, which is designed to operate as a part of the All-mode real-time modeling complex of electric power systems. The article provides the fragments of test studies of the produced specialized hybrid processor that confirm its correct operation. The solution of the problem of adequate modeling of 4 type wind turbines proposed in the article is new and relevant (as applied to the certain electric power system, its composition and topology) and allows to obtain sufficiently reliable, all-mode information on the processes occurring in it for further planning of modes, setting of automatic control systems, relay protection, automation, etc.

MACHINE BUILDING AND MACHINE SCIENCE

8-24 205
Abstract
The purpose of the work is to increase the machining efficiency of parts made of hard-to-process materials such as titanium-based alloys and high-strength stainless steels of the Cr-Ni-Si type by using special designs of end mills equipped with disposable carbide or high speed steel inserts. The work applies a theoretically justified and experimentally proved method of improving performance of special end mill designs by controlling the shape of the cut cross-section, which reduces the loads on the technological system and thereby intensifies processing modes. The simplest way to control the shape of cut cross-section is to use alternating cutting patterns. The proposed arrangement pattern of disposable carbide or high speed steel inserts located on one auxiliary technological helix allows to formalize the designing of special end mills and intensify milling modes at the stage of their design. This makes it possible to develop a designing methodology for special designs of end mills with disposable carbide inserts for milling hard-to-process materials. The use of calculation methods eliminates the influence of subjective factors of engineering stuff on the quality of tool design and reduces the complexity of design works. Creation of special end mills with disposable carbide or high speed steel inserts for rough milling of parts made of hard-to-process materials has intensified metal removal from 2 to 5 times, ensured a significant reduction in the consumption of tool materials in comparison with monolithic tool structures, and provided a multi-fold use of tool bodies as well.
25-35 202
Abstract
The purpose of the paper is to identify the limitations when selecting materials for the production of coaxial radio component parts for ultra-high-frequency microelectronics, to reveal the features and problems in their manufacturing, to study the methods used to solve the problem of burr formation and removal, to choose promising deburring methods for experiment setting and evaluation of their effectiveness. The article describes the features of the manufacturing technology of radio component parts for ultra-high-frequency electronics, gives part assortment classification by geometry and used materials for the selection of a deburring method. It also describes and compares the application results of proven deburring methods on parts made from 29NK (29НК) and beryllium bronze on longitudinal turning machines. Promising deburring methods are selected for further research. High-quality deburring of parts made of 29NK and beryllium bronze materials and having no hard-to-reach surfaces on longitudinal turning machines is achieved by using "tumbling with the selected abrasive medium". High-quality deburring of parts made of 29NK and beryllium bronze materials and having hard-to-reach surfaces (slots, pockets, side holes, grooves, threads, etc.) on longitudinal turning machines can be performed through the use of a cleaning robot installed on each machine-tool, tumbling with abrasive medium selection followed by manual benchworking, thermal removal of burrs, and for 29NK material - by orderly changing of the selected cutting tool for finishing treatment. The following promising methods including benchwork automation with the use of a robot, thermal deburring, selection of tools and processing modes for each type of material taking into account the design of parts have not been sufficiently studied.
36-51 269
Abstract
The purpose of the article is to analyze contact interactions under abrasive flow machining by a high viscosity medium, to reveal a number of common phenomena characteristic of other processing methods of molybdenum powder alloy workpieces, to describe some features of the process. One of the problems of modern production is mechanical processing of parts made of hard-to-work materials, e.g. molybdenum alloys. The abrasive flow machining by a high viscosity medium is proposed for finish processing of workpieces made of molybdenum powder alloys. For this purpose the model of material removal by a single abrasive grain is refined. This model presents an abrasive grain as a multi-blade tool that impacts the treated surface both on the actual contact area and contour. It is proved that the origination of the components of the cutting force that impacts a single abrasive grain is due to tangential and normal stresses of the working medium flow. Analysis is given to the features of contact interactions taking place under abrasive flow processing of molybdenum powder alloy workpieces. To assess the initial state of the surface before finishing the surface layer of molybdenum powder workpieces is described after turning and EDM wire cutting in terms of the initial state. Justification is given to abrasive flow treatment in two stages with varying the type of abrasive and its grain size. Experiments proved the possibility of using an abrasive flow of high viscosity medium for finishing treatment of molybdenum powder workpieces. The features of the abrasive flow processing using a high viscosity working medium are revealed. The recommendations are given on the use of abrasive flow treatment modes for specific sizes of holes in molybdenum powder workpieces.
