A New Approach for the Wear Failure Risk of Copper Staves in Blast Furnaces

Copper staves are widely used as cooling systems for blast furnaces. Since the inside wall of the furnaces are completely covered with copper staves, the failure of the system plays a significant role for premature blast furnace relining. Especially the bosh area is the critical part of blast furnaces because it faces high heat load. The damage to the bosh area directly affects the service period of BF’s. The lifetime of furnaces can be prolonged considerably by preventing the premature damage of this section. For this purpose, a new approach has been introduced to define the premature risk factor of copper staves based on design and operation parameters. The data of 34 different blast furnaces obtained from the members of World Steel Assoc. are applied to this new approach to calculate the premature risk factors. The results are recorded and analyzed according to service lifetime and actual wear situations of copper staves. Finally, all these analyzes show that the new approach, which is represented in this paper can be a new design check parameter for blast furnaces and a practical solution to define the premature wear risk of copper staves. Therefore, blast furnace designers and users can extend the blast furnace lifetime by using this new approach resulting in high economic benefits.     

安钢高炉生产和炉体破损调查研究

安钢2座380m^3高炉第一代炉役经济技术指标相差较大。结合大修前炉体破损情况,对这2座高炉第一代炉役生产中出现的问题进行调查研究,认为7号高炉在应用大型模块和炉腰冷却壁设计上存在不足,高炉边缘气流发展,操作炉型不合理,炉况不顺;7号高炉炉底温度偏高是炉底炭砖渗铁造成的,6号高炉炉底温度偏高是炉底串煤气所致;7号高炉铁口失常的主要原因是铁口组合砖损坏严重和该部位炉壳开裂,并提出了改进建议。     

解决中天钢铁高炉炉壳上涨实践

 高炉炉壳上涨是近几年钢铁企业部分高炉面临的一个难题,控制高炉炉壳上涨对高炉的长寿、安全稳定运行有重要意义。针对中天高炉炉壳上涨问题,以压力容器盲板力的计算为依据,结合长期分析和治理实践,明确了高炉炉壳上涨的关键原因是由炉内压力产生的盲板力所导致;并给出了高炉炉壳上涨的5个具体步骤,炉底板变形,炉内耐材变形,耐材之间出现缝隙,有害金属沿着缝隙富集,炉壳逐步长高。在此基础上,针对性地研发了双炉底板结构,并在中天钢铁的多座高炉上进行了成功应用,解决了高炉炉壳上涨的难题。将探索高炉炉壳上涨原因的焦点从原料、操作、施工和耐材材质等方面转向高炉炉底板自身强度上。     

Diagnostics of blast-furnace linings

Hatch (Canada) has developed a system for the nondestructive monitoring of the residual lining thickness in blast furnaces and eletrofurnaces. This system, which is based on an acoustic–ultrasound echo signal (AU-E), supplements the traditional thermal simulation of the furnace lining by means of built-in thermocouples or on the basis of the thermal load on the cooling units in the blast furnace. By this means, the position of cracks and anomalies may be determined, and the boundary between the coating and the refractory may be identified. The constraints and sources of error in the AU-E method are analyzed, and an improved version is outlined. The improved method takes account of the influence of the following factors on the wave propagation: high temperatures; the furnace shape and size; and the difference in acoustic resistance of different layers in a multilayer refractory lining. The AU-E method permits reliable and nondestructive monitoring of the refractory lining in smelting furnaces. The hardware and software of the AU-E system have been significantly improved, so as to obtain measurements of satisfactory accuracy. Estimates of the method’s precision are confirmed by physical measurements on inoperative blast furnaces. Examples of the utilization of this diagnostic system at various Russian and non-Russian plants are presented. Some technological measures that extend the blast-furnace run are noted. As shown in the present study, the use of several successive measurements permits the determination of the lining’s wear rate and the time remaining before major repair. The AU-E method continues to operate well at more than 70 blast furnaces around the world, including those at the Novolipetsk, Cherepovets, Nizhny Tagil, Western Siberian, and Magnitogorsk steel works, as well as at electrofurnaces producing ferroalloys, copper, and platinum.     

