太钢高炉炉底炉缸长寿探讨

通过分析计算确定了太钢3号高炉侵蚀预测数学模型。为了保障高炉生产的安全,根据太钢3号高炉热电偶历史最高数据预测了炉缸炉底侵蚀状况。同时应用该软件分析铁水流动、耐材导热系数、死铁层深度和高炉异常对炉缸炉底的侵蚀影响,并得出炉缸炉底长寿的若干推论,对评价目前侵蚀状况和护炉及未来太钢长寿高效高炉的建设提出若干参考意见。     

昆钢新区2500m~3高炉炉缸炉底侵蚀模型

为了分析投产初期高炉炉缸炉底的温度分布情况,以经典传热模型为基础,采用有限元计算技术,建立了昆钢新区2 500 m~3高炉炉缸炉底侵蚀模型。本模型以高炉开炉初期温度为基础,绘制出炉缸炉底温度场分布曲线,模型计算值与热电偶实测值相比,误差在-6.52%~+7.69%的范围内,表明模型计算较为准确。根据模型计算结果,提出了加长风口小套长度、提高鼓风动能和加大死铁层厚度等工作建议,为制定高炉合理的操作维护方针和完善高炉长寿设计提供重要参考。     

武钢1号高炉炉底与炉缸长寿新技术

武钢1号高炉改造性大修，炉底与炉缸采用长寿新技术：增大炉缸容积，加深死铁层；选用半石墨炭砖和德国的高密质炭砖；炉底冷却采用软水密闭循环，以及设置完善的检测设施。总结运用钒钛矿护护经验，以减缓或消除炉底与炉缸“环缝”、“熔洞”、“蒜头状”侵蚀，达到炉底、炉缸高校长寿的目的。     

高炉炉缸炉底长寿实践

介绍杭钢高炉炉缸炉底结构的发展变化情况,分析了几种炉缸结构和内衬材质的特点和应用效果,经多年探讨和发展,杭钢高炉长寿达到了国内先进水平。     

马钢2500m~3高炉炉底炉缸侵蚀模型的研究

针对马钢2500m~3高炉,利用有限元法、两点法及两者相结合的方法,开发了高炉炉底、炉缸侵蚀的数学模型,该模型可离线或在线监测高炉炉底、炉缸侵蚀状况。研究结果表明,高炉炉底、炉缸1150℃侵蚀线处于第七层碳砖的中部位置,形如“象脚“。因此,认为高炉炉底、炉缸侵蚀状况基本正常。     

长寿高炉炉缸的设计

结合高炉炉缸的侵蚀机理，分析了当前国内外高炉常用的炉缸结构，详细对比了各种炉缸结构的性能，提出了高冶炼强度和强化操作下长寿高炉炉缸设计的参考意见。     

高炉炉缸炉底结构设计研究

简述了高炉炉缸炉底结构发展的过程及目前国外高炉炉缸炉底所采用的形式；介绍了鞍钢７号高炉炉缸炉底的设计情况，并总结了其采用的陶瓷杯结构和半石墨化碳砖的优点。     

莱钢2~#高炉炉底炉缸侵蚀分析与长寿改造

莱钢2#高炉因炉缸侧壁温度异常升高而停炉大修,在炉缸炉底拆除过程中,发现炉缸出现象脚侵蚀,炉底出现锅底状侵蚀等异常侵蚀现象。通过选用优质耐材、优化砌筑结构、完善炉底侵蚀监测系统,对高炉炉缸炉底进行了长寿改造,达到了预期效果。     

延长高炉炉缸寿命的技术措施

介绍了3种典型炉缸结构的特点及在我国高炉的应用效果;对合理死铁层深度进行了分析,并介绍了近年世界上新建的部分高炉的死铁层深度及死铁层深度与炉缸直径之比。介绍了目前已获得应用的炉缸状态监测技术,以及实践证明较好的炉缸缝隙压浆和护炉新技术。指出强化冶炼情况下,炉缸死铁层深度应至少为炉缸直径的20%;炉缸出现缝隙时,用重油压浆比用碳糊效果好;如能开发出含钛化物的炭砖,既能起到较好护炉作用,又不会像添加含钛矿那样会造成焦比升高。     

Heat Transfer Modelling of a Blast Furnace Hearth

This paper describes the development of a heat transfer model with the purpose of studying the heat flows in the hearth of an operating blast furnace. Temperature profiles were calculated for a period of time to study the transition from steady blast furnace operation to an unsteady period, and back to a steady period. This total time period had the highest lining temperatures registered since the beginning of the current campaign. It was concluded that no part of the lining had an inner temperature higher than the critical temperature of 1150 °C. Thus, no refractory could have been in direct contact with slag or iron. The corner between the wall and the bottom was identified to be the most sensitive part of the lining. It is suggested that thermocouples are installed in this area, to improve the temperature control.     

