澳矿配比对烧结矿性能的影响研究
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摘要
近年来随着我国粗钢产量的突飞猛进,国内各钢铁企业矿石来源日趋紧张,对国外矿石的进口依存度仍居高不下,为了提高高炉产量、改善质量和降低生产成本,钢铁企业必须使用各种不同性能和质量的矿石,从而使得烧结矿性能存在一定的不稳定性。本论文以重钢环保搬迁后新区实际铁矿石资源配置为基础,结合企业现有实际烧结生产配料情况,重点考察了不同澳矿配比条件下烧结物料的基础特性、烧结混合料的制粒性能以及烧结矿的物理及冶金性能,并对混合料加水制粒成球及高温烧结成块过程中的相关机理问题进行了实验研究和理论分析。研究结果对于提高烧结矿资源的利用、改善烧结矿性能以及丰富铁矿石烧结理论具有一定的的理论和现实意义。
论文首先对烧结用原燃料进行了基础特性研究,考察了各物料的化学成分、粒度及比表面分析、吸水特性以及升温过程的热量变化等,为后续研究方案的制定和具体研究工作的开展奠定基础。针对铁矿石吸水特性,根据lagergren一级速率方程建立了铁矿粉吸水宏观动力学模型,获得了水在不同铁矿粉中的传质系数。对于澳矿粉,属于典型的赤铁矿型矿石,升温过程中减重最明显,存在结晶水和易烧损物质最多;澳矿粉是容量最大,粒度分布均匀,>0.7mm的成核粒子较多, 0.2-0.7mm的粘附粒子占20%以上,对制粒成球不利;澳矿颗粒比表面积最大,颗粒孔径和孔体积也最大,属典型的多孔颗粒,易于吸水,其湿容量和吸水传质系数也最高,有利于改善制粒效率。
对烧结混合料制粒性能进行了实验研究和理论分析,获得了具有工业指导意义的研究结果。混合料制粒研究的基本结论是:①随着加水量的增加,物料颗粒经制粒后细小颗粒逐步降低,大颗粒越来越多、尺寸越来越大。当>10mm粒级含量为50%,5～8mm粒级含量为30%,8～10mm粒级的含量为10%,其他粒级含量占10%时生料层的透气性最好。②随着制粒过程中加水量的逐渐增加,烧结料制粒后3~8mm粒级含量经历了由低到高在变低的过程,呈现出典型的倒“V”。透气性指数等其他制粒效果评价指标随着含水量变化也有同样的规律。③存在适宜含水量使得混合物料的制粒效果最佳。④烧结料制粒适宜含水量随着烧结料湿容量的增大而增大,二者存在显著的线性关系。铁矿石烧结研究的主要结论为:①以烧结矿物理性能转鼓强度,落下强度,抗磨指数和成品率为依据,结合其他参考标准(如烧结时间,温度等),筛选出的适用于烧结生产的11组配料方案,并进行了重现性实验;②进行了烧结矿冶金性能实验,未添加冷固球团的2#和18#配比以及添加冷固球团的30#配比,有良好的低温还原粉化指数;未添加冷固球团的18#的还原度最好,添加冷固球团后,30#的还原度较好;对于高温熔融滴落性能,未添加冷固球团时,18#的高温熔融滴落性能较好,添加冷固球团后,30#的高温熔融滴落性能也较好。依据烧结矿冶金性能实验及分析,筛选出18#和冷固30#为获得良好物理性能的配矿方案。③与烧结实验优选的18#和冷固30#相比,采用重钢实际生产用混合料实验室烧结获得的烧结矿具有良好的物理性能,低温还原粉化指数,不足是烧结速度、还原度、高温熔融滴落性能偏小。综合分析看来,18#和冷固30#的配矿方案可以满足重钢实际生产需要。④各指标综合考虑,当澳粉加入量为55%时,烧结矿物理性能指标与成品率相对较优。⑤添加冷固球团可以提高烧结矿的物理性能,如转鼓指数,落下强度,抗磨指数等指标相对稳定或有一定程度的提升;对烧结矿的低温还原粉化指数有一定的改善。缺点是垂直烧结速度变慢;烧结矿还原度有所下降;对烧结矿熔融滴落性能有一定的不利影响。可以通过控制冷固球团的添加量来改善烧结矿的物理强度,但是不宜配加过量。
针对高温烧结过程烧结液相生成,采用Factsage软件计算了烧结液相量、理论燃烧比以及复合铁酸钙等温液相线图,考察了Al2O3和MgO对烧结矿液相生成的影响,计算结果与表明Factsage用于烧结矿理论计算是可信的,可以有效地指导烧结燃料配加量和合理配矿,以获得良好性能的烧结矿。
建立了烧结料层蓄热模型。燃烧层厚度和燃烧层反应完后产生的废气热量在各层的分配对烧结过程中各单元层的热量蓄积有很大的影响,随着燃烧层厚度增加,各单元层蓄积的热量值逐渐降低,料层的蓄热量也逐渐降低;随着热量给预热层分配的增加,单元层蓄热量逐渐增加,料层的热量蓄积值也逐渐增加;通过应用模型对300mm烧结料层进行热量蓄积计算,得到料层上、中、下的蓄热量比为1∶1.08∶1.13;烧结杯实验结果得到,当料柱各层燃料配加比上、中、下层分别为5. 2 %、3. 1 %、2. 7 %时,各种烧结结果参数比较理想。
论文主要创新性研究成果为:建立了铁矿石制粒过程吸水动力学模型,并得到了不同烧结物料中水的传质系数,结合单矿湿容量的测定,可以有效地指导烧结制粒过程加水量的控制,具有较好的理论和实际意义;进行了高配比澳矿条件下的烧结矿理化及冶金性能研究,研究结果对于高配比条件下的烧结生产及高炉冶炼具有较好的指导意义;采用Factsage计算了烧结过程液相铁酸钙不同成分条件下的等温线图,考察了物料成分对液相生成的影响,对烧结过程工艺调控和优化烧结矿质量具有较好的理论指导;
