铁矿石烧结节能与环保的研究
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摘要
钢铁行业是能源消耗和环境污染的大户，而烧结生产是钢铁生产过程中的一个重要环节，且近年来，随着钢铁产能的不断扩大，烧结行业得到了前所未有的快速发展，烧结过程中的能耗和环境污染问题也日益严重，成为影响钢铁企业可持续发展的一个瓶颈，引起了高度重视。
本文在大量文献调研的基础上，针对武钢目前生产现场的需要以及烧结过程中普遍关心的几个节能和环保问题进行了深入细致的研究。在节能方面，主要从降低固体燃料消耗入手，进行了改善武钢烧结混合料制粒性能研究；熔剂和燃料分加工艺研究；烧结系统漏风率测试新技术及抑制烧结机边缘效应研究；在环保方面，从对烧结废气SO_2的治理入手，进行了降低烧结烟气SO_2排放新工艺的研究。
通过武钢烧结混合料制粒性能的研究，对武钢常用铁矿石的理化性能、同化性以及制粒性能等进行了系统的研究，发现在所有铁矿石中，加拿大精粉（以下简称加粉）的品位最高，硅铝及杂质含量较低，但其粒度组成、亲水性以及同化性都很差，从而导致其制粒性能也很差。为了进一步了解加粉配比对烧结混合料透气性、烧结指标以及烧结矿矿物组成等的影响，特进行了不同加粉配比的烧结试验，结果表明，随加粉配比的增加，混合料制粒性能逐渐变差，混合料透气性及平均粒径呈逐渐下降的趋势，且在试验配矿方案条件下，当加粉配比超过18%时，烧结利用系数及转鼓强度下降，固体燃耗上升，由此得出在高配比加粉条件下，强化制粒是改善武钢烧结矿质量，降低固体燃耗的关键。在此研究结果基础上，本文通过系统的实验室试验和离散元法（DEM）数学模型研究，提出了提高加粉配比、保证混合料制粒效果和烧结矿产质量、降低固体燃料消耗的一系列技术措施，包括优化配矿、使用RB型有机粘结剂、优化制粒参数等，使加粉配比最高达到了32%。
对熔剂和燃料分加工艺研究表明，采用生石灰和无烟煤同时分加工艺，可以有效提高烧结矿的产质量，降低固体燃料消耗，效果显著。且在武钢原料条件下，最理想的分加方案为：生石灰外配比例在65%～80%之间，无烟煤外配比例在75%左右。通过显微镜及扫描电镜观察，发现生石灰和无烟煤同时分加后，烧结矿中复合铁酸钙及原生赤铁矿含量增多，残留熔剂物质及硅酸盐玻璃相减少，且复合铁酸钙多呈细针状交织在一起，中间包裹有原生赤铁矿颗粒，从微观结构上验证了该工艺的合理性。
在对烧结系统漏风率测试新技术的研究中，提出了一种测量烧结机系统漏风率的新方法，该方法首次在废气量计算时考虑了烧结混合料中的水分所产生的水蒸汽，测量简便易行，误差小。采用该方法对武钢两个烧结车间进行了现场测试，结果令人满意。在抑制烧结机边缘效应的研究中，设计了一种新型烧结机台车挡板，其内壁在原来平板结构的基础上增加了两个凸起，凸起高度根据武钢烧结料层的收缩情况设计。工业试验结果表明，使用新型台车挡板后，烧结系统漏风率下降了约3个百分点，台车宽度方向上风量和机尾“红层”分布均匀，有效抑制了烧结机的“边缘效应”。
在对烧结废气SO_2的治理方面，提出了一种降低烧结烟气SO_2排放的新工艺，该工艺与目前烧结烟气脱硫工艺的最大区别是通过在烧结原料中添加某种物质，将烧结过程中产生的SO_2转移到除尘灰中，然后对除尘灰进行浸泡过滤处理，脱除其中的硫、碱金属等有害物质后再返回参加配料，因此属于“过程中控制”，而不是通常的“末端治理”。本工艺对除尘灰提出了三种处理方案，分别是抛弃法、过滤法以及抛弃与过滤相结合的方法，三种方法各有优缺点，在设计过程中可视具体情况合理选取。工业试验结果表明，该工艺脱硫率可达82%，并具有设备投资少、占地面积小、运行成本低等优点。
The steel industry is a big energy consumption and environmental pollution, and the sinteringproduction is an important link in steel production process. and in recent years, with thedevelopment of iron and steel production capacity continues to expand, the sintering industrygained a rapid development of hitherto unknown. The energy consumption and environmentalpollution problems in sintering process is becoming more and more serious, and it has become abottleneck of the sustainable development of iron and steel enterprises, drawing attention of thesociety.