欧洲高炉长寿技术发展现状

介绍了欧洲高炉炉缸设计,包括炉缸死铁层深度、冷却系统以及炉缸耐火材料内衬设计。指出耐火材料要与较深的死铁层相匹配,并介绍了一些高炉炉缸耐火材料设计实例;同时还介绍了欧洲高炉炉腹、炉腰和炉身下部采用的冷却技术,以及塔塔克鲁斯艾莫伊登铜冷却板配石墨/半石墨整体式设计,得出可供我们借鉴的欧洲高炉长寿经验。     

高炉高风温问题的探讨

分析全国重点钢铁企业和首钢历年年均风温的变化,介绍了首钢近年提高高炉风温情况。分析了近年首钢各厂区高炉的年均风温,结合1 250℃以上月均风温的实例,说明迁钢2号高炉高风温实践是首钢高炉风温进步的主要标志。讨论了与高风温紧密关联的工艺流程、设备及材料、原燃料和高炉操作等问题。高风温是1项综合技术,与大喷煤、富氧等技术融为一体,才能充分发挥其节能作用。     

高炉本体内衬耐火材料技术进步

介绍了宝钢自1985年1号高炉建成投产以来,包括大修工程在内的共6座高炉的内衬用耐火材料的技术进步。     

高炉本体内衬耐火材料技术进步

介绍了宝钢自1985年1号高炉建成投产以来,包括大修工程在内的共6座高炉的内衬用耐火材料的技术进步。     

高炉大型化后对焦炭性质及在炉内劣化的思考

 焦炭作为高炉炼铁的主要燃料,对高炉的顺行和高效冶炼发挥着极其重要的作用,随着高炉大型化和智能化的发展,对焦炭质量及对其的评价、预测和控制的要求亦越来越高。针对高炉内不同部位焦炭的劣化经历、劣化后焦炭的高温反应特性及焦炭组织结构的变化进行了分析。依据国内一些特大型高炉的生产实践,提出了在达到高水平高炉操作指标时不同容积高炉焦炭高温反应特性所需的指标,并对适合评价高炉大型化焦炭劣化后质量的标准做了探讨。     

烧成微孔铝炭砖在高炉上的应用

烧成微孔铝炭砖具有优良的使用性能，是一种适合高炉炉缸到炉身中部区域的新型优质耐火材料。该砖已在１４座大型高炉上推广应用，使用效果良好。     

Monitoring the wear of the refractory lining in the blast-furnace hearth

The Razgar Gorna computer program is developed for calculating two-dimensional temperature fields in any vertical and horizontal cross section of the blast-furnace hearth. In the calculations, the heat-conduction equations are solved by means of readings from many temperature sensors (up to 1000, depending on the volume) installed within the furnace lining between the refractory modules. Continuous temperature monitoring at each point permits the determination of the remaining lining thickness and prediction of the onset of lining wear, as necessary. A mathematical model is employed in continuous temperature monitoring of the lining. The database of the Razgar Gorna program relies on the collection, analysis, and transmission of information from the temperature or heat-flux sensors. The program is in use at blast furnaces in Chinese steelworks at Jinan (two furnaces), Jiyuan, and Liuzhou.     

高炉大型化与我国高炉的发展状况

论述了世界高炉大型化发展情况，指出世界高炉大型化的发展过程是以建造大型，巨型高炉逐步淘汰小，中型高炉，而我国在建造大，中型高炉的同时小型高炉也蜂拥而上，星罗密布，这些地小高炉设备水平落后，生产效率低，造成矿产资源和能源严重浪费和对环境的严重污染。     

高炉富氧喷煤条件下理论燃烧温度的即时算法

计算高炉富氧喷煤条件下理论燃烧温度有多种公式，但多不便于现场使用。本文提出的理论燃烧温度新型算法直接利用高炉操作仪表参数，计算结果可以较好地指导高炉操作。以某厂高炉实际数据说明了该算法的正确性和实用性。     

高炉炉缸炉底破损研究

根据近年来武钢2座大型高炉破损调查的资料,分析炉缸、炉底耐火材料破损的特征和原因。炉缸、炉底产生环形裂缝的主要原因是碱金属和锌的侵蚀,重点讨论锌对产生环形裂缝的影响。基于对炉衬侵蚀机理的分析,提出了能满足炉缸、炉底长寿要求的适宜的耐火材料。用于炉缸、炉底的耐火材料应具备导热率高、微孔或超微孔、抗铁水渗透性好和抗铁水熔蚀性好等性能。     

The production and development of large blast furnaces in China during 2015

The development of large blast furnaces in China is crucial for energy saving, emission reduction and transformation and promotion processes of iron and steel industry. However, the development of large blast furnaces in China was affected by the lower stability state and lack of new technology developments. In this article, the operation indexes of large blast furnaces of China in 2015 were introduced. Then the reasons for lower stability state of large blast furnaces were analysed and some improved measures were proposed. In addition, some new technical thoughts on the development of large blast furnaces were also proposed.     

