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Simulation and Techno-Economic Performance of a Novel Charge Calculation and Melt Optimization Planning Model for Steel Making

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Journal of Minerals and Materials Characterization and Engineering 2020年第4期8卷 277-300页

作者： onigbajumo adetunji Saliu Ojo Seidu School of Mechanical Medical and Process Engineering Queensland University of Technology Brisbane Australia Department of Metallurgical and Materials Engineering Federal University of Technology Akure Ondo State Nigeria

Process algorithm, numerical model and techno-economic assessment of charge calculation and furnace bath optimization for target alloy for induction furnace-based steelmaking is presented in this study. The developed algorithm combines the make-to-order (MTO) and charge optimization planning (COP) of the steel melting shop in the production of target steel composition. Using a system-level approach, the unit operations involved in the melting process were analyzed with the purpose of initial charge calculation, prevailing alloy charge prediction and optimizing the sequence of melt chemistry modification. The model performance was established using real-time production data from a cast iron-based foundry with a 1- and 2-ton induction furnace capacity and a medium carbon-based foundry with a 10- and 15-ton induction furnace capacity. A simulation engine (CastMELT) was developed in Java IDE with a MySQL database for continuous interaction with changing process parameters to run the model for validation. The comparison between the model prediction and production results was analyzed for charge prediction, melt modification and ferroalloy optimization and possible cost savings. The model performance for elemental charge prediction and calculation purpose with respect to the charge input (at overall scrap meltdown) gave R-squared, Standard Error, Pearson correlation and Significance value of (0.934, 0.06, 0.97, 0.0003) for Carbon prediction, (0.962, 0.06, 0.98, 0.00009) for Silicon prediction, (0.999, 0.048, 0.999, 9E -11) for Manganese Prediction, and (0.997, 0.076, 0.999, 6E -7) for Chromium prediction respectively. Correlation analysis for melt modification (after charging of ferroalloy) using the model for after-alloying spark analysis compared with the target chemistry is at 99.82%. The results validate the suitability of the developed model as a functional system of induction furnace melting for combined charge calculation and melt optimization Techno-economic evalu

关键词： Charge Calculation Process Simulation Modelling Induction Furnace Steel Making Techno-Economics Mass and Energy Balance

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Effect of Cu-Ni and Cu-Ni-Mn on the Microstructural and Mechanical Behaviour of As-Cast Non-Inoculated Hypereutectic Grey Iron

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Journal of Minerals and Materials Characterization and Engineering 2020年第2期8卷 27-46页

作者： Seidu Ojo Adama Sumaila onigbajumo adetunji Department of Metallurgical and Materials Engineering Federal University of Technology Akure Ondo State Nigeria Ajaokuta Steel Company Limited (ASCO) Ajaokuta Complex Kogi State Nigeria School of Mechanical Medical and Process Engineering Queensland University of Technology Brisbane Australia

The hypereutectic region of grey cast iron has received very little attention especially for designing cast products by researchers. Due to its high carbon equivalence, hypereutectic grey iron poses some challenges especially its tendency for grey to white transition (GWT) at this level of carbon content. However, hypereutectic grey iron possesses inherent properties that could be easily utilized for improved performance in automobile engines and brake pad system. Significantly, they could be modified for superior hardness, strength and toughness. This study presents the effect of microalloying on the mechanical behaviour of hypereutectic grey cast iron with carbon equivalence above 4.5. The first part of this work presented in this paper considers the addition of Cu-Ni and Cu-Ni-Mn to series of as-cast hypereutectic grey cast iron and their hardness and tensile strength were studied and compared. A total of 33 cast samples were obtained with the control sample. The examination of the micrographs revealed that graphite eutectics cells of Type A and A + D were obtained in the resulting microstructure. Results analyses showed that the ferrite forming tendency of silicon was suppressed due to the high carbon content of the as-cast hypereutectic grey iron coupled with the absence of inoculation which plays a great role in the graphite flake type, network, size and distribution. Cu-Ni microalloying was also confirmed to promote hardness with the hardening effect limit of nickel observed at 1.3% composition. For Cu-Mi-Mn addition, excess and free sulphur in the hyper- eutectic grey iron results in reverse effect of manganese on strength, hardness, reduced graphite flake size and shape.