52-63 223
Abstract
The purpose of the paper is to conduct research to assess the possibility of increasing the St 3 steel surface layer hardness under plasma heating of surface coating containing PR-N80H13S2R powder alloy. Research methods involve measuring macrohardness using a stationary device HBRV-187,5. Microhardness is measured using the DuraScan G5 device with an automatic fingerprint reading system. The theoretical methods include the analysis of chemical composition of coatings. As a result coatings are divided into 2 groups: for furnace chemical-heat treatment and plasma surface reflow. Calculation methods include statistical processing of experiment results and building dependencies. The depth of the modifying layer (depending on the processing method) is 1 mm under chemical and thermal treatment, and 2 mm under plasma reflow. Measurement results of surface macrohardness have shown that the resulting coating from PR-N80H13S2R+Cr2O3+NH4Cl mixture features a more uniform distribution of high surface hardness (31-64 HRC according to the Rockwell method of non-destructive testing of material hardness), if the coating consists from PR-N80H13S2R alloy only the surface hardness varies in a larger range (15-60 HRC). The studies of the surface layer cross-section microhardness have shown that the diffusion region made of PR-N80H13S2R+Cr2O3+NH4Cl powder mixture features a uniform hardness (450-490 HV). Coating of the PR-N80H13S2R alloy increases hardness in the depth of the melted area (from 300 to 600 HV) and decreases it sharply in the zone of thermal influence (210-170 HV). The use of the powder alloy PR-N80H13S2R as the main component of coating applied to the steel 3 surface under plasma treatment results in the formation of a modified surface layer of high hardness.
64-76 283
Abstract
The purpose of the paper is to develop a thermal model of the brake disc of the disc-pad brake friction assembly and present it as a multi-layer object. While developing the brake disc, it is necessary to predict the performance parameters of its design in various operating modes. Various tests are carried out periodically, in which the maximum operating temperature reached on the surface of the metal friction element is a determining parameter of the brake disc. However, the thermal state of the model of the designed disc does not take into account the changes that occur in the operation process, namely, the origination of near-surface layers on the working surface of the brake disc and on the matte surface of the ventilation device. The processes that occur as a result of operation on working surfaces cause changes in the structure of the material of the brake disc working surface. Cyclic heating results in the appearance of oxidation and rust on the matte surfaces of the ventilation apparatus of the brake disc, which is a factor for revising the existing thermal model for brake disc calculation. These two indicators serve the basis for considering the thermal model of the brake disc as a multi-layer element. Having conducted all necessary theoretical studies, the computer simulation method (using the finite element method) based on the ANSYS software product is used. The result of the research is the dependence of the temperature in different points of the brake disc (the working surface of the metal friction element on the matte surface of the ventilation device) and the evaluation of the brake disc ventilation device efficiency. Performed studies enable to derive a conclusion on the efficiency of heat removal from the brake disc working surfaces by means of a ventilation device.
