COREX-3000运行分析及改进途径

分析了宝钢1号COREX-3000运行近4年的生产实绩和技术攻关问题。系统总结了COREX-3000的工艺技术和生产操作取得的重大进步,燃料比、焦比和作业率等重要指标逐年改善。影响COREX-3000生产稳定的重大问题已经基本解决,如竖炉清空周期延长,风口破损数大幅减少,下降管和发生煤气管堵塞次数明显减少,铁水质量稳定,设备运行稳定性逐步提高。提出了进一步改进、完善COREX工艺和降低成本的技术方向。     

宝钢COREX-3000运行现状及发展前景

宝钢COREX-3000投产以来经历了认识、探索及改进三个阶段,在降低风口破损、提高金属化率、提高块矿比、稳定铁水质量、减少下降管堵塞、降低发生煤气管堵塞及降低燃料消耗等方面取得明显成效,炉况日趋稳定,生产过程受控,基本掌握COREX-3000的运行控制技术,为提高作业率,降低铁水成本打下坚实基础。COREX-3000需要在原燃料改善、优化配煤配矿结构、提升操作水平、煤气综合利用及保持高作业率等方面,不断改进,系统思考,实现COREX与高炉优势互补,充分发挥整体效能,是持续提高COREX竞争力的有效途径。     

采用炉顶煤气循环和风口喷吹技术降低COREX/FINEX燃料消耗的理论分析

COREX/FINEX工艺与高炉工艺相比,能耗较大,因而限制了自身的推广,COREX-2000的吨铁燃料消耗平均达到1 000 kg.从工艺特点分析,气化炉还原煤气温度从1 050℃降到850℃的物理热损失和风口前理论燃烧温度过高导致[Si]偏高,是目前COREX/FINEX工艺本身无法避免的高能耗原因.计算研究表明,采用炉顶煤气循环利用技术以及氧气风口喷煤技术可以有效降低燃料消耗.在同一熔炼率、同一煤种时,未计入循环煤气加热能耗的条件下,COREX/FINEX工艺每循环利用5%的尾气,吨铁综合燃料比平均下降8.6 kg;吨铁喷煤50 kg,燃料比平均下降11 kg.     

COREX炉壳制作过程中焊接质量的控制

COREX-3000作为世界上最大的COREX炼铁炉,其工艺设备的研究至关重要.文章介绍了从COREX炉炉体设备制作工艺入手进行的COREX炉设备研究,为后期新建的COREX项目实施提供技术支持.     

块煤粒径与COREX-3000生产指标的关系

COREX工艺是目前惟一可以非焦煤为燃料的成功产业化的炼铁工艺。块煤粒径和粉率(5 mm含量)是影响气化炉生产指标的重要因素。分析COREX-3000生产中块煤粒径和粉率对生产指标的影响,结果表明,粉率的增加会导致块煤中水分增加,燃料比、焦比增加以及熔炼率降低;同时会导致铁水成分恶化、铁水中硅含量增加以及铁水温度降低。块煤平均粒径控制在18～20 mm,熔炼率、燃料比以及焦比均可以达到较优值,能够产生稳定并有较好透气性的半焦床,生产稳定顺行。通过Minitab对生产数据分析得出燃料比拟合方程,对方程进行验证表明,生产值和理论值具有较好的吻合性。     

COREX—3000生产现状和存在问题的分析

介绍了宝钢COREX-3000投产8个月来的生产情况和主要技术经济指标,剖析了COREX-3000稳定生产的技术问题,包括精料、避免竖炉黏结、避免煤气流反窜、提高金属化率、降低非计划休风率等;并提出从合理配煤配矿、降低焦比、优化喷煤、粉煤压块等方面提高COREX-3000竞争力;同时提出了COREX需要技术攻关的一些问题和思路.     

COREX-3000配料计算模型原理与实现

COREX工艺是目前世界上惟一工业化的熔融还原炼铁新工艺,它最大特点是采用非焦煤资源作为主体燃料,省去了炼焦、烧结过程,排放显著降低,是资源节约、环境友好、可循环的新一代炼铁工艺流程。宝钢研究解析出了COREX-3000配料计算模型原理与实现方法,其在同一装入条件下的计算结果与奥钢联模型的计算结果很接近,为生产操作者和计算机模型维护人员的使用提供了很大方便。     

COREX-3000风口破损的原因分析和对策

宝钢1#COREX-3000投产以来,风口破损较为频繁,对COREX-3000生产的稳定及产量带来了很大的影响。从COREX纯氧鼓风工艺特点、风口氧气流速、单风口熔炼率、风口通氮、出铁制度、焦炭比例和生产工况等方面进行了分析,分析结果显示,COREX风口破损的主要原因是由于风口理论燃烧温度高,风口前端焦炭和半焦粒度小,透气透液性能较差,导致风口前端氧气孔道高温熔化或磨损扩孔,出现漏水现象而破损。通过适度降低风口氧气流速和单风口熔炼率、风口添加氮气、稳定炉况和优化出铁制度可以有效减少风口破损数。     

COREX炉纯水密闭循环系统设计及调试探讨

介绍了上海浦钢2座COREX-3000塔体的纯水密闭系统设计特点、设备选型,并对COREX炉的纯水密闭系统的调试做了简单介绍,为以后的COREX炉炼铁给排水设计和调试工作提供参考.     