With the crude steel yield in China increasing rapidly these recent years, the source of iron ore tends to become increasingly strained, and the import dependence of iron ore remains extraordinary high for several years. In order to improve the blast furnace output, to enhance the product properties and to decrease the production cost, many kinds of iron ore with different property and quality has been used in China steel enterprises, which result in the unstable iron ore sinter performance. Based on the practical iron ore resource distribution of Chongqing Iron and Steel Co. Ltd. (CISC), the basic characteristics of raw materials, the granulation property of sintering blend and the physical and metallurgical properties of iron ore sinter have been investigated, the relative mechanism during the blend granulating and the high temperature sintering has been also studied by experimental research and theoretical analyse. The investigation results have certain theoretical contributions and practical significance for the iron ore resource utilization efficiency, the sinter property improvement and the iron ore sintering theory enrichment.
In this study, the basic characteristics of the raw materials were investigated firstly, including the chemical composition, the size distribution and specific area, the moisture absorption capacity and the thermal change during the heating process. According to the Lagergren first order rate equation, a macro dynamics model of water absorbing of iron ore fines were established and the water mass transfer coefficient were obtained. The Australia iron ore fines are the classical hematite, which contents crystal water and carbonate and have obvious loss when it was heated; the Australia iron ore fines have the largest moisture capacity and homogeneous size distribution, there are more particles greater than 0.7mm and the particles between 0.2 to 0.7mm contains 20%, which have the negative influence to the granulation effect; The Australia iron ore have the larhest specific area and the diameter and the volume of micropore, which is the classical porous particles and easy to absorb water; The Australia iron ore have the largest moisture capacity and water mass transfer coefficient, which can improve the granulation efficiency.
