不锈钢冶炼AOD炉烘烤新工艺过程数值仿真与优化研究
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摘要
AOD炉是不锈钢生产的重要设备,其炉本体的烘烤质量将直接影响到能量的消耗和产品的质量。目前国内外的不锈钢生产厂家已开始探索先进的烘烤器和烘烤工艺,以便解决普遍存在的能耗大、效率低、烘烤温度不均匀的突出问题。在高温空气燃烧(HTAC)技术的基础上发展起来的蓄热式烘烤,近些年来,在钢包、中间包等冶金设备的烘烤方面得到了广泛的应用,但还没有在AOD炉中得到应用。AOD炉外型尺寸比较特殊,属于狭长型,能否成功应用此项先进的燃烧技术需要大量的研究和创新设计。因此,开展AOD烘烤过程的研究和新烘烤工艺的开发具有十分重要的现实意义。
本论文对AOD烘烤技术的现状、HTAC技术的发展以及在AOD烘烤中应用的可行性、AOD烘烤过程的数值分析方法进行分析,在对120tAOD炉烘烤工艺现场研究的基础上,采用CFD数值模拟,对现有120tAOD烘烤器的烘烤过程及HTAC技术在AOD烘烤设备中的应用新工艺过程进行了数值仿真与优化研究,开展的主要研究工作和获得的结果如下：
(1)对现有工艺烘烤AOD炉内的温度分布进行了测试,考察了AOD烘烤的温度均匀性及炉内的温度分布情况,同时测试废气成份,掌握在对AOD炉的烘烤过程中的天然气燃烧时的废气排放情况。为进一步开展对AOD的系统节能奠定了基础,为数值仿真模型的验证提供了参考。
(2)利用商业软件STAR-CD,对现有AOD炉烘烤过程的炉衬温度分布及烘烤器的燃烧特性进行了数值模拟研究,计算模拟结果进行了实际验证。
结果表明：烘烤结束时炉壁最高温度可达1380K,同一圆周方向上温度最大相差20K,靠近烟气出口一侧温度稍高；炉壁高度方向上温度最高相差56K,中下部温度高；炉内烟气流动速度小,温度低,导致炉壁加热不够均匀。目前的烘烤器烘烤效果不甚理想。模拟计算结果与实测结果吻合良好。
(3)针对AOD炉体结构和烘烤过程的特点,设计了新型的蓄热式AOD烘烤装置,以新型分体式复合型蓄热式燃烧系统替代原燃烧系统,结合现场实际情况,制定了完整的蓄热式设备新方案。
(4)为研究新型蓄热式AOD烘烤器的烘烤效果,对AOD炉烘烤过程的流动、燃烧、传热现象进行数值模拟研究,定量考察了空—燃比、空气预热温度、天然气流量等烘烤工艺参数对炉衬温度、炉内燃烧温度场及气氛中的02和NO浓度场的影响规律。同时对同一烘烤装置的燃料适应性进行了数值模拟研究,分析几种不同成分的燃料对温度场的影响,讨论用混合煤气等燃料替代天然气的可行性。
结果表明：增加天然气流量和空气预热温度是提高炉壁温度的有效措施,空—燃比变化对温度的影响较小；应用此蓄热式AOD烘烤器,天然气流量在380～420Nm3／h范围内,空气预热温度1073K左右,空—燃比在10：1～12：1之间,天然气预热773K,在满足烘烤温度1373K的基础上,温差基本可以控制在50K以内,烘烤温度均匀性较好。燃烧后的炉内气氛中02浓度分布均匀；NO浓度比原系统稍高,由于一个炉次的烘烤时间比原系统大幅缩短,所以总的NO排放量并不大。几种燃料组分中使用天然气作燃料的烘烤效果较好,混合煤气的烘烤温度可达到烘烤要求,替代天然气作燃料是可行的。本文提出了供现场参考的烘烤工艺参数。
AOD (Argon and Oxygen Decarburization)furnace is one of the most important equipment for stainless steel-making. The baking quality of AOD furnace directly affects the product quality and energy consumption. At present, the exploration of advanced AOD baker and baking process are carried out in most of the stainless steel making plants at home and abroad to solve the outstanding problems such as high energy consumption, low efficiency and non-uniform baking temperature. Regenerative baking technique is developed on HTAC (high temperature air combustion) technique and is extensive applied to metallurgical equipment especially for the aspect of ladle and tundish baking, however it has not been applied to AOD baking process yet. The configuration of AOD furnace is relatively special because of its long-narrow type, so the application of the advanced combustion technology on AOD needs plenty of research work and innovative design. Therefore, it is very necessary to understand the baking process in AOD and to develop new baking technology.
