铁矿石均热烧结基础与技术研究
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摘要
随着我国钢铁工业的持续快速发展,钢铁生产的能源消耗总量持续上升。在整个钢铁生产系统中,烧结工序能耗约占15%。研究降低烧结工序能耗的基础理论与新技术对降低我国钢铁生产综合能耗,节约生产成本,提高企业竞争力具有重要意义。
在烧结工序能耗中,固体燃料消耗占75%-80%。本文从降低烧结固体燃耗的目的出发,以宝钢股份公司含铁原料、燃料及烧结工艺为对象,通过气体运动和传热规律的研究,揭示了烧结料层的蓄热规律;开发了利用蓄热实现均热烧结的新技术—分层布料和气流辅助布料均热烧结技术,达到显著降低燃料消耗的目的,其中气流辅助布料均热烧结技术在宝钢实现了工业应用。
对烧结蓄热现象进行的研究发现,烧结过程中料层蓄热量自上而下不断升高。若将料高为700mm的宝钢烧结料层平均分为七个单元,获得第二至第七单元料层的总蓄热率依次为40.37%、54.07%、61-39%、66.60%、70.30%、72.99%。
由于烧结饼离开烧结机时自上而下各单元热状态不同,依据总蓄热量还无法确定料层合理的燃料分布,本研究首次提出了可利用的蓄热量概念。可利用蓄热量是从总蓄热量中扣除烧结饼所带走的物理热后的蓄热量,是利用蓄热实现均热节能烧结的依据。通过研究烧结饼各单元的热状态和物理热的计算,获得了第二至第七单元可利用蓄热率依次为38.18%、50.80%、56.84%、60.33%、60.92%、58.39%,从而为均热烧结新技术的开发提供了可靠依据。
在理论研究的基础上,首先开发了分层布料均热烧结技术。采取分层布料技术,能够在不降低烧结矿产、质量指标的前提下显著降低固体燃耗。烧结试验表明,若将混合料分为三层,上层焦粉用量为4.9%,中层焦粉用量为4.3%,下层焦粉用量为3.4%,混合料平均焦粉用量为4.2%,所得烧结矿转鼓强度62.13%,成品率80.02%,利用系数1.85t/(m2·h),固体燃耗53.85kg/t-s。分层布料均热烧结比普通烧结可节约固体燃耗3.69kg/t-s。
鉴于分层布料烧结技术的生产实施受现有厂房布局的限制,本论文进一步研究开发了气流辅助布料均热烧结技术。
通过研究烧结混合料在气体流场中的运动规律,查明了不同颗粒在气体流场中运动轨迹的差异性,建立了气流辅助布料实现与原料粒度和燃料分布偏析的理论依据。结合现行烧结生产工艺,在实验室中设计和制造了烧结混和料气流辅助布料试验装置,利用该布料装置,查明了气体流速、喷嘴结构、喷吹位置和倾角等对混合料粒度和燃料分布的影响,获得了优化的偏析布料工艺参数,开发出实现粒度和燃料分布合理偏析的气流辅助布料均热烧结新技术。
以宝钢原料为对象,采用气流辅助烧结技术在实验室进行的烧结试验可将混合料燃料配比降低约8.7%(由4.6%降低至4.2%)此外,烧结矿的成品率由73.26%提高到78.26%,利用系数由1.40t-(m2·h)-1提高到1.46t·(m2·h)-1。
试验结果充分表明气流布料烧结技术能实现烧结料层蓄热的高效利用,不仅显著降低了固体燃料消耗,而且明显提高了烧结矿产量和质量。本研究为降低烧结工序能耗提供了新的方法和技术。气流布料均热烧结技术已在我国宝钢烧结厂实现工业应用,单台烧结机每年效益达602.85万元。
With the rapid development of Chinese steel industry, the total energy consumption of the steel industry continues to rise. In the system of whole steel production, energy consumption of sintering process accounts for15%of the total energy consumption of steel production. It has a great significance to study basic theory and new technology of reducing the energy consumption of sintering process for reducing the comprehensive energy consumption of steel production, saving the cost of production and improving the competitiveness of enterprises.
The consumption of solid fuel accounts for75%-80%of the energy consumption of sintering process. Taking the iron raw materials and fuel from Baosteel and sintering process as research objects in this thesis, the law of the accumulation of heat in sinter layer is revealed through the study of gas kinetics and heat transfer. The new technologies of segregation feeding and airflow feeding which realize the heat-homogenizing sintering by the heat of accumulation are developed, reducing fuel consumption significantly. Particularly, the technology of heat-homogenizing sintering of airflow feeding has been applied into industrial production in Baosteel.
From the study of the accumulation of heat, it can be found that the amount of accumulated heat increases from top to bottom in the material layer during sintering. If the sinter layer with height of700mm is averagely divided into seven units, the total ratios of accumulation of heat from the second to seventh layer are40.37%.54.07%.61.39%.66.60%.70.30%,72.99%successively.