77-84 206
Abstract
The purpose of the paper is to study the parameters of surface micro- and macro-geometry of high-speed R9M4K8 plates when grinding by high-porosity wheels made of cubic boron nitride. The quality of the ground surface is estimated using the following selected parameters: Ra (arithmetic mean of profile deviation) , Sm (average pitch of profile irregularities - micro-deviations) and EFEmax(flatness deviation - macro-deviations). Quality is assessed using the expected medians along with the categorical values for the roughness parameters and the accuracy degree for macro-deviations. The formation stability of these parameters is analyzed. Stability is assessed using the quartile latitudes of the non-parametric statistical method. The application of high-porosity wheels made of cubic boron nitride for grinding complex alloyed high-speed steels is justified. These wheels allow to reduce the temperature in the cutting zone and improve grinding efficiency. The expediency of using the probability-theoretic methods for evaluating the high-speed plate grinding is shown. A nonparametric statistical method, for which observations turned out to be "their own field" is chosen in the accepted technological conditions. The quality of the ground plates is evaluated by means of the nonparametric statistical method. The influence of high-porosity CBN wheel permeability on process stability is confirmed. Technological recommendations for selecting the pore sizes of high-porosity CBN wheels are given. The pore former KF40 surpasses the pore former KF25 in process reproducibility. Grinding by the wheel CBN30 B126 100 L V K27 KF40 ensures the best quality of R9M4K8 high-speed inserts and demonstrates its high formation stability. When grinding with this tool, the following surface quality parameters are achieved: Ra 0.29 (0.32), Sm 79.00 (80), EFEmax 11.50 (7).

METALLURGY AND MATERIALS SCIENCE

195-207 195
Abstract
The purpose of the paper is to study the chemical and physical properties of a hard alloy obtained from tungsten-containing multicomponent mineral raw materials of the far East region by the method of local high-energy impact of the flow of ionized plasma, the specific power of which is > 104-105 W/cm2. The methods of X-ray phase and spectral microanalysis, as well as scanning electron microscopy are used to study the chemical composition of W-C system alloy samples. The PMT-3M microhardometer is used to determine the microhardness. The Ntegra Prima modular atomic force microscope is used to determine the nanohardness of the alloy phases. The chemical elemental and phase compositions of samples of the W-C alloy obtained by the method of local high-energy impact on the charge consisting of scheelite concentrate and graphite are studied. Consideration is given to the experimental dependences of the amount of obtained tungsten carbides on the temperature of the plasma flow Tp and its action time τ in the synthesis chamber, as well as on the amount of graphite introduced. The results of spectral and scanning electron microscopy of alloy samples are examined. The values of microhardness and nanohardness of the resulting alloy of the system W-C are determined. Laboratory tests of experimental alloy samples have revealed that the alloy is a solid solution mainly composed of two phases: WC and W2C. The obtained solid solution of W-C system features a high hardness (Vickers hardness number is from 13 to 20 GPA) and wear resistance. The study results of the phase composition of the W-C system solid solution and its structure suggest that the solid ‘skeleton’ of the WC carbide phase is intertwined with the ‘skeleton’ of the W2C phase. The prospects of the method of plasma-chemical synthesis of tungsten carbides from scheelite concentrate for obtaining a solid solution of the W-C system are estimated.
208-219 229
Abstract
The research and development of ferrosilicoaluminium smelting technology using carbonaceous raw materials from the Kuu-Chekinsky coal field (the Karaganda region, Kazakhstan) is aimed at the expansion of the raw material base for smelting a new type of a complex alloy with the comprehensive study of experimental raw materials and their behavior in high-temperature conditions. Increased demand in the market of high-quality metal products makes us look for the new types of ferroalloys and deoxidizers, which are complex alloys. Ferrosilicoaluminium is one of the most effective complex alloys, the use of which in the processing of steel improves its quality characteristics and reduces its cost. The article presents the study results on determining the effect of the treatment mode of steel with ferrosilicoaluminium of FS55A20 and FS55A15 grades on the metallurgical properties of steel samples. The latter have been smelted in an induction laboratory furnace UIP-25 with an upgraded cooling system in a weakly oxidizing medium by remelting. The study is given to the influence of deoxidizer nature on the indicators of metallurgical quality of steel including the index of non-metallic inclusion contaminations, the nature of non-metallic inclusions, the degree of chemical liquation, and the grain score. The methods of chemical, electron microprobe, and microstructure analyses are used. Comparison of experimental samples suggests that, all other conditions being equal, the FS55A20 alloy used for deoxidation has a more favorable effect on the metallurgical quality of steel than the FS55A15 alloy according to the estimated parameters including the average grain score, the liquation degree, and the contamination index. In case of deoxidation with the FS55A15 alloy the contamination index increases by 17%. Using the method of electron microprobe analysis the nature of non-metallic inclusions represented by 4 groups including oxides, sulfides, silicates and an unidentified phase, the proportion of which varies within 10-15% has been identified.