The current status of AOD baking technology, the development of HTAC technique and the feasibility of the application of HTAC technique on AOD, the method of numerical simulation of the AOD baking process were reviewed in this thesis. Combined with research work in steelworks, CFD was employed to simulate the present 120 ton AOD baking process and the application of HTAC in AOD. Main research work and results are described as follows.
(1) The distribution of temperature of AOD furnace with present baking process was measured and the temperature uniformity and the distribution in the furnace were obtained. As well as, the composition of off gas was measured, thus the exhaust gas emission during the baking process with natural gas combustion in AOD was understood. All these have provided the important data for the validation of numerical simulation and laid the base for the further system energy saving of AOD.
(2) By means of commercial software STAR-CD, the temperature distribution of AOD furnace lining during the present baking process and the combustion characteristics of the baker were investigated with numerical simulation, and the predicted results were validated by actual measurements. The results show that the maximum temperature of AOD furnace lining after baking can reach 1380K, and the biggest temperature difference in the same circle direction is 20K. The temperature at the side close to the outlet is relatively high. The biggest temperature difference in height direction is 56K, and the temperature in the lower-middle part is relatively high. The small flow rate and lower temperature of the off gas in AOD lead to the non-uniform temperature of the wall. The present baking effectiveness is not satisfactory. The predictions are in good agreement with the measured.
(3) According to the characteristics of AOD structure and baking process, the new type regenerative AOD baker was designed in order to replace the original combustion system. Combined with the actual situation on site, the complete reform scheme of regenerative equipments was established.
(4) In order to study the effect of the new regenerative baker on the baking process in AOD, numerical simulation of gas flow, combustion and heat transfer in AOD during the baking process has been carried out. The influences of air-fuel ratio, preheated air temperature and nature gas flux on the lining temperature and combustion temperature field and distribution of O2/NO in AOD after baking were quantitatively analyzed. The influences of components of various fuels on temperature distribution were presented to investigate the fuel adaptability of the AOD baker. The feasibility of replacing nature gas with mixed gas and other fuels were discussed.
Results show that raising the flux of nature gas and preheated air temperature are effective measures to increase the lining temperature, while the influence of air-fuel ratio on the lining temperature is relatively small. Using the regenerative AOD baker, with the flux of nature gas of 380～420Nm3/h and preheated air temperature of about 1073K and air-fuel ration of 10:1～12:1, the lining temperature can reach the desired temperature 1373K, and the temperature difference can maintain lower than 50K, that shows a good uniformity for the temperature. Distribution of O2 in furnace is uniform, and NO concentration is some higher than original baking system. But because the baking time of new system will shorter than before, the total amount of NO is not large. The heating effect of baker using nature gas as fuel is relatively better than other fuels. The heating temperature of mixed gas can also match the requirement of AOD baking, so replacing nature gas is feasible. In addition, the optimal baking parameters for the actual performance were presented in this paper.
本论文对AOD烘烤技术的现状、HTAC技术的发展以及在AOD烘烤中应用的可行性、AOD烘烤过程的数值分析方法进行分析,在对120tAOD炉烘烤工艺现场研究的基础上,采用CFD数值模拟,对现有120tAOD烘烤器的烘烤过程及HTAC技术在AOD烘烤设备中的应用新工艺过程进行了数值仿真与优化研究,开展的主要研究工作和获得的结果如下：
(1)对现有工艺烘烤AOD炉内的温度分布进行了测试,考察了AOD烘烤的温度均匀性及炉内的温度分布情况,同时测试废气成份,掌握在对AOD炉的烘烤过程中的天然气燃烧时的废气排放情况。为进一步开展对AOD的系统节能奠定了基础,为数值仿真模型的验证提供了参考。
(2)利用商业软件STAR-CD,对现有AOD炉烘烤过程的炉衬温度分布及烘烤器的燃烧特性进行了数值模拟研究,计算模拟结果进行了实际验证。
结果表明：烘烤结束时炉壁最高温度可达1380K,同一圆周方向上温度最大相差20K,靠近烟气出口一侧温度稍高；炉壁高度方向上温度最高相差56K,中下部温度高；炉内烟气流动速度小,温度低,导致炉壁加热不够均匀。目前的烘烤器烘烤效果不甚理想。模拟计算结果与实测结果吻合良好。
(3)针对AOD炉体结构和烘烤过程的特点,设计了新型的蓄热式AOD烘烤装置,以新型分体式复合型蓄热式燃烧系统替代原燃烧系统,结合现场实际情况,制定了完整的蓄热式设备新方案。
(4)为研究新型蓄热式AOD烘烤器的烘烤效果,对AOD炉烘烤过程的流动、燃烧、传热现象进行数值模拟研究,定量考察了空—燃比、空气预热温度、天然气流量等烘烤工艺参数对炉衬温度、炉内燃烧温度场及气氛中的02和NO浓度场的影响规律。同时对同一烘烤装置的燃料适应性进行了数值模拟研究,分析几种不同成分的燃料对温度场的影响,讨论用混合煤气等燃料替代天然气的可行性。
结果表明：增加天然气流量和空气预热温度是提高炉壁温度的有效措施,空—燃比变化对温度的影响较小；应用此蓄热式AOD烘烤器,天然气流量在380～420Nm3／h范围内,空气预热温度1073K左右,空—燃比在10：1～12：1之间,天然气预热773K,在满足烘烤温度1373K的基础上,温差基本可以控制在50K以内,烘烤温度均匀性较好。燃烧后的炉内气氛中02浓度分布均匀；NO浓度比原系统稍高,由于一个炉次的烘烤时间比原系统大幅缩短,所以总的NO排放量并不大。几种燃料组分中使用天然气作燃料的烘烤效果较好,混合煤气的烘烤温度可达到烘烤要求,替代天然气作燃料是可行的。本文提出了供现场参考的烘烤工艺参数。
