Smelting is an industry of long industrial chain, complex working environment, adverse condition and encompassed with various hazard. It is exceptionally significant to identify and prevent relative hazards and undertake emergent rescue if a disaster happens. In detail, the following researches need to be explored:

(1) Hazards identification and prevention of metallurgical high-temperature reaction vessel

According to failure cases, it is essential to summarize the damaged characteristics of vessels under high-temperature conditions. The relative work involves:

 Identify the failure mode of vessels under the high-temperature employment process, and perform the root-cause analysis.

 Establish the damage characteristics database of high-temperature reaction vessels.

 Identify the mass transferring, heat transmission, and chemical reaction mechanism of high-temperature vessels during the damage process.

 Comprehensively assess destroyed causes and mechanisms of essential metallurgical equipment like high-temperature vessels corresponding to smelting conditions.

 Enhance the safety of metallurgical smelting equipment.

 Simulate the equipment employment condition and establish the experimental platform of high-temperature equipment.

 Establish the safety assessment system.

 Develop the predictive and warning models by quantifying the life of significant equipment.

(2) Hazards identification and prevention of poisonous volatile and hazardous gas

Hazardous gases-related disaster always occurs along with metallurgical production. The following works are essential with eliminating these hazards:

 Developing the analytical system of the accidents referred to the forming mechanism of hazardous gases, including poisonous, combustible, and volatile ones.

 Establish the accidental cases database according to the hazardous gases spill frequently.

 Coordinating with combustion science, gas diffusion aerodynamics, coal injection, and the dedusting system simulate the working environment under the critical condition of the accident.

 Monitor the risk sources of hazardous gases and predict the spilling risk.

 Develop the safety management system, including an online monitoring module of smart safety producing equipment and a hazardous gas spilling monitoring module.

 Warn the potential risks in time.

 Cut down the risk rate and alleviate causality.

(3) The safety analysis and monitoring of the metallurgical operation process

 According to the fusion of data and knowledge, engage the abnormality diagnosis of metallurgical producing process and explore the research of the self-healing control theory with practicing.

 Develop the metallurgical equipment and process control theory toward large scale, integration, and intelligence, coping with the demand of self-adaption, self-learning, abnormality diagnosis, and self-healing control referred in safe producing.

 Dissect the problem in typical metallurgical production processes, like frequent abnormalities and malfunction spreading widely.

 Support the metallurgical system operating with robust reliability and constancy from theoretical and technical perspectives.

 Integrated with machine learning and HCI, study the elaborate taxonomy and smart identification of metallurgical working conditions.

 Study the technologies of time-frequency analysis, timing causation, data-driven feature matching, malfunction identification, diagnosis, and prediction based on multimodal data.

 Study intelligent self-healing technology and self-repair strategy.

 Assess the safety condition of the metallurgical producing process and research the remaining service life of relative equipment.

(4) The integration system of digital twins and hazards identification of metallurgical industry

 Study the influence of multi-causes on smelting safety.

 Identify the dynamic transmission process of mass and energy involved in steel-producing processes.

 Simulate the wholesome smelting processes, especially for the essential processes, by using the smelting big data platform and data-driven process analog system.

 Estimate the risk status of the potential hazardous sources according to the equipment condition, energy media, and high-temperature molten metal referred to the long and short term of the smelting process.

 For preventing accidents happen.

 Develop the smelting digital twin system.

 Develop the integrated system of accident warning and monitoring to eliminate the risk sources of the smelting process and equipment from the early stage and lift the intrinsic safety.

 Set up the prediction model and database referred to smelting hazards by integrating corresponding data.

 Set up hazard identification and warning modules by continuously optimizing key parameters of machine learning models.

(5) The emergency treatment and rescue technology employed in metallurgical accidents

 Develop the technology mitigating chain-breaking disasters, setting up rescue systems against the coupling effect of multiple disaster types in the production process.

 From the perspectives of accidents, staff, equipment, and working conditions, analyze the causation of hazards (e.g. fire, explosion, spilling, diffusion, splashing, and suffocation).

 Analyze the mechanism of dynamical risk evolution and transmission.

 Estimate and rate the consequence of accidents, and generate the assessment method for safety conditions.

 By summarizing the hazard characteristics of typical high-temperature molten metal accidents, develop the predictive model of hazard evolution considering the workshop layout, equipment arrangement, and people management.

 Develop the matching algorithm of hazard evolution analog system with the actual disaster status.

 Identify the impact of various hazards (e.g., molten metal flows, high-temperature metal particles splash, thermal radiation, and thermal convection) on the safety of people, equipment, working conditions in different regions.

 Coordinate the happening, evolution, and predictive consequences of various hazards and emergency management, explore the formal treatment methodology against the predictive primary and derivative hazards involved in typical smelting production processes, and establish coordinated emergency support and disposal mechanism.