The conclusion of the study of mixture granulation are as follows:①with the water content increases, the small size particles decreases; When the blend contens 50% gtain with size grater than 10mm, 30% with 5-8mm, 10% with 8-10mm and 10% with other size, the green ball bed have the best permeability.②With the water input increases, the content of 3-8mm size changes with the trend of the curve with the classical curve of reverse V.③An adapted water content corresponding to the best granulation effect.④A linear realation exist between the adapted water content and the moisture capacity. The conclusion of the iron ore sintering experiment are as follows:①Accorrding to the test of the iron ore sinter physical properties, 11 group of mixture ratio are chosen to conduct the reproducibility test.②The metallurgical properties of the samples were measured and the 18# and the 30# with cold set pellet added were selected as the best one.③When the Australia iron ore mix ratio is 55%, the sinter retain the best properties.④The adding of cold set pellet can improve the sinter physical properties such as the Tumbler strength, abrasion index and Shatter strength.
The Factsage software were used to calculate the mass of the liquid phase of the sitering of iron ore, the theoretical fuel ratio and the isothermal line for the liquid phase SFCA. The influence of the content Al2O3 and MgO on the liquid phase generating were conducted, the calculated result shows that it is reliable to use the Factsage software to proceed the theoretical computation of the sintering, which can instruct the suitable fuel addition an the rational mixture ratio to get the good sinter property.
This assignment brings forward the calculation model of accumulation heat and fuel distribution along the bed. Mathematical model of accumulation heat in sinter layers is founded and Matlab program is compiled. It is subject to the sintering materials of Chongqing Iron and Steel Corp. The heat balance and auto accumulation heat of layers is calculated in the sintering process. The result of the best fuel distribution model is achieved after sintering experiment validated. All of this make heat of layer distribute reasonably and sinter layers remain high temperature stability, achieve the result of high-quality, high-yield, low fuel consumption sintering. Figure which is via to model calculation shows that, heat accumulation quantity in lower layers is gradually increased. Dividing the bed into 3 layers, the ratio of upper, middle and lower bed’s heat accumulation is 1:1.08:1.13. Resulted from sintering pot test for the best segregate feed of fuel, it was shown that when the upper bed is 5.2%, the middle bed is 3.1%,the lower bed is 2.7%.
The innovative research works are as follows: The dynamic classification diagram was obtained by the classification model. It realized the dynamic classification of iron ore in CISC. The impacts of mixture properties on the properties of sinter ore were studied via single factor analysis and range analysis. Influence of the carbon mixture ratio is more significant than that of other mixture properties on the properties of sinter ore in addition to reducibility. Basicity and temperature were propitious to the production of liquid-phase.The appropriate amount of carbon mixture ratio could be determined on the base of relationship between amount of liquid-phase and temperature. The results showed that the applications of model are benefit for guiding experiments and production.
