浅谈高炉炉缸异常侵蚀的原因及防治

通过对国内多座高炉炉缸的破损调查发现,在圆周方向上,铁口附近炉缸侧壁的炭砖侵蚀比较严重;在高度方向上,铁口中心线以下区域,特别是铁口中心线下方1.0～2.0 m处的炭砖,侵蚀比铁口中心线上方区域严重;部分高炉的炉缸侧壁局部存在类似“老鼠洞”的侵蚀现象。导致炉缸异常侵蚀的原因主要有气隙影响传热、入炉碱金属负荷及锌负荷过高、高炉烘炉不彻底、高炉冶炼强度过高、风口漏水导致炉缸积水现象严重等。在高炉日常生产操作中,炉缸积水及气隙对炉缸的长寿及安全的危害应得到足够的重视,建议采取措施并形成一种常规管理制度,加强对炉缸积水及气隙的防治。     

高炉炉缸炉底热电偶在线监测系统设计

为实现炉缸侵蚀自动预警及预警记录查询,设计在高炉炉缸炉底增设热电偶在线监测系统。从热电偶点位设置、性能要求以及测温采集系统网络架构原理及布置进行介绍,设计一套炉缸炉底侵蚀在线监测预警系统。     

基于FEA和DNN的高炉炉缸侵蚀状态监测模型

现阶段，国内高炉的自动化程度已基本覆盖正常生产需求，对于高炉炉缸部位的监测手段大多采用热电偶温度监测技术实现，而由于高炉生产工艺的复杂性和生产环境的恶劣性，高炉炉缸内部直接监测手段几乎无法实现，因此采用智能模型对炉缸侵蚀状态进行监测成为高炉炼铁发展的新趋势。简述了高炉炉缸砌筑的结构，结合高炉生产特点确定炉缸区域的传热模型及求解条件。利用正交试验法实现高炉炉缸不同侵蚀状态的划分和组合，得到共59组炉缸侵蚀形状样本且边界形貌基本覆盖训练全域。将1 150℃等温线作为炉缸侵蚀线，利用有限元算法完成不同炉缸侵蚀状态下温度场的可视化并构建炉缸侵蚀样本数据库实现炉缸炉底侵蚀样本的采集。通过深度神经网络模型建立热电偶数据和炉缸侵蚀边界的对应关系，拟合优度R²达到0.802,相较于随机森林算法、BP神经网络算法、单独线性回归组合算法拟合优度分别提高56.64%、26.50%和84.37%,达到指导生产的精度要求。对比利用停炉前实际数据监测侵蚀形貌结果和停炉后的实际侵蚀状态，得出侵蚀监测结果符合实际炉缸侵蚀状态形貌的结论，验证了炉缸侵蚀状态监测模型的可靠性。利用高炉炼铁工业互联网平...     

基于微小温差监测的炉缸侵蚀状况的研究

为了查明凌钢3号高炉炉缸在炉役中侧壁砖衬温度高达900℃而二段热负荷大多低于10 000 W/m2的原因,通过传热学建模分析了炉缸传热和侵蚀的影响因素。采用可检测微小水温差波动的无线高精度数字化在线监测系统和吸附式无线炉皮测温系统,实现了对炉缸安全状态的准确监测。结果表明:炉缸侧壁热阻过大,尤其是炭砖和冷却壁间的填料层过厚是炉缸侵蚀加剧而水温差较低的主要原因,水速调整对"隔热"型炉缸侵蚀影响较小,稳定冶炼强度及改善炉缸透液性是抑制侵蚀的有效措施。     

济钢3座1750m~3高炉炉缸侵蚀情况对比分析

对济钢3座1 750 m~3高炉一代炉役炉缸侵蚀情况进行了分析,扒炉过程中对炭砖残存厚度或重点部位炭砖残存厚度进行了实际测量,结果表明,3座高炉侵蚀最严重的位置都在铁口方向,但3座高炉炉缸的侵蚀情况不同,最大区别在于,2~#、3~#高炉都有较严重的环裂,并且环裂位置基本相同。分析认为,环裂与炭砖材质关系不大,与设计结构有关。提出可否降低炉底冷却水流量而增加炉缸冷却水流量以延缓炉缸侧壁侵蚀速度及改进炉缸结构设计等进一步探讨的问题。     

鞍钢高炉炉缸炭砖的应用探讨

对鞍钢不同炉役阶段高炉炉缸炭砖选型、砌筑情况进行了阐述,分析了不同类型炭砖高炉炉内使用效果和侵蚀状况。从炉缸炭砖破损的状况来看,渗铁、铁水溶蚀及冲刷、裂纹现象、锌及碱金属侵蚀等,是鞍钢高炉炉缸炭砖破损的主要原因。依据鞍钢多座高炉成功的生产经验,认为合理选用炭砖型号、严格监管砌筑质量、控制有害元素入炉、减少炉况波动等,是延长炉缸炭砖使用寿命的关键。     

高炉铁沟侵蚀监测装置的构建与开发

通过对高炉铁沟耐材特点和铁沟侵蚀监测现状的分析,与炉缸侵蚀监测模型特点进行对比研究,以炉缸侵蚀模型为基础,对铁沟永久衬表面进行网格化划分,建立了高炉铁沟侵蚀监测与判断系统,避免了铁沟烧穿事故发生,实现了铁沟侵蚀的自动预警,有效地预防了铁沟烧穿,从而降低吨铁耐材消耗,提高高炉生产的安全性。     

