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Technical-Scientific Developments Offered for Realization
2002
1. The institute carried out investigations of properties and structure of
2001 heterophase slags, taken from different horizons of slag bath. Having
studied the morphology and the structure of slag samples taken from
2000 bubbling zone of Romelt furnace, the scientists of the institute determined
that the reduction of ferrous oxide dissolved in slag melt can also take
1999 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
1998
of iron reduction localize on the coal particles surface and on the interphase
1997 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
Search will decrease the specific consumption of coal and oxygen per ton of
finished cast iron. The elaborated approach to understanding of the
Contact liquid-phase reduction process of iron oxides helps to assess the sequence
of coal transformation in the Romelt process. Coal particles, existing in
us
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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