220-230 545
Abstract
The purpose of the reserch is to develop and justify the principles of the energy model of an industrial reverberatory furnace taking into account chemical composition and properties of natural gas, which is widely used as a fuel in metallurgical processes to ensure the efficient operation of open gas furnaces in the production of crude Nickel. Сombustion of natural gas in the burners of the gas brands GGSB-1.4 and GGSB-2,2 (of medium pressure with the heat capacity of 1.4 MW, gas flow rate of 140 m3/h and connecting gas pressure before the burner of not more than 40 kPa, nominal gas pressure before the burner of not more than 20 kPa) always results in the production of carbon dioxide and soot, which have an adverse effect on the process flow. High content of hydrogen and carbon in the gas changes the thermal balance of the process of crude Nickel smelting. To study the combustion process of natural gas of different composition taking place in the burners of medium pressure the computer program STANJAN is used with the application of the wet gas-based flowmeter OPTISONIC 7300 for pressure measurement. The flowmeter confirmed the stable operation of the device when the liquid content in the gas is up to 1% of the gas volume. The amount of waste flue gases is measured using MRU Delta 65-3 gas analyzers, which identify the total amount of gases (O2, CO, NO), temperature, pressure (vacuum), as well as calculate the content of CO2 and plant efficiency. The value of the maximum temperature of combustion products and their ratio to the excess values in the balance during the entire heating of the air is obtained. The dependencies for industrial burner automation process optimization while minimizing energy losses and emission of harmful substances are determined. Conducted research allows to reveal the negative effect of excess air on the maximum temperature of melting products and the positive effect of air preheating at this temperature. When the air with the temperature of 50°C (instead of 25°C) arrives to the burner the temperature of flame rises, which increases the heat added to the load and reduces the energy consumption of the process. Excess air and product temperature in a thermal process based on natural gas combustion are the primary factors in the determination of environmental and energy aspects of the process.
231-240 319
Abstract
The purpose of the paper is to provide a quantitative estimate of the red mud effect on bicalcium silicate β-phase stability based on the previously identified ability of the red mud to increase sinter strength. The work is aimed at solving the problem of reduction of the amount of stored red mud waste resulting from the production of alumina from bauxites. Red mud accumulators occupy large areas, damage the environment and cause periodical emergencies. A promising field of red mud utilization is associated with its use in ferrous metallurgy as a protector of spontaneous destruction of blast furnace sinter. In this case, the productivity of blast furnaces grows and coke consumption drops in equivalent to the reduction of the amount of fines in the charge (particles of 0-5 mm fraction). Spontaneous destruction of the flux iron ore sinter is explained by the occurrence of internal stresses, which are caused by the 10% increase in the volume of the crystal lattice of bicalcium silicate 2CaO.SiO2 (Ca2SiO4) and chemical instability of free lime as a sinter component. When cooled up to 675°C, bicalcium silicate undergoes a polymorphic transformation associated with the change in the crystal structure during the transition from β - to γ-modification and its volume increase. CaO grains interact with the moisture contained in the air and transform into Ca(OH)2. The agglomeration process has been reproduced on example of the charge of given composition and its sintering at the temperature of 1200-1250°C. Self-destruction resistance of the briquetted charge after its heat treatment is determined by the content of the resulting fines (particles of 0-5 mm) after sinter cooling. Red muds as technogenic raw materials for alumina production at one of the domestic plants serve as a material for investigation. Research results have shown that the content of red mud of at least 3-5% wt in the charge with the ratio of CaO/SiO2 = 2 provides the resistance of the resulting sintering products to self-destruction. All cake samples obtained with the addition of red mud in the amount of 3-5% wt. have the ability to prevent bicalcium silicate polymorphism and, therefore, prevent self-destruction of the agglomerated material. It is found that this effect is enhanced if the content of Al2O3 and Na2O(K2O) in red mud increases.


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ISSN 2782-4004 (Print)
ISSN 2782-6341 (Online)