长寿高炉炉缸和炉底温度场数学模型及数值模拟

高炉炉缸和炉底的寿命是影响高炉长寿的关键因素之一。实现高炉炉缸、炉底与高炉寿命同步的措施之一就是在高炉炉缸和炉底冻结一层渣铁壳。要想冻结渣铁壳,在高炉设计时应将1150℃等温线推离炉缸和炉底热面,这就需要计算高炉炉缸和炉底的温度场。为此讨论了目前应用于高炉炉缸和炉底温度场的一些数学模型,并在此基础上开发了通用的炉缸、炉底温度场计算软件。     

高炉炉缸长寿探讨

从炉缸结构设计关键要素的分析着手,从侵蚀机制、炉缸传热体系的建立到炉缸的设计理念对炉缸的长寿 进行了全面的论述。指出高炉长寿的关键控制环节为:设计、施工、烘炉、开炉节奏、操作稳定、维护管理。在合适 的炉缸冷却系统和结构配置条件下,有效杜绝和防止气隙是炉缸长寿的关键。设计要有完善的防止气隙的措施; 安装中要严格控制每一个环节;采用热水烘炉提高炉墙温度,促进水分蒸发;控制高炉开炉进程,给予新高炉一个 磨合期,保证炉缸的传热体系可靠、有效,以实现炉缸的无气隙化操作。无论炉缸耐材采用何种配置结构和采用何 种冷却系统,都必须以建立良好的传热体系为前提,只有尽快形成稳定的渣铁壳,才能实现炉缸的长寿。     

Analysis of All-Carbon Brick Bottom and Ceramic Cup Synthetic Hearth Bottom

One of the bottlenecks of the blast furnace （BF） campaign is the life length of hearth bottom. The basic reason for the erosion of hearth bottom is its direct contact with hot metal. According to the theory of heat transfer, models of BF hearth bottom are built based on the actual examples using software and VC language, and the calculated results are in good agreement with the data of BF dissection after blowing out. The temperature distribution and the capability of the resistance to erosion for different structures of hearth bottom are analyzed, especially the two prevalent kinds of hearth bottom arrangements called ＂the method of heat transfer＂ for all-carbon brick bottom and ＂the method of heat isolation＂ for ceramic synthetic hearth bottom. Features of the two kinds of hearth bottoms are analyzed. Also the different ways of protecting the hearth bottom are clarified, according to some actual examples. After that, the same essence of prolonging life, and the fact that the existence of a ＂protective skull＂ with low thermal conductivity between the hot metal and brick layers is of utmost importance are shown.     

长寿高炉炉底传热学分析

 高炉侵蚀归根结底是动量传输、热量传输和质量传输这三传的问题。如果炉底热面凝结一层渣铁壳,将有利于高炉长寿。目前,虽然已经有了许多数值求解三维导热微分方程的软件,但对于设计人员来说,快速评估所设计炉底热面能否形成渣铁壳有重要意义。笔者利用一维温度场分析(热阻分析)方法,通过炉底各层对冷却水冷却能力及1 150 ℃等温线的影响,估测渣铁壳的形成。最终得到影响炉底侵蚀的限制性环节,为优化高炉炉底结构设计,提高高炉寿命奠定理论基础。     

CFD Modeling and Analysis of The Flow,Heat Transfer and Mass Transfer in a Blast Furnace Hearth

Understanding the complex phenomena in the BF hearth is essential to increasing furnace productivity and to extending furnace campaign. Numerical modeling provides a cost‐effective tool to obtain such knowledge. We have developed several continuum‐based mathematical/numerical models to simulate the flow, heat transfer and mass transfer in the lower part of BF and in the hearth. These models have generated an improved insight into the mechanisms for liquid drainage efficiency, lining erosion and wall protection in BF hearth under operational conditions. The current paper provides an overview of these studies, as well as dealing with three specific aspects: (a) Gas flow and pressure on the liquid surface, and its effect on the drainage characteristics; (b) Flow and temperature distributions of liquid iron in the hearth, and the temperature distribution in the refractories; and (c), Titania injection to form Ti(C,N)‐rich scaffolds on the hearth refractory surface, to protect the hearth from erosion.     

国外高炉炉缸长寿技术研究

高炉长寿是系统工程。介绍了国外一批长寿高炉的经验。介绍了近20多年来对长寿高炉进行的解剖;提出了在日常生产中,延缓炉缸侵蚀的措施:如炉缸侧壁形成凝结层,改进出铁制度控制铁水环流;改变死料堆的内部结构避免局部侵蚀。还提出了在炉缸不同侵蚀阶段采用相应的具体措施。     

Critical Heat Flux of Blast Furnace Hearth in China

The critical heat flux surveys of thirteen Chinese blast furnaces were carried out.The mathematical model of hearth bottom was established and the temperature field was simulated by utilizing the method of inverse problem based on the collected parameters and temperature data.The critical heat flux and dangerous critical heat flux of hearth were defined and analyzed as well as the initial and investigative critical heat flux of hearth,and the influences of thermal conductivity and residual thickness of carbon bricks on critical heat flux were discussed.The relationships between critical heat flux of stave and hearth bricks were also compared.It is found that the dangerous critical heat flux of these blast furnaces ranged from 9.38 to 57kW/m2.Therefore,there was no uniform critical heat flux of hearth due to the structure design,refractory materials selection,construction quality of hearth and other factors.The heat flux should be lower than the critical heat flux with corresponding thickness of carbon bricks to control the erosion of hearth.The critical heat flux of stave would be much lower than that of hearth bricks with the air gap.However,the critical heat flux of stave should be higher than that of hearth bricks when gas existed between furnace shell and staves.     

高炉炉缸炉底侵蚀模型的研究与开发

采用边界元方法建立某一大型高炉炉缸炉底的侵蚀推测二维模型,能够推定高炉炉缸炉底侵蚀线的位置和形状,及时了解炉衬侵蚀状态。从计算所得的侵蚀图来看,侵蚀轮廓是比较合理的,与实际侵蚀情况非常相近。