In this paper, on the basis of literature research, aimed at the need of the WISCO production,several energy and environmental issues of concern in sintering process were studied in detail. Inthe aspect of energy saving, mainly from the reduction of solid fuel consumption, studied onimprove the sintering mixture granulation performance of WISCO; The flux and the fuel dividedadding technology research; Study on leakage rate of sintering system test new technology andthe inhibition of edge effect of sintering machine; In the aspect of environmental protection,starting from the sintering pollutant control，studied on the decrease of SO_2emission in sinteringflue gas.
Through the research of sintering mixture granulation performance, the WISCO common ironore physicochemical properties, assimilation and granulation properties were studied, the resultsshowed that in all iron ore, Canada concentrate (Hereinafter referred to as Canada fines) has thehighest grade, and lower silicon, aluminum and impurity content, but its size, hydrophilism andassimilation were very poor, so the granulation performance was very poor. In order to furtherunderstand the effect of Canada fines ratio on permeability, sintering indexes and sinter mineralcomposition, the sintering test of Canada fines proportion were carried on. The results showedthat, with the increase of the Canada fines proportion, the sintering mixture granulationperformance becomes worse, the permeability of the mixture and the average size showed adecreasing trend, and In the test conditions, When the Canada fines ratio is more than18%, thegranulation performance significantly worse, sintering utilization coefficient and the drumstrength decreased significantly, fuel consumption rise. Conclude from this: strengthengranulation is the key of improving sinter quality and reducing fuel consumption in WISCO. Onthe basis of this result, the comprehensive laboratory test and study on mathematical model ofDEM are carried. This paper proposed a series of technical measures to increase Canada finesratio, ensure the granulating effect and sinter yield and quality, and reduce fuel consumption,including optimizing ore proportioning, addition of RB organic binder and selection ofappropriate granulation parameters, and Canada fines ratio finally is up to32%.
Through the study of flux and fuel divided adding technology showed that the process of fluxand fuel divided adding can effectively improve the yield and quality of sinter, reduction of solid fuel consumption obviously. And in WISCO raw material conditions, the ideal divided addingsolution for: Lime with the outside ratio of65%~80%, and anthracite with around75%in theoutside proportion. Through microscopic and SEM observation of sinter by flux and fuel dividedadding process found that the contents of SFCA and primary hematite increased, residual fluxsubstances and silicate glass phases decreased and the tiny-needle-shaped SFCA intertwinedwith each other and embraced primary hematite particles, so the rationalization of this process isvalidated with microscopic structure.
In the study of test technology of the leakage rate of sintering system, a new method wasproposed. In this method, the steam generated by water in mixture was first considered in thecalculation of exhaust volume. The measuring method has the advantages of simple and easy andsmall deviation. Two sintering machines for production site was tested in WISCO, the result issatisfied. In the study of inhibition of edge effect of sintering machine, a new type of trolleybaffle was designed. The new trolley baffle was added two heaves based on the original slabbedconstruction, the height of heaves are designed according to the shrinkage of sinter layer ofWISCO. Industrial tests showed that the leakage rate of sintering system dropped about3percentage points, the air volume in the whole width direction and sintering machine tail "redbeds" were balanced, so the edge effect of the sintering machine was inhibited effectively.
In the aspect of control of sintering waste gas SO_2, a new technology of reducing SO_2emission in sintering flue gas is presented. Unlike other sintering flue gas desulfurizationprocesses, this process is that the SO_2gas generated in the sintering process was transferred todust by adding a substance in sintering material, and then the dust returned to the raw materialsafter soaked and filtered to remove sulfur and alkali metals, so this process belongs to"process-control", not the usual "end-control". In this paper, three methods were proposed todispose the dusts. They are discarding, filtration and a combination of the both. Three methodshave their advantages and disadvantages, in the design process, can reasonable selectionaccording to the concrete circumstance. The industrial test results showed that the desulfurizationrate of this process is up to82%. At the same time, this process has the advantages of lowequipment investment, small occupied area and low operating cost.