关键词： Hypereutectic Grey Iron Microstructure Hardness Tensile Strength Inoculation Graphitization Cast Iron Alloying

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Melting Time Prediction Model for Induction Furnace Melting Using Specific Thermal Consumption from Material Charge Approach

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Journal of Minerals and Materials Characterization and Engineering 2021年第1期9卷 61-74页

作者： onigbajumo adetunji Seidu Saliu Ojo Akinlabi Oyetunji Newton Itua School of Mechanical Medical and Process Engineering Queensland University of Technology Brisbane Australia Department of Metallurgical and Materials Engineering Federal University of Technology Akure Ondo State Nigeria

A system-level evaluation was used to analyze the induction furnace operation and process system in this study. This paper presents an investigation into the relationship between the instantaneous chemical composition of a molten bath and its energy consumption in steelmaking. This was evaluated using numerical modelling to solve for the estimated melting time prediction for the induction furnace operation. This work provides an insight into the lowering of energy consumption and estimated production time in steelmaking using material charge balancing approach. Enthalpy computation was implemented to develop an energy consumption model for the molten metal using a specific charge composition approach. Computational simulation program engine (CastMELT) was also developed in Java programming language with a MySQL database server for seamless specific charge composition analysis and testing. The model performance was established using real-time production data from a cast iron-based foundry with a 1 and 2-ton induction furnace capacity and a medium carbon-based foundry with a 10- and 15-ton induction furnace capacity. Using parameter fitting techniques on the measured operational data of the induction furnaces at different periods of melting, the results from the model predictions and real-time melting showed good correlation between 81% - 95%. A further analysis that compared the relationship between the mass composition of a current molten bath and melting, time showed that energy consumption can be reduced with effective material balancing and controlled charge. Melting time was obtained as a function of the elemental charge composition of the molten bath in relation to the overall scrap material charge. This validates the approach taken by this research using material charge and thermodynamic of melting to optimize and better control melting operation in foundry and reduce traditional waste during iron and steel making.

关键词： Charge Calculation Mass and Energy Balance Melting Time Optimization Induction Furnace Numerical Model Iron and Steelmaking CastMELT

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Proximate, Chemical and Functional Properties of Wheat, Soy and Moringa Leaf Composite Flours

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Agricultural Sciences 2021年第1期12卷 18-38页

作者： Tivde Benedict Verem Igbabul Bibiana Dooshima Eke Michael Ojoutu Oladapo Okanlawon Owolabi adetunji onigbajumo Center for Food Technology and Research Benue State University Makurdi Nigeria Department of Food Science and Technology Federal University of Agriculture Makurdi Nigeria Department of Agricultural Engineering Federal University of Technology Akure Ondo State Nigeria School of Mechanical Medical and Process Engineering Queensland University of Technology Brisbane Australia

The study presents the effect of utilizing wheat, soy and moringa leaf flour and quality analysis of the flour. The composite flour was prepared using refined wheat flour, soy flour and moringa leaf flour. Four composite flour, compositions were formulated such as 100% wheat flour (control) designated as sample A. Sample B consisted of 75% wheat, 20% soybean and 5% moringa leaf. Sample C consisted of 70% wheat, 20% soybean and 10% moringa leaf. Sample D was 65% wheat, 20% soybean and 15% moringa leaf. Sample E was 60% wheat, 20% soybean and 20% moringa leaf, respectively. Proximate, chemical, and functional properties of wheat, soy and moringa leaf flours were studied in composite flour variation and preparations. The present study highlighted the nutrients enrichment of flour on incorporation of soy and moringa leaf. Relevant statistical tests were done to analyse the significance of means for all tested parameters. Composite flour composition with 20% soybean was identified to produce optimal nutrient, mineral quality and yield. The addition of soybean and moringa flour in baked products has been shown in this study to improve the nutrition and health benefits of the body. It also serves as a good cut on the cost of wheat importation in communities with supply challenges.

关键词： Proximate Analysis Composite Flour Soybeans Wheat Flour and Moringa Leaf

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