Fire Science
How Thermophysics Cools the Planet and Heats Metallurgists' Budgets
Introduction: The Invisible Revolution in Fiery Workshops
Imagine a world where steel plants reduce energy consumption by 15% and COâ‚‚ emissions by half, without compromising metal quality. This is not a futuristic utopia but a reality being created by thermophysics - the science of heat, its transfer and transformation. In an era of climate challenges and expensive resources, it has become a key tool for metallurgy, one of the most energy-intensive industries.
The work of the Ural scientific school (Y.G. Yaroshenko et al.) demonstrates how the symbiosis of physics, computer modeling and engineering solutions is changing the perception of "dirty" production 1 .
Modern metallurgical plants are implementing thermophysics to reduce energy consumption and emissions.
Key Concepts: The Science of Savings Behind Every Smelt
Thermodynamics in Action
Fundamental laws of heat transfer, gas dynamics and phase transitions form the basis of all energy-saving technologies in metallurgy.
Digitalization of Fiery Workshops
Mathematical modeling combined with physical experiment has revolutionized metallurgical processes through virtual testing and optimization.
Breakthrough Focus Areas
Key applications include sintering, pellet firing, blast furnace production, slag utilization and heating wells/furnaces.
The basis of all energy-saving technologies lies in fundamental laws:
- Heat transfer (conduction, convection, radiation): Optimizing these processes in furnaces and units is a direct path to reducing losses. For example, applying new furnace linings reduces unwanted thermal conductivity.
- Gas dynamics: Managing flows of hot gases (in blast furnaces, during pellet firing) critically affects fuel combustion efficiency and heat transfer.
- Phase transitions: Accurate calculation of the heat of melting, crystallization of slags allows the use of the latent energy of processes.
The revolution was made by mathematical modeling in combination with physical experiment. The dynamic zonal-nodal method of calculating radiative and complex heat exchange, developed by Ural scientists, allows 1 :
- Virtually test new operating modes of furnaces and units.
- Optimize designs with unprecedented speed.
- Predict thermal fields and stress distribution.
- Create digital twins of real installations (as at the Magnitogorsk Combine - MMK).
- Sintering: Modernization of sintering machines with automated control systems for thermal and gas-dynamic processes, new furnace throat designs. Result: Increased environmental friendliness and cost-effectiveness of sintering plants 1 .
- Pellet firing: Reconstruction of gas distribution systems and tracts. Result: Increase in machine productivity by 10-17%, reduction in specific fuel consumption by 8-15%, sharp (50-58%) reduction in emissions after cleaning (experience in Russia, Brazil, Iran) 1 .
- Blast furnace production: New air heaters (Cowpers) capable of producing blast at 1300°C+ on blast furnace gas without natural gas, and powerful software for process modeling.
- Slag utilization: Liquid slag granulation plants (capacity up to 15 t/min, up to 2 million t/year) in Russia, Ukraine, India, China, at Norilsk Nickel - turning waste into product 1 .
- Heating wells and furnaces: Hundreds of modernized furnaces based on accurate thermophysical models. Result: Reduced specific fuel consumption, improved metal heating quality 1 .
Deep Dive: Pellet Firing Optimization Experiment
Task
Significantly reduce energy costs and emissions on the firing machine without reducing pellet quality and productivity.
Methodology
- Audit and Modeling: Detailed measurement of temperatures, pressures and gas flow rates on the operating machine. Built 3D CFD model of gas dynamics and heat transfer in the machine's working space.
- Identifying Bottlenecks: Modeling revealed zones of non-optimal gas distribution (hot/cold spots), excessive hydraulic resistances in tracts, heat loss points.
- Solution Development: Based on analysis proposed reorganization of gas supply/exhaust systems, installation of new adjustable nozzles, reconstruction of gas ducts, implementation of automated control system.
- Physical Validation: Proposed changes tested on scale physical models to confirm hydrodynamic similarity and expected effect.
- Industrial Implementation: Reconstruction conducted on one of the firing machines (pilot project).
- Monitoring: Additional sensors installed for continuous data collection.