本文在大量文献调研的基础上，针对武钢目前生产现场的需要以及烧结过程中普遍关心的几个节能和环保问题进行了深入细致的研究。在节能方面，主要从降低固体燃料消耗入手，进行了改善武钢烧结混合料制粒性能研究；熔剂和燃料分加工艺研究；烧结系统漏风率测试新技术及抑制烧结机边缘效应研究；在环保方面，从对烧结废气SO_2的治理入手，进行了降低烧结烟气SO_2排放新工艺的研究。
通过武钢烧结混合料制粒性能的研究，对武钢常用铁矿石的理化性能、同化性以及制粒性能等进行了系统的研究，发现在所有铁矿石中，加拿大精粉（以下简称加粉）的品位最高，硅铝及杂质含量较低，但其粒度组成、亲水性以及同化性都很差，从而导致其制粒性能也很差。为了进一步了解加粉配比对烧结混合料透气性、烧结指标以及烧结矿矿物组成等的影响，特进行了不同加粉配比的烧结试验，结果表明，随加粉配比的增加，混合料制粒性能逐渐变差，混合料透气性及平均粒径呈逐渐下降的趋势，且在试验配矿方案条件下，当加粉配比超过18%时，烧结利用系数及转鼓强度下降，固体燃耗上升，由此得出在高配比加粉条件下，强化制粒是改善武钢烧结矿质量，降低固体燃耗的关键。在此研究结果基础上，本文通过系统的实验室试验和离散元法（DEM）数学模型研究，提出了提高加粉配比、保证混合料制粒效果和烧结矿产质量、降低固体燃料消耗的一系列技术措施，包括优化配矿、使用RB型有机粘结剂、优化制粒参数等，使加粉配比最高达到了32%。
对熔剂和燃料分加工艺研究表明，采用生石灰和无烟煤同时分加工艺，可以有效提高烧结矿的产质量，降低固体燃料消耗，效果显著。且在武钢原料条件下，最理想的分加方案为：生石灰外配比例在65%～80%之间，无烟煤外配比例在75%左右。通过显微镜及扫描电镜观察，发现生石灰和无烟煤同时分加后，烧结矿中复合铁酸钙及原生赤铁矿含量增多，残留熔剂物质及硅酸盐玻璃相减少，且复合铁酸钙多呈细针状交织在一起，中间包裹有原生赤铁矿颗粒，从微观结构上验证了该工艺的合理性。
在对烧结系统漏风率测试新技术的研究中，提出了一种测量烧结机系统漏风率的新方法，该方法首次在废气量计算时考虑了烧结混合料中的水分所产生的水蒸汽，测量简便易行，误差小。采用该方法对武钢两个烧结车间进行了现场测试，结果令人满意。在抑制烧结机边缘效应的研究中，设计了一种新型烧结机台车挡板，其内壁在原来平板结构的基础上增加了两个凸起，凸起高度根据武钢烧结料层的收缩情况设计。工业试验结果表明，使用新型台车挡板后，烧结系统漏风率下降了约3个百分点，台车宽度方向上风量和机尾“红层”分布均匀，有效抑制了烧结机的“边缘效应”。
在对烧结废气SO_2的治理方面，提出了一种降低烧结烟气SO_2排放的新工艺，该工艺与目前烧结烟气脱硫工艺的最大区别是通过在烧结原料中添加某种物质，将烧结过程中产生的SO_2转移到除尘灰中，然后对除尘灰进行浸泡过滤处理，脱除其中的硫、碱金属等有害物质后再返回参加配料，因此属于“过程中控制”，而不是通常的“末端治理”。本工艺对除尘灰提出了三种处理方案，分别是抛弃法、过滤法以及抛弃与过滤相结合的方法，三种方法各有优缺点，在设计过程中可视具体情况合理选取。工业试验结果表明，该工艺脱硫率可达82%，并具有设备投资少、占地面积小、运行成本低等优点。
The steel industry is a big energy consumption and environmental pollution, and the sinteringproduction is an important link in steel production process. and in recent years, with thedevelopment of iron and steel production capacity continues to expand, the sintering industrygained a rapid development of hitherto unknown. The energy consumption and environmentalpollution problems in sintering process is becoming more and more serious, and it has become abottleneck of the sustainable development of iron and steel enterprises, drawing attention of thesociety.