Due to the different heat states of each unit from top to bottom when the sinter cakes leave the sinter machine, it is hard to ascertain the reasonable distribution of fuel for the material layers according to the total accumulation of heat, so the concept of available accumulation of heat is first put forward in this study. The available accumulation of heat is the surplus amount of accumulated heat after deducting the physical heat taken away by the sinter cake, and it is the basis of heat-homogenizing sintering by accumulating heat. Through the study of heat state of every unit and calculation of physic heat, the available accumulations of heat from the second to the seventh unit are38.18%、50.80%.56.84%.60.33%.60.92%.58.39%successively, and therefore the reliable basis is provided for the development of new heat-homogenizing sintering.
On the basis of theory study, the heat-homogenizing sintering technology of distribution feeding is developed firstly. Taking the advantage of distribution feeding, the solid fuel consumption can be reduced significantly on the premise of guaranteeing the output and quality of agglomerate. The results of sintering experiment show that if the mixed material is divided into three layers and the dosage of coke breeze of the upper layer is4.9%, middle layer is4.3%, lower layer is3.3%and the average amount is4.2%, the quality indicators of agglomerate will be as follows:the drum strength of agglomerate62.13%, the yield80.02%, the utilization coefficient1.85t/(m2-h), and solid fuel consumption53.85kg/t-s. The solid fuel consumption of heat-homogenizing sintering is3.69kg/t-s less than the ordinary sintering.
Taking into the consideration that the production application of distribution feeding is limited by the plant layout, the heat-homogenizing sintering technology of airflow feeding is further researched and developed in this thesis.
Through the study of motion character of sinter mixture in the gas flow field, the diversities of motion trails among different particles are found out and the basic theory on segregation of particle size and fuel is established. Combining with the present sintering process, the test device of airflow feeding is designed and manufactured in the laboratory. The influence of airflow speed, nozzle structure, injection position and angel on the distribution of fuel and particle size of mixture is found out by making use of this feeding device and the optimized parameters of segregation feeding process are obtained. The new heat-homogenizing sintering technology of airflow feeding to realize the segregation of particle size and fuel distribution is developed.
Taking the raw material from Baosteel as research object, the fuel proportion of mixture can be reduced by8.7%(from4.6%to4.2%) in the laboratorial sintering experiment by adopting the sintering technology of airflow feeding. In addition, the yield of agglomerate is improved from73.26%to78.26%and the utilization coefficient is raised from1.40t·(m2·h)-1to1.46t·(m2·h)-1.
The results of experiments show that efficient utilization of the accumulated heat of sinter layers can be realized by the sintering technology of airflow feeding, so not only the consumption of solid fuel is significantly reduced, but also the output and quality of sinter product are both raised obviously. The new method and technology are provided in this thesis. The heat-homogenizing sintering technology of airflow feeding has been applied into industry in sintering plant of Baosteel, and the benefit of602.85million yuan can be achieved by single sintering machine every year.
在烧结工序能耗中,固体燃料消耗占75%-80%。本文从降低烧结固体燃耗的目的出发,以宝钢股份公司含铁原料、燃料及烧结工艺为对象,通过气体运动和传热规律的研究,揭示了烧结料层的蓄热规律;开发了利用蓄热实现均热烧结的新技术—分层布料和气流辅助布料均热烧结技术,达到显著降低燃料消耗的目的,其中气流辅助布料均热烧结技术在宝钢实现了工业应用。
对烧结蓄热现象进行的研究发现,烧结过程中料层蓄热量自上而下不断升高。若将料高为700mm的宝钢烧结料层平均分为七个单元,获得第二至第七单元料层的总蓄热率依次为40.37%、54.07%、61-39%、66.60%、70.30%、72.99%。
由于烧结饼离开烧结机时自上而下各单元热状态不同,依据总蓄热量还无法确定料层合理的燃料分布,本研究首次提出了可利用的蓄热量概念。可利用蓄热量是从总蓄热量中扣除烧结饼所带走的物理热后的蓄热量,是利用蓄热实现均热节能烧结的依据。通过研究烧结饼各单元的热状态和物理热的计算,获得了第二至第七单元可利用蓄热率依次为38.18%、50.80%、56.84%、60.33%、60.92%、58.39%,从而为均热烧结新技术的开发提供了可靠依据。
在理论研究的基础上,首先开发了分层布料均热烧结技术。采取分层布料技术,能够在不降低烧结矿产、质量指标的前提下显著降低固体燃耗。烧结试验表明,若将混合料分为三层,上层焦粉用量为4.9%,中层焦粉用量为4.3%,下层焦粉用量为3.4%,混合料平均焦粉用量为4.2%,所得烧结矿转鼓强度62.13%,成品率80.02%,利用系数1.85t/(m2·h),固体燃耗53.85kg/t-s。分层布料均热烧结比普通烧结可节约固体燃耗3.69kg/t-s。
鉴于分层布料烧结技术的生产实施受现有厂房布局的限制,本论文进一步研究开发了气流辅助布料均热烧结技术。
通过研究烧结混合料在气体流场中的运动规律,查明了不同颗粒在气体流场中运动轨迹的差异性,建立了气流辅助布料实现与原料粒度和燃料分布偏析的理论依据。结合现行烧结生产工艺,在实验室中设计和制造了烧结混和料气流辅助布料试验装置,利用该布料装置,查明了气体流速、喷嘴结构、喷吹位置和倾角等对混合料粒度和燃料分布的影响,获得了优化的偏析布料工艺参数,开发出实现粒度和燃料分布合理偏析的气流辅助布料均热烧结新技术。
以宝钢原料为对象,采用气流辅助烧结技术在实验室进行的烧结试验可将混合料燃料配比降低约8.7%(由4.6%降低至4.2%)此外,烧结矿的成品率由73.26%提高到78.26%,利用系数由1.40t-(m2·h)-1提高到1.46t·(m2·h)-1。
试验结果充分表明气流布料烧结技术能实现烧结料层蓄热的高效利用,不仅显著降低了固体燃料消耗,而且明显提高了烧结矿产量和质量。本研究为降低烧结工序能耗提供了新的方法和技术。气流布料均热烧结技术已在我国宝钢烧结厂实现工业应用,单台烧结机每年效益达602.85万元。
With the rapid development of Chinese steel industry, the total energy consumption of the steel industry continues to rise. In the system of whole steel production, energy consumption of sintering process accounts for15%of the total energy consumption of steel production. It has a great significance to study basic theory and new technology of reducing the energy consumption of sintering process for reducing the comprehensive energy consumption of steel production, saving the cost of production and improving the competitiveness of enterprises.