熔融还原炼铁技术

COREX熔融还原炼铁工艺用非炼焦煤直接炼铁，流程短、投资省、成本低、污染少、铁水质量好，过程煤气可用于生产海绵铁，成为当代冶金工业的前沿技术。本文分析了COREX工艺的特点，原、燃料的性能要求，技术经济指标，讨论了其发展前景和进一步研究完善的方向。     

Analysis of the factors affecting the fuel rate in the COREX process and improvement measures

Increasing production capacity and operating rate,reducing fuel rates and costs of hot metal(HM)are the urgent tasks for the COREX process.In this study,the various factors on the fuel consumption of COREX are researched from the theoretical analysis based on the calculations of material balances and heat balances.Combined with the production performances and practices of COREX-2000(Saldanha,India)and COREX-3000(Baosteel),the technical measures of reducing the fuel rate are analyzed and the way forward of technical innovation is addressed and discussed with the standpoint of the COREX process improvement.     

Analysis of the factors affecting the fuel rate in the COREX process and improvement measures

Increasing production capacity and operating rate,reducing fuel rates and costs of hot metal (HM) are the urgent tasks for the COREX process.In this study,the various factors on the fuel consumption of COREX are researched from the theoretical analysis based on the calculations of material balances and heat balances.Combined with the production performances and practices of COREX-2000 (Saldanha,India) and COREX-3000 (Baosteel),the technical measures of reducing the fuel rate are analyzed and the way forward of technical innovation is addressed and discussed with the standpoint of the COREX process improvement.     

Estimation of Energy Consumption in COREX Process Using a Modified Rist Operating Diagram

Fuel consumption in the COREX-3000 process run in Baosteel is currently higher than the design index.Therefore,mass and heat balance equations for the COREX process were established using the basic principles included in the Rist operating diagram for blast furnace(BF)as a reference.Thermodynamic calculations were then used to modify the Rist operating diagram so that it was suitable for the COREX process.The modified Rist operating diagram was then applied for the evaluation of metallization rate(MR)and fuel structure to reduce the energy consumption in the COREX process.The modified Rist operating diagram for the shaft furnace(SF)provided a nearly ideal value for the restriction point W when the metallization rate was increased,while the point Pon the operating line for the melter gasifier(MG)moved upward due to reduction in the heat required in hearth.The feasibility of reducing the energy consumption during the COREX process by changing the fuel structure was also demonstrated.     

COREX用煤及检测块煤热解新方法

COREX工艺是目前惟一工业化的熔融还原炼铁新工艺,其优势之一为可以尽可能少用焦炭,能直接使用块煤。针对COREX工艺给出了其用煤要求,为了减少其焦炭使用量,发挥其直接用煤优势,必须找出焦炭与块煤使用的匹配关系,对块煤运输和装卸产生的粉煤总结出几种利用途径。通过观测用于COREX-3000的块煤在熔化气化炉中的裂解和脱气过程,提出了块煤热爆裂性能和脱气性能测试的实验室可视化试验方法。     

COREX-3000发生煤气管堵塞物的分析

宝钢COREX-3000是世界上规模最大的COREX熔融还原炼铁装置。熔融气化炉的发生煤气管（GGD）堵塞是实际生产中遇到的重大问题之一。通过对COREX-3000发生煤气管堵塞物进行取样,并在实验室中采取多种手段对其化学成分、理化特征等进行分析,结果表明,堵塞物呈明显的层状结构,由大量液相包裹铁颗粒构成。堵塞物试样在1 000～1 100℃开始软化收缩,而在1 250～1 300℃产生明显液相。     

Minimization of Exergy Losses in the COREX Process

The COREX process is being projected as an alternative for blast furnace iron making. The coal consumption of the COREX process is large with a net fuel rate of ~1000 kg/tone of hot metal (THM). The reason for a higher net fuel rate of the COREX process compared with the net coal rate for the blast furnace process has been investigated. Exergy analysis has been performed for identifying the causes, locations, and magnitudes of process inefficiencies for the COREX process. Whereas blast furnace process data are available in the literature, no systematic data for stream information of the COREX process are available for different input coal rates required for exergy computation. A composite model of the COREX process (i.e., models for the smelter gasifier and the reduction shaft) using FactSage 6.2 (Thermfact/CRCT, Montreal, Canada, and GTT Technologies, Aachen, Germany) is used to generate stream data. A new methodology for the calculation of exergy of the COREX process streams using the database in FactSage is proposed in this work. Exergy data for blast furnace process streams have been obtained from the literature. The exergy loss and exergy efficiencies of the COREX process are evaluated at various coal rates and compared with those of the blast furnace. Operating the COREX process is theoretically feasible at lower coal rates with higher exergy efficiencies when lesser export gas is generated.