In this paper, on the basis of literature research, aimed at the need of the WISCO production,several energy and environmental issues of concern in sintering process were studied in detail. Inthe aspect of energy saving, mainly from the reduction of solid fuel consumption, studied onimprove the sintering mixture granulation performance of WISCO; The flux and the fuel dividedadding technology research; Study on leakage rate of sintering system test new technology andthe inhibition of edge effect of sintering machine; In the aspect of environmental protection,starting from the sintering pollutant control，studied on the decrease of SO_2emission in sinteringflue gas.
Through the research of sintering mixture granulation performance, the WISCO common ironore physicochemical properties, assimilation and granulation properties were studied, the resultsshowed that in all iron ore, Canada concentrate (Hereinafter referred to as Canada fines) has thehighest grade, and lower silicon, aluminum and impurity content, but its size, hydrophilism andassimilation were very poor, so the granulation performance was very poor. In order to furtherunderstand the effect of Canada fines ratio on permeability, sintering indexes and sinter mineralcomposition, the sintering test of Canada fines proportion were carried on. The results showedthat, with the increase of the Canada fines proportion, the sintering mixture granulationperformance becomes worse, the permeability of the mixture and the average size showed adecreasing trend, and In the test conditions, When the Canada fines ratio is more than18%, thegranulation performance significantly worse, sintering utilization coefficient and the drumstrength decreased significantly, fuel consumption rise. Conclude from this: strengthengranulation is the key of improving sinter quality and reducing fuel consumption in WISCO. Onthe basis of this result, the comprehensive laboratory test and study on mathematical model ofDEM are carried. This paper proposed a series of technical measures to increase Canada finesratio, ensure the granulating effect and sinter yield and quality, and reduce fuel consumption,including optimizing ore proportioning, addition of RB organic binder and selection ofappropriate granulation parameters, and Canada fines ratio finally is up to32%.
Through the study of flux and fuel divided adding technology showed that the process of fluxand fuel divided adding can effectively improve the yield and quality of sinter, reduction of solid fuel consumption obviously. And in WISCO raw material conditions, the ideal divided addingsolution for: Lime with the outside ratio of65%~80%, and anthracite with around75%in theoutside proportion. Through microscopic and SEM observation of sinter by flux and fuel dividedadding process found that the contents of SFCA and primary hematite increased, residual fluxsubstances and silicate glass phases decreased and the tiny-needle-shaped SFCA intertwinedwith each other and embraced primary hematite particles, so the rationalization of this process isvalidated with microscopic structure.
In the study of test technology of the leakage rate of sintering system, a new method wasproposed. In this method, the steam generated by water in mixture was first considered in thecalculation of exhaust volume. The measuring method has the advantages of simple and easy andsmall deviation. Two sintering machines for production site was tested in WISCO, the result issatisfied. In the study of inhibition of edge effect of sintering machine, a new type of trolleybaffle was designed. The new trolley baffle was added two heaves based on the original slabbedconstruction, the height of heaves are designed according to the shrinkage of sinter layer ofWISCO. Industrial tests showed that the leakage rate of sintering system dropped about3percentage points, the air volume in the whole width direction and sintering machine tail "redbeds" were balanced, so the edge effect of the sintering machine was inhibited effectively.
In the aspect of control of sintering waste gas SO_2, a new technology of reducing SO_2emission in sintering flue gas is presented. Unlike other sintering flue gas desulfurizationprocesses, this process is that the SO_2gas generated in the sintering process was transferred todust by adding a substance in sintering material, and then the dust returned to the raw materialsafter soaked and filtered to remove sulfur and alkali metals, so this process belongs to"process-control", not the usual "end-control". In this paper, three methods were proposed todispose the dusts. They are discarding, filtration and a combination of the both. Three methodshave their advantages and disadvantages, in the design process, can reasonable selectionaccording to the concrete circumstance. The industrial test results showed that the desulfurizationrate of this process is up to82%. At the same time, this process has the advantages of lowequipment investment, small occupied area and low operating cost.
引文
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