加氢反应炉炉衬结构分析及施工质量控制

对加氢反应炉辐射室、对流室等部位的衬里结构及衬里选材进行分析,提出了衬里施工质量的控制措施,烘炉后检查确认衬里质量非常理想.     

回转窑窑衬里的设计和施工方法

在水泥窑采用复合衬里经验的基础上,提出了球团回转窑不同温度区段复合衬里的构成。分别介绍了各段衬里材质的配合比,热工性能和施工方法。根据我国具体情况,作出了硅型系列化设计。对复合衬里的优点,作了详细介绍。     

浅析瓷砖衬里开裂原因

因设备安装在热带区域,衬里施工后出现多台设备耐酸瓷砖沿砖缝开裂的现象,本文对裂缝产生的原因进行了分析并提出了修复的建议,并探讨在高温和温差较大环境下衬里如何进行合理的设计和施工。     

甲烷化反应器衬里设计及其传热计算

确定衬里的结构和厚度,并对衬里进行传热计算。将计算数据与工程检测数据进行对比,确定衬里厚度及其传热计算方法的正确性。该设计、计算方法可以为同类容器的设计提供一定的参考。     

酸性高温高压介质下槽体陶砖衬里的应用实践

陶砖衬里设备在耐酸、耐温方面应用广泛.本文对陶砖衬里设备的设计及有限元应力分析进行了总结,并对这类设备的生产实际使用情况进行了说明.     

探析湿法冶炼中耐酸砖的化学膨胀

湿法冶炼项目中,耐酸砖作为性价比较高的防腐蚀材料被广泛用于高温、高压设备的衬里结构。本文以某工程所用的耐酸砖为实验材料,对时间、操作环境、材料成分及制造工艺等影响其化学膨胀的因素进行了分析,并对实际工况下与试验条件下的化学膨胀差异进行了分析,探讨化学膨胀对衬里系统稳定性、设备操作过程的影响。实际设计工作中,建议采用实验数据和有限元分析相结合进行辅助设计,以设计出可靠的耐酸砖衬里系统。     

高温膨胀节衬里结构的研制与应用

衬里是许多石油化工设备通常采用的一种内部结构,对设备的安全运行起着举足轻重的作用。文章分析和探讨了高温膨胀节衬里脱落的原因,研究设计出了以耐火砖、耐火浇注料和耐火浇泥为主的衬里材料,对衬里结构重新设计,不仅满足了生产需要,同时也在这方面开闢出了一条新思路。     

磁性耐磨衬里在磨矿行业的研究和应用进展

在分析磨机内研磨介质运动形态和磁性耐磨衬里磨损机理的基础上,利用COMSOL Multiphysics软件对磁性耐磨衬里的磁场特性进行了优化。优化后磁性耐磨衬里在磁铁矿、非磁铁矿中的球磨机、立磨机中均取得了成功应用,且其较普通高锰钢衬里具有使用寿命长、磨机作业率高、节球、节电等显著优点。     

酸再生文丘里预浓缩器衬里损坏的原因分析与改进

分析了奥地利ANDRITZ公司为冷轧硅钢设计的盐酸再生设备文丘里预浓缩器衬里失效特征及原因,并制定了文丘里预浓缩器衬里结构优化措施.实施后,文丘里预浓缩器内的防腐衬里能够适用于较为苛刻的工况中,避免了因文丘里预浓缩器衬里损坏而造成的钢结构腐蚀、酸再生停产等,延长了设备使用寿命,提高了文丘里预浓缩器设备利用率.     

湿式磨矿机橡胶衬里的试用效果综述

本文对国内金属矿选厂使用橡胶衬里的概况和效果进行了综述。作者还提出了使用橡胶衬里的看法和建议。     

Thermal and thermomechanical evaluations of channel induction furnace applying strong insulation containing lightweight aggregates

Monolithic materials with a strong thermal insulating effect are required by the foundry industry for further energy savings, meanwhile possible premature wear of refractory linings caused by over-insulation should be avoided. A monolithic insulating material containing lightweight aggregates possessed strong thermal insulation and was proposed to replace the traditional insulating material made of chamotte currently used in a channel induction furnace. To evaluate the new lining concept, creep of the working lining was considered in the finite element modelling and followed the classical von Mises creep model, which was defined with the Norton–Bailey strain hardening creep equation. The results showed that the lightweight design of the insulating lining reduces the heat loss from the steel shell and material consumption. Moreover, the thermomechanical loads in the refractory linings and steel shell remain within a reasonable range when compared with the currently in-use refractory lining concept.     

Thermal stress fracture of refractory lining components: Part I. Thermoelastic analysis

This paper presents a mathematical model and corresponding stress analysis suitable for the development of theoretical criteria useful for the design and selection of refractory components of linings of high-temperature furnaces and metallurgical process vessels. Refractory lining components, for which the maximum principal tensile stress fracture criterion is assumed valid, are simulated using a two-dimensional constant heating rate thermoelastic model. Dimensional analysis and the finite element numerical method are utilized to develop a general solution for the maximum principal tensile stress in a rectangular shape of arbitrary length and width in terms of thermal and mechanical properties and heating and cooling rate. Implications of the general stress solution with regard to fracture behavior and design recommendations are discussed with reference to results previously reported in the literature.     

Spinel and carbide formation in oxide-carbon refractories for steel-casting ladles

In the converter shop at OAO Nizhnetagil’skii Metallurgicheskii Kombinat (NTMK), the steel-casting ladle is lined with oxide-carbon refractories. The aggressiveness of slags toward the refractory lining is explained. The composition of the linings is studied, along with the processes within the refractories at high temperatures. The basic requirements on refractory components supplied to OAO NTMK are formulated. The life of casting-ladle linings in the converter shop is increased.     