AOD (Argon and Oxygen Decarburization)furnace is one of the most important equipment for stainless steel-making. The baking quality of AOD furnace directly affects the product quality and energy consumption. At present, the exploration of advanced AOD baker and baking process are carried out in most of the stainless steel making plants at home and abroad to solve the outstanding problems such as high energy consumption, low efficiency and non-uniform baking temperature. Regenerative baking technique is developed on HTAC (high temperature air combustion) technique and is extensive applied to metallurgical equipment especially for the aspect of ladle and tundish baking, however it has not been applied to AOD baking process yet. The configuration of AOD furnace is relatively special because of its long-narrow type, so the application of the advanced combustion technology on AOD needs plenty of research work and innovative design. Therefore, it is very necessary to understand the baking process in AOD and to develop new baking technology.
The current status of AOD baking technology, the development of HTAC technique and the feasibility of the application of HTAC technique on AOD, the method of numerical simulation of the AOD baking process were reviewed in this thesis. Combined with research work in steelworks, CFD was employed to simulate the present 120 ton AOD baking process and the application of HTAC in AOD. Main research work and results are described as follows.
(1) The distribution of temperature of AOD furnace with present baking process was measured and the temperature uniformity and the distribution in the furnace were obtained. As well as, the composition of off gas was measured, thus the exhaust gas emission during the baking process with natural gas combustion in AOD was understood. All these have provided the important data for the validation of numerical simulation and laid the base for the further system energy saving of AOD.
(2) By means of commercial software STAR-CD, the temperature distribution of AOD furnace lining during the present baking process and the combustion characteristics of the baker were investigated with numerical simulation, and the predicted results were validated by actual measurements. The results show that the maximum temperature of AOD furnace lining after baking can reach 1380K, and the biggest temperature difference in the same circle direction is 20K. The temperature at the side close to the outlet is relatively high. The biggest temperature difference in height direction is 56K, and the temperature in the lower-middle part is relatively high. The small flow rate and lower temperature of the off gas in AOD lead to the non-uniform temperature of the wall. The present baking effectiveness is not satisfactory. The predictions are in good agreement with the measured.
(3) According to the characteristics of AOD structure and baking process, the new type regenerative AOD baker was designed in order to replace the original combustion system. Combined with the actual situation on site, the complete reform scheme of regenerative equipments was established.
(4) In order to study the effect of the new regenerative baker on the baking process in AOD, numerical simulation of gas flow, combustion and heat transfer in AOD during the baking process has been carried out. The influences of air-fuel ratio, preheated air temperature and nature gas flux on the lining temperature and combustion temperature field and distribution of O2/NO in AOD after baking were quantitatively analyzed. The influences of components of various fuels on temperature distribution were presented to investigate the fuel adaptability of the AOD baker. The feasibility of replacing nature gas with mixed gas and other fuels were discussed.
Results show that raising the flux of nature gas and preheated air temperature are effective measures to increase the lining temperature, while the influence of air-fuel ratio on the lining temperature is relatively small. Using the regenerative AOD baker, with the flux of nature gas of 380～420Nm3/h and preheated air temperature of about 1073K and air-fuel ration of 10:1～12:1, the lining temperature can reach the desired temperature 1373K, and the temperature difference can maintain lower than 50K, that shows a good uniformity for the temperature. Distribution of O2 in furnace is uniform, and NO concentration is some higher than original baking system. But because the baking time of new system will shorter than before, the total amount of NO is not large. The heating effect of baker using nature gas as fuel is relatively better than other fuels. The heating temperature of mixed gas can also match the requirement of AOD baking, so replacing nature gas is feasible. In addition, the optimal baking parameters for the actual performance were presented in this paper.
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