长寿高炉使用真正的微孔炭砖的必要性

 针对目前出现的高炉炉缸烧穿和短寿的情况,对其中一些高炉用的炭砖进行了解剖分析。结果发现：高炉炉缸烧穿和短寿的最主要原因是所用的炭砖质量太差。进口热压小炭砖是全部或部分采用电极石墨为原料生产的炭砖,而且不是微孔炭砖。某些高炉所采用的国产微孔炭砖和半石墨炭砖均为假冒伪劣产品。这些炭砖的生产工艺和技术已倒退到用普煅无烟煤生产普通炭砖的水平,而且由于加入大量电极石墨,使用效果还不如普通炭砖。为扭转高炉出现短寿的被动局面,建议采用岩相检验方法鉴别真假微孔炭砖,保证使用炭砖的高炉长寿。     

邯钢高炉炉料结构优化研究

结合邯钢高炉的现有原料条件,通过对邯钢高炉人炉含铁炉料进行还原性、低温还原粉化及熔滴性能的试验研究,分析了不同含铁原料和综合炉料结构的冶金性能,指出了在当前原料条件下邯钢高炉炉料结构的合理搭配,为实际生产提供了理论依据。     

Application of the triad of blast furnace,oxygen converter,and electric arc furnace for reducing of carbon footprint

Carbon footprint is the mass of carbon formed in the full cycle of manufacturing one kind or another product. This carbon is included in greenhouse gases. During production of iron and steel are generated carbon monoxide and greenhouse gases: methane, and carbon dioxide. Methane and carbon monoxide burn to carbon dioxide by secondary energy resources. By this means, the carbon footprint by the production of iron and steel has determined by the weight of carbon dioxide formed in this production. As results of analysis of the processes of manufacture of iron and steel, it has revealed that the tandem of blast furnace with electric arc furnace is characterized by a lower value of integrated emissions of CO₂ than the tandem of blast furnace with an oxygen converter. It was proposed to process of the cast iron made by one blast furnace, then in the oxygen converter, and, at last, in one or more electric arc furnaces. Moreover, the electric arc furnace is loaded by 30% of iron produced in blast furnace, and the remaining 70% are complemented by metal scrap. In the oxygen converter is loaded, the part of cast iron (75–85%), that remained after processing in the arc furnace. The converter is applied the metal scrap for full loading. Calculations of total emission of carbon dioxide for different triads of these units are made. Simultaneous use of oxygen converter with electric arc furnaces for cast iron smelting (obtained from one blast furnace) helps to reduce reliably the emission of carbon dioxide to 20% as it is follows from these calculations. This suggests that such a triad of used units conforms to green technology. Example of the use of mentioned triad is for a full load of the converter applied to metal scrap. The calculations total emissions of carbon dioxide for different triads of these units were performed. From these calculations it follows that the simultaneous use of oxygen converters after electric arc furnaces for smelting iron (obtained from one blast furnace), it helps to reduce the emission of carbon dioxide to 20%. This suggests that this triad of used units conforms to green technology. An example of using this triad is in the Magnitogorsk Iron and Steel Works, where along with the oxygen converter, electric arc furnaces with the use of locally produced electricity at burning fuel of secondary energy resources from units, in which the fuel is burnt. This practice can be recommended for a number of other metallurgical enterprises.     

Improving blast-furnace operation by optimizing the natural-gas and oxygen consumption

The goal is to improve the operation of a group of blast furnaces by redistribution of the available energy resources between them. Analysis of production data yields the energy characteristics of the blast furnaces. Consumption figures are used to develop recommendations regarding the rational distribution of energy resources between the furnaces so as to reduce the overall coke consumption by 2.0?C2.5 kg/t of hot metal. The optimal theoretical combustion temperature in all the furnaces may be derived by correlation calculations and used to determine the optimal ratio of oxygen and natural-gas consumption. In furnace operation at near-optimal temperature, the coke consumption is reduced by 0.40?C0.90 kg/t of hot metal, while the productivity rises by 1.2?C3.1%.     

高炉喷吹焦炉煤气技术的研究进展

综述了国外高炉风口喷吹焦炉煤气(COG)技术的研究进展,包括瑞典律勒欧使用风口理论模型模拟高炉风口喷吹焦炉煤气,奥钢联林茨厂和维也纳大学联合对高炉风口采用单、双枪喷吹焦炉煤气的模拟研究,以及喷吹焦炉煤气时在炉子下部形成CO和H2的还原能力分析。介绍了日本高炉炉身喷吹焦炉煤气的基础研究。也介绍了喷吹焦炉煤气的工业高炉及相关结果,其经验可供钢铁企业鉴借。