炉衬热应力分析中几类特殊结构的建模方法

耐火材料炉衬决定高温容器件的使用寿命,热机械应力过大是其破坏的主要原因。有限单元法是进行应力分析的重要手段。论述了高温炉衬系统进行热应力分析中,对炉衬结构中所含砖缝和金属锚固件在建立有限元分析模型时的处理方法。     

MgO–C bricks for BOF linings

Abstract

MgO–C brick linings have become standard in basic oxygen furnaces (BOFs) all over the world. Developments in the refractory technology for BOFs over the last few years and their impact on the lifetime and performance of refractory linings are presented. These developments comprise optimised shapes for the lining of BOF and steel fibre reinforced MgO–C bricks. Optimised shapes with double wedges lead to a smooth inner surface of the refractory lining and fewer stresses and refractory consumption. Stainless steel fibre reinforced MgO–C bricks have proven to be the ultimate choice for scrap impacts or other areas with ultra high mechanical loads. They have brought down refractory wear in these particular areas significantly. Moreover, typical lining patterns of different zones in a BOF and the development of the raw material grades (MgO grades and graphite) for refractories as well as the development of lining lifetimes over the last years are discussed.     

耐火材料对钢水纯净度影响的试验研究

通过对钢包、中间包衬层内示踪剂在浇铸过程中变化的试验分析，判断衬层耐火材料在钢水中的变化情况，分析每炉钢水对耐火材料的冲刷量及耐火材料对钢水纯净度的影响程度。从而提出减少耐火材料衬层对钢水污染的措施。     

基于VB的稳定态多层壁炉衬参数的计算

根据稳定态下多层平壁炉衬传热原理,介绍了炉衬各层间温度及热流密度的计算方法。利用VB编程环境中的可视化编程,建立各种耐火材料的热传导系数数据库,有利于平壁层数及材质种类等参数的选取,输入热面温度及各层平壁厚度,计算出炉衬相应的各种参数。在实际应用中,该程序性能稳定,界面美观。     

Interaction between molten steel and different kinds of MgO based tundish linings

Abstract

Interactions between the molten steel and the refractory linings are of fundamental importance for the steelmaking industry. During the casting process, the steel cleanliness can be made worse because of the reoxidation of the molten steel in contact with the atmosphere and/or other sources of oxygen (refractories, top slag, etc.). In the industrial trial periods, four tundish refractory linings (preformed boards, two kinds of gunning materials and dry vibrating material, all MgO based refractories) were used in order to evaluate the interactions between the refractories and the molten steel. Owing to the small dimension of the tundish (5 ton) used in the continuous casting at Villares Metals SA, after casting, the chilled steel was cut in order to show, in a single section, the stopper, submerged entry nozzle, MgO ramming and the working refractory lining. Cross-sections of samples from the steel/refractory interface were investigated by electron probe microanalysis (EPMA). Four major aspects were observed at the steel/refractory interface: steel infiltration into the tundish refractory lining, mainly in the gunning materials; a steel oxidised layer formed at the steel/refractory lining interface; formation of a spinel layer between steel and tundish working refractory lining; and many particles were found in the steel phase, near to the steel/refractory interface, being a potential source of non-metallic inclusions.     

Modeling and parametric studies of heat transfer in a direct-fired continuous reheating furnace

A mathematical system model of a direct-fired continuous reheating furnace has been developed. The furnace is modeled as several well-stirred gas zones with one-dimensional (1-D) heat conduction in the refractory walls and two-dimensional heat transfer in the load. The load travels either parallel or counterflow to the combustion gases which enter the furnace throughout its length. The convective heat-transfer rate to the load and refractory surfaces is calculated using existing correlations from the literature. Radiative heat exchange within the furnace is calculated using Hottel’s zone method by considering the radiant energy exchange between the load, the combustion gases, and the refractories. The nongray characteristics of the combustion gases are considered by using a four-gray gas model to treat the mixture as a radiatively participating medium. An extensive parametric investigation has been completed to determine the furnace design and operating characteristics that lead to optimum furnace efficiency. The parametric investigations included in this paper study the effects of the load and refractory emissivities and the height of the combustion space on the thermal performance of the furnace.     

耐材方案对炼钢过程节能的贡献

在目前欧洲能源价格上涨以及CO2排放税成本高企的背景下,提高能源利用效率和降低CO2排放量已日趋重要。基于上述目标,奥镁公司可提供一系列多样化解决方案,包括使用优质耐材内衬、优化内衬维护以及改进工艺等。用多个实例论证了在炼钢过程中,智能耐材方案对于提高能源利用效率和减少CO2排放所起的作用。在电炉和转炉炉底使用含底吹气系统的一体化耐材产品,能加强熔池搅拌和加快冶金反应,从而改善多项生产参数,包括电耗、处理周期、电弧稳定性以及加快脱碳反应速率。毫无疑问,对于能量和质量转换效率、成本和CO2排放等多方面都有着重要意义。经过计算流体动力学(CFD)优化的电炉和转炉出钢系统,是改善能源效率管理的另一个耐材解决方案实例。利用这些先进的系统,不但缩短了出钢时间,同时节约了能源损耗以及提高了产能。另外,还有一种节约能源的有效方式是优化钢包衬和使用耐材内衬包盖,可减少热损失,降低转炉或电炉的出钢温度,同时降低LF炉中能量输入或化学反应热的需求。近期,奥镁公司新研发出一种中间包工作内衬(即自硬性喷涂料)。由于省去了像普通中间包工作内衬的烘烤过程,从而相应减少了CO2排放。综述了各种耐火材料产品的特点,并重点讲述了它们在节能和CO2减排等方面的应用效果。