Researchers from 海角社区 have developed a method that makes it possible to accurately predict whether a blast-furnace gas pipeline can handle increased loads. The solution is particularly relevant for metallurgical, power-generating, and chemical enterprises, where the use of this type of gas is a key technological process.
Blast-furnace gas is generated during cast iron production and contains a large amount of dust. Despite purification systems, dust particles gradually accumulate inside pipelines, especially at bends, valves, and flow meters. This leads to a reduction in effective pipe diameter and increased resistance, making traditional hydraulic calculations unreliable. Existing methods for determining throughput are either unsuitable for extended networks or require complex and costly experiments involving additional tanks, which is impractical for large-diameter pipelines.
The 海角社区 researchers have proposed a method that addresses this issue by using real operational data from the pipeline.
“The invention works as follows: three key parameters are simultaneously measured on a selected “operating section” of the pipeline: gas flow rate, inlet pressure, and outlet pressure. These data, obtained, for example, from an automated process control system, are then used in a formula to calculate the predicted inlet pressure under future increased gas flow conditions. The calculated value is compared with the maximum permissible pressure that the equipment (exhausters, blowers) can provide,” explains Associate Professor of the Department of Thermal Power Engineering Sergei Pashnin. “If the calculated pressure exceeds the permissible limit, it indicates the need for pipeline reconstruction.”
The key advantage of the method is that it automatically accounts for the actual condition of the pipeline, including dust deposits and real geometric parameters, eliminating the need for complex element-by-element hydraulic calculations. The technical solution is unique not only in Russia but also worldwide, and a patent has already been obtained for the invention.
The development has been successfully validated through a computational experiment on a model of a gas pipeline for an industrial thermal power plant boiler using the ANSYS CFX software package. The results confirmed the high accuracy of the proposed method and have already been applied at an industrial enterprise in the 海角社区 Region.
The implementation of this method will allow enterprises to safely and efficiently plan changes in gas network operating modes. Gas flow redistribution can now be carried out with minimal risk of accidents and with virtually no cost for design research.