Results and Analysis
- Productivity +12%
- Specific fuel consumption -11%
- Emissions after cleaning -54%
- Pellet quality Stable/Improved
Comparison of Key Indicators
| Indicator | Before | After | Change |
|---|---|---|---|
| Productivity | Base level | +10-17% | ↗ 10-17% |
| Specific fuel consumption | Base level | -8-15% | ↘ 8-15% |
| Emissions (after cleaning) | Base level | -50-58% | ↘ 50-58% |
| Process stability | Low | High | Significant ↗ |
| Operating costs | High | Reduced | ↘ |
Scientific Importance
This experiment (and similar ones) proved that deep understanding of thermo-hydrodynamic processes, supported by modern modeling tools, allows for precise, highly effective modernizations of existing equipment. The effect is achieved not by simply replacing burners with "newer" ones, but through fundamental optimization of energy and material flows. This reduces the carbon footprint and increases competitiveness 1 .
Thermophysicist's Toolkit: Research Solutions
Key Research Tools in Modern Metallurgical Thermophysics
| Tool/Solution | Function/Purpose |
|---|---|
| CFD Software | Modeling complex 3D flows of gases/liquids, heat transfer, combustion, chemical reactions in virtual furnaces. |
| High-Temperature Sensors | Accurate temperature measurement in aggressive environments (furnaces, slag flows, hot gases). |
| Dynamic Zonal-Nodal Method | Efficient calculation of radiative and complex heat exchange in technological furnaces and units. |
| Automated Control Systems | Real-time control/regulation of temperature, pressure, fuel, air, charge consumption. |
| AI/ML Platforms | Analysis of big data from productions. Prediction of lining wear, charge recipe optimization. |
| Laboratory Models | Validation of CFD calculations, study of hydrodynamics on scalable installations. |
| Thermal Imaging Cameras | Visualization of thermal fields on equipment surfaces (finding losses, lining control). |
| 2-Mercaptopyridine | 2637-34-5 |
| Ethyl 2-naphthoate | 3007-91-8 |
| 1,2-Dichloroethane | 107-06-2 |
| 3-Vinyloxetan-3-ol | 1207175-07-2 |
| 1,3-Cyclohexadiene | 592-57-4 |
Modern Research in Action
Thermal imaging and computational modeling have become indispensable tools for optimizing metallurgical processes and reducing energy consumption.
Broad Applications: Savings Beyond the Workshop
Thermophysics principles work not only in metallurgy:
Energy-Efficient Buildings
Implementation of Individual Heat Points (IHP) with automatic regulation in schools/hospitals instead of central heating points gave up to 75% heat savings in winter .
Smart Heating Networks
Transition from 4-pipe to 2-pipe systems with DHW preparation in building IHPs (Eastern Europe, Russia) saves up to 25% thermal energy .
Other Industrial Applications
Thermophysics solves heat removal problems in microchips and thermal regulation of spacecraft 2 .
Energy-Saving Effect of Thermophysical Solutions in Different Areas
| Application Area | Technology/Approach | Achievable Savings/Effect |
|---|---|---|
| Metallurgy (Pellet firing) | Reconstruction of gas ducts, automated control systems | ↘ Fuel 8-15%, ↗ Productivity 10-17%, ↘ Emissions 50-58% 1 |
| Utilities (Schools, Hospitals) | Individual Heat Point (IHP) | ↘ Heat consumption up to 75% (in heating season) |
| Urban Heating | Decentralization (IHPs in buildings) | ↘ Heat consumption up to 25% |
| Industrial Heating (Furnaces) | Dynamic zonal-nodal modeling | ↘ Specific fuel consumption, ↗ Metal quality 1 |
| Slag Processing | Granulation plants | Waste utilization (0.66-2 million t/year), product obtainment 1 |
Conclusion: The Science That Creates the Future
Thermophysics has ceased to be an abstract discipline - it has become a key driver of green transformation in heavy industry. From a sintering machine in Magnitogorsk to a firing line in Brazil, from a slag granulator in China to a school boiler room in the Moscow region - its methods significantly reduce the carbon footprint and energy bills.
The "Yenisei Thermophysics-2025" forum with its hundreds of reports and focus on AI and youth 2 is a vivid confirmation of this dynamic. Research in this area is not just academic interest, but a strategic contribution to sustainable development, where resource and energy conservation goes hand in hand with industrial power.