论文首先对烧结用原燃料进行了基础特性研究,考察了各物料的化学成分、粒度及比表面分析、吸水特性以及升温过程的热量变化等,为后续研究方案的制定和具体研究工作的开展奠定基础。针对铁矿石吸水特性,根据lagergren一级速率方程建立了铁矿粉吸水宏观动力学模型,获得了水在不同铁矿粉中的传质系数。对于澳矿粉,属于典型的赤铁矿型矿石,升温过程中减重最明显,存在结晶水和易烧损物质最多;澳矿粉是容量最大,粒度分布均匀,>0.7mm的成核粒子较多, 0.2-0.7mm的粘附粒子占20%以上,对制粒成球不利;澳矿颗粒比表面积最大,颗粒孔径和孔体积也最大,属典型的多孔颗粒,易于吸水,其湿容量和吸水传质系数也最高,有利于改善制粒效率。
对烧结混合料制粒性能进行了实验研究和理论分析,获得了具有工业指导意义的研究结果。混合料制粒研究的基本结论是:①随着加水量的增加,物料颗粒经制粒后细小颗粒逐步降低,大颗粒越来越多、尺寸越来越大。当>10mm粒级含量为50%,5～8mm粒级含量为30%,8～10mm粒级的含量为10%,其他粒级含量占10%时生料层的透气性最好。②随着制粒过程中加水量的逐渐增加,烧结料制粒后3~8mm粒级含量经历了由低到高在变低的过程,呈现出典型的倒“V”。透气性指数等其他制粒效果评价指标随着含水量变化也有同样的规律。③存在适宜含水量使得混合物料的制粒效果最佳。④烧结料制粒适宜含水量随着烧结料湿容量的增大而增大,二者存在显著的线性关系。铁矿石烧结研究的主要结论为:①以烧结矿物理性能转鼓强度,落下强度,抗磨指数和成品率为依据,结合其他参考标准(如烧结时间,温度等),筛选出的适用于烧结生产的11组配料方案,并进行了重现性实验;②进行了烧结矿冶金性能实验,未添加冷固球团的2#和18#配比以及添加冷固球团的30#配比,有良好的低温还原粉化指数;未添加冷固球团的18#的还原度最好,添加冷固球团后,30#的还原度较好;对于高温熔融滴落性能,未添加冷固球团时,18#的高温熔融滴落性能较好,添加冷固球团后,30#的高温熔融滴落性能也较好。依据烧结矿冶金性能实验及分析,筛选出18#和冷固30#为获得良好物理性能的配矿方案。③与烧结实验优选的18#和冷固30#相比,采用重钢实际生产用混合料实验室烧结获得的烧结矿具有良好的物理性能,低温还原粉化指数,不足是烧结速度、还原度、高温熔融滴落性能偏小。综合分析看来,18#和冷固30#的配矿方案可以满足重钢实际生产需要。④各指标综合考虑,当澳粉加入量为55%时,烧结矿物理性能指标与成品率相对较优。⑤添加冷固球团可以提高烧结矿的物理性能,如转鼓指数,落下强度,抗磨指数等指标相对稳定或有一定程度的提升;对烧结矿的低温还原粉化指数有一定的改善。缺点是垂直烧结速度变慢;烧结矿还原度有所下降;对烧结矿熔融滴落性能有一定的不利影响。可以通过控制冷固球团的添加量来改善烧结矿的物理强度,但是不宜配加过量。
针对高温烧结过程烧结液相生成,采用Factsage软件计算了烧结液相量、理论燃烧比以及复合铁酸钙等温液相线图,考察了Al2O3和MgO对烧结矿液相生成的影响,计算结果与表明Factsage用于烧结矿理论计算是可信的,可以有效地指导烧结燃料配加量和合理配矿,以获得良好性能的烧结矿。
建立了烧结料层蓄热模型。燃烧层厚度和燃烧层反应完后产生的废气热量在各层的分配对烧结过程中各单元层的热量蓄积有很大的影响,随着燃烧层厚度增加,各单元层蓄积的热量值逐渐降低,料层的蓄热量也逐渐降低;随着热量给预热层分配的增加,单元层蓄热量逐渐增加,料层的热量蓄积值也逐渐增加;通过应用模型对300mm烧结料层进行热量蓄积计算,得到料层上、中、下的蓄热量比为1∶1.08∶1.13;烧结杯实验结果得到,当料柱各层燃料配加比上、中、下层分别为5. 2 %、3. 1 %、2. 7 %时,各种烧结结果参数比较理想。
论文主要创新性研究成果为:建立了铁矿石制粒过程吸水动力学模型,并得到了不同烧结物料中水的传质系数,结合单矿湿容量的测定,可以有效地指导烧结制粒过程加水量的控制,具有较好的理论和实际意义;进行了高配比澳矿条件下的烧结矿理化及冶金性能研究,研究结果对于高配比条件下的烧结生产及高炉冶炼具有较好的指导意义;采用Factsage计算了烧结过程液相铁酸钙不同成分条件下的等温线图,考察了物料成分对液相生成的影响,对烧结过程工艺调控和优化烧结矿质量具有较好的理论指导;
With the crude steel yield in China increasing rapidly these recent years, the source of iron ore tends to become increasingly strained, and the import dependence of iron ore remains extraordinary high for several years. In order to improve the blast furnace output, to enhance the product properties and to decrease the production cost, many kinds of iron ore with different property and quality has been used in China steel enterprises, which result in the unstable iron ore sinter performance. Based on the practical iron ore resource distribution of Chongqing Iron and Steel Co. Ltd. (CISC), the basic characteristics of raw materials, the granulation property of sintering blend and the physical and metallurgical properties of iron ore sinter have been investigated, the relative mechanism during the blend granulating and the high temperature sintering has been also studied by experimental research and theoretical analyse. The investigation results have certain theoretical contributions and practical significance for the iron ore resource utilization efficiency, the sinter property improvement and the iron ore sintering theory enrichment.