The consumption of solid fuel accounts for75%-80%of the energy consumption of sintering process. Taking the iron raw materials and fuel from Baosteel and sintering process as research objects in this thesis, the law of the accumulation of heat in sinter layer is revealed through the study of gas kinetics and heat transfer. The new technologies of segregation feeding and airflow feeding which realize the heat-homogenizing sintering by the heat of accumulation are developed, reducing fuel consumption significantly. Particularly, the technology of heat-homogenizing sintering of airflow feeding has been applied into industrial production in Baosteel.
From the study of the accumulation of heat, it can be found that the amount of accumulated heat increases from top to bottom in the material layer during sintering. If the sinter layer with height of700mm is averagely divided into seven units, the total ratios of accumulation of heat from the second to seventh layer are40.37%.54.07%.61.39%.66.60%.70.30%,72.99%successively.
Due to the different heat states of each unit from top to bottom when the sinter cakes leave the sinter machine, it is hard to ascertain the reasonable distribution of fuel for the material layers according to the total accumulation of heat, so the concept of available accumulation of heat is first put forward in this study. The available accumulation of heat is the surplus amount of accumulated heat after deducting the physical heat taken away by the sinter cake, and it is the basis of heat-homogenizing sintering by accumulating heat. Through the study of heat state of every unit and calculation of physic heat, the available accumulations of heat from the second to the seventh unit are38.18%、50.80%.56.84%.60.33%.60.92%.58.39%successively, and therefore the reliable basis is provided for the development of new heat-homogenizing sintering.
On the basis of theory study, the heat-homogenizing sintering technology of distribution feeding is developed firstly. Taking the advantage of distribution feeding, the solid fuel consumption can be reduced significantly on the premise of guaranteeing the output and quality of agglomerate. The results of sintering experiment show that if the mixed material is divided into three layers and the dosage of coke breeze of the upper layer is4.9%, middle layer is4.3%, lower layer is3.3%and the average amount is4.2%, the quality indicators of agglomerate will be as follows:the drum strength of agglomerate62.13%, the yield80.02%, the utilization coefficient1.85t/(m2-h), and solid fuel consumption53.85kg/t-s. The solid fuel consumption of heat-homogenizing sintering is3.69kg/t-s less than the ordinary sintering.
Taking into the consideration that the production application of distribution feeding is limited by the plant layout, the heat-homogenizing sintering technology of airflow feeding is further researched and developed in this thesis.
Through the study of motion character of sinter mixture in the gas flow field, the diversities of motion trails among different particles are found out and the basic theory on segregation of particle size and fuel is established. Combining with the present sintering process, the test device of airflow feeding is designed and manufactured in the laboratory. The influence of airflow speed, nozzle structure, injection position and angel on the distribution of fuel and particle size of mixture is found out by making use of this feeding device and the optimized parameters of segregation feeding process are obtained. The new heat-homogenizing sintering technology of airflow feeding to realize the segregation of particle size and fuel distribution is developed.
Taking the raw material from Baosteel as research object, the fuel proportion of mixture can be reduced by8.7%(from4.6%to4.2%) in the laboratorial sintering experiment by adopting the sintering technology of airflow feeding. In addition, the yield of agglomerate is improved from73.26%to78.26%and the utilization coefficient is raised from1.40t·(m2·h)-1to1.46t·(m2·h)-1.
The results of experiments show that efficient utilization of the accumulated heat of sinter layers can be realized by the sintering technology of airflow feeding, so not only the consumption of solid fuel is significantly reduced, but also the output and quality of sinter product are both raised obviously. The new method and technology are provided in this thesis. The heat-homogenizing sintering technology of airflow feeding has been applied into industry in sintering plant of Baosteel, and the benefit of602.85million yuan can be achieved by single sintering machine every year.
引文
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