In this study, the basic characteristics of the raw materials were investigated firstly, including the chemical composition, the size distribution and specific area, the moisture absorption capacity and the thermal change during the heating process. According to the Lagergren first order rate equation, a macro dynamics model of water absorbing of iron ore fines were established and the water mass transfer coefficient were obtained. The Australia iron ore fines are the classical hematite, which contents crystal water and carbonate and have obvious loss when it was heated; the Australia iron ore fines have the largest moisture capacity and homogeneous size distribution, there are more particles greater than 0.7mm and the particles between 0.2 to 0.7mm contains 20%, which have the negative influence to the granulation effect; The Australia iron ore have the larhest specific area and the diameter and the volume of micropore, which is the classical porous particles and easy to absorb water; The Australia iron ore have the largest moisture capacity and water mass transfer coefficient, which can improve the granulation efficiency.
The conclusion of the study of mixture granulation are as follows:①with the water content increases, the small size particles decreases; When the blend contens 50% gtain with size grater than 10mm, 30% with 5-8mm, 10% with 8-10mm and 10% with other size, the green ball bed have the best permeability.②With the water input increases, the content of 3-8mm size changes with the trend of the curve with the classical curve of reverse V.③An adapted water content corresponding to the best granulation effect.④A linear realation exist between the adapted water content and the moisture capacity. The conclusion of the iron ore sintering experiment are as follows:①Accorrding to the test of the iron ore sinter physical properties, 11 group of mixture ratio are chosen to conduct the reproducibility test.②The metallurgical properties of the samples were measured and the 18# and the 30# with cold set pellet added were selected as the best one.③When the Australia iron ore mix ratio is 55%, the sinter retain the best properties.④The adding of cold set pellet can improve the sinter physical properties such as the Tumbler strength, abrasion index and Shatter strength.
The Factsage software were used to calculate the mass of the liquid phase of the sitering of iron ore, the theoretical fuel ratio and the isothermal line for the liquid phase SFCA. The influence of the content Al2O3 and MgO on the liquid phase generating were conducted, the calculated result shows that it is reliable to use the Factsage software to proceed the theoretical computation of the sintering, which can instruct the suitable fuel addition an the rational mixture ratio to get the good sinter property.
This assignment brings forward the calculation model of accumulation heat and fuel distribution along the bed. Mathematical model of accumulation heat in sinter layers is founded and Matlab program is compiled. It is subject to the sintering materials of Chongqing Iron and Steel Corp. The heat balance and auto accumulation heat of layers is calculated in the sintering process. The result of the best fuel distribution model is achieved after sintering experiment validated. All of this make heat of layer distribute reasonably and sinter layers remain high temperature stability, achieve the result of high-quality, high-yield, low fuel consumption sintering. Figure which is via to model calculation shows that, heat accumulation quantity in lower layers is gradually increased. Dividing the bed into 3 layers, the ratio of upper, middle and lower bed’s heat accumulation is 1:1.08:1.13. Resulted from sintering pot test for the best segregate feed of fuel, it was shown that when the upper bed is 5.2%, the middle bed is 3.1%,the lower bed is 2.7%.
The innovative research works are as follows: The dynamic classification diagram was obtained by the classification model. It realized the dynamic classification of iron ore in CISC. The impacts of mixture properties on the properties of sinter ore were studied via single factor analysis and range analysis. Influence of the carbon mixture ratio is more significant than that of other mixture properties on the properties of sinter ore in addition to reducibility. Basicity and temperature were propitious to the production of liquid-phase.The appropriate amount of carbon mixture ratio could be determined on the base of relationship between amount of liquid-phase and temperature. The results showed that the applications of model are benefit for guiding experiments and production.
引文
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