高炉炉缸炉底温度场及异常侵蚀在线监测诊断系统

分析了高炉炉缸炉底常用侵蚀监测方法的不足:一维传热、不含凝固潜热、不考虑异常情况对侵蚀影响的模型很难准确预测炉缸侧壁"象脚状"侵蚀的发生。建立了包含凝固潜热的三维非稳态柱坐标温度场计算模型,引入了"诊断知识库"实时判断和处理异常情况对侵蚀的影响,开发了炉缸炉底温度场及异常侵蚀在线监测诊断系统,成功应用于首钢、迁钢、唐钢、攀钢、长钢等多座高炉。介绍了该系统的侵蚀计算流程、程序设计特点、具体模块功能和在高炉生产中的指导作用。模型计算结果的准确性在高炉大修破损调研时得到了充分的验证。     

高炉炉缸破损的原因与控制

 近年来,中国高炉长寿技术取得了长足的进步,部分高炉寿命达到国际先进水平,但同时也出现数十座高炉发生炉缸事故或异常侵蚀破损。高炉长寿技术是一项综合技术,高炉要实现长寿除需要保障炉衬、炉体材质和建筑施工质量外,科学合理的设计是关键,高炉生产操作监控维护是基础。基于对多座高炉长寿技术应用状况和高炉炉缸的破损调查,从设计、操作等多方面对炉缸破损原因进行分析,并提出了长寿炉缸设计的优化原则和实现炉缸长寿的生产操作、监测、维护及管理的控制对策。     

宝钢1号高炉炉缸温度升高的治理

宝钢1号高炉2017年以来炉缸温度出现4次异常升高的现象,认为主要是炉体热负荷波动及崩滑料、炉前作业状况不稳定、处理上不够果断等引起的。通过采取改善炉缸状态消除局部不均匀侵蚀、优化炉前作业制度稳定铁口区工作状态、建立炉缸温度异常预警机制等措施,高炉技术经济指标改善,同时炉缸温度处于安全、稳定受控范围。炉缸温度2号铁口测温点由最高的680℃下降至130℃,3号铁口测温点由最高的615℃下降至150℃。     

Design and Operation Control for Long Campaign Life of Blast Furnaces

At the beginning of 1990s, Shougang blast furnaces (BFs) No. 2, No. 4, No. 3 and No. 1 were rebuilt sequently for new technological modernization in succession. The campaign life of BFs No. 1, No. 3 and No. 4 reaches 16. 4, 17. 6 and 15. 6 years, respectively, and the hot metal output of one campaign reaches 33. 8, 35. 48 and 26. 37 Mt, respectively; the hot metal output of BF effective volume of one campaign reaches 13328, 13991 and 12560 t/m³, respectively, which reaches the international advanced level of BF high efficiency and long campaign life. In BF designing, several advanced BF long campaign technologies were adopted. BF proper inner profile was optimized, reasonable inner profile was adopted, and closed circulating soften water cooling technology was applied in 4 BFs. Double row cooling pipe high efficiency cooling stave was developed which could prolong the service life of bosh, belly and stack. Hot pressed carbon brick and ceramic cup hearth lining structure were applied and optimized. BF operation was improved continuously to ensure stable and smooth operation of BF. Hearth working condition control was strengthened, burden distribution control technology was applied to achieve reasonable distribution of gas flow, and heat load monitoring was strengthened to maintain BF reasonable working inner profile. Proper maintenance at the end of BF campaign was enhanced. Hearth and bottom service life was prolonged by adding titaniferous material and enhancing hearth cooling. Gunning of lining was carried out periodically for the area above tuyere zone.     

长寿高炉炉缸的设计与实践

高炉炉缸长寿的关键是在设计和生产过程中如何消除其“蒜头奖”侵蚀。邯钢1260m^3高炉和2000m^3高炉在设计中较好地解决了这个问题,根据开炉后炉缸侵蚀情况,这两座高炉的炉缸可以实现长寿。     

梅山高炉长寿实践

从高炉冷却设备改进、炉身冷却结构形式的改进、炉缸炉底结构及材质的改进以及高炉操作维护等方面阐述了梅山三代高炉的长寿经验。认为现役高炉采用的炉身板壁结合的冷却结构以及炉缸陶瓷杯结构适合梅山高炉长寿要求。     

Estimation model of the hearth refractory thickness and its application to the operation

A numerical model considering heat flow path and heat flux area was developed to estimate residual refractory thickness of blast furnace hearth. The predictions indicated that the wear profile of Kwangyang No. 1 BF was elephant foot type, deeply eroded around the tap‐hole and the corner of the hearth. The high heat load at the hearth sidewall was caused mainly by the carbon brick with low thermal conductivity, and it resulted in a severe erosion of hearth refractory. In the early stage of the furnace campaign, the wear rate of hearth refractory turned out to be higher than that of the following 7 years. Additionally, a thermal analysis of the hearth shell was carried out by means of an infrared camera, which is effective for simultaneous observation of a large area. A locally hot spotted region was not detected and the measured results showed a good agreement with the temperature trends measured by thermocouple.     

高炉炉缸炭砖砌筑结构的传热学

 从传热学角度通过建立炉缸传热数学模型,分别对大块炭砖的炉缸结构和小块炭砖的炉缸结构进行了讨论。计算了它们在烘炉阶段和高炉开炉后炉缸砖衬的温度,发现了按照目前的烘炉规范进行烘炉,难以将炭砖与冷却壁间的填料烘干,填料的导热系数达不到设计值。填料的存在导致砖衬热面温度升高,致使砖衬侵蚀加剧。因此,在冷却壁与炭砖之间取消填料,让炭砖直接顶砌冷却壁具有明显的传热优势。对于使用小块炭砖的炉缸,可以直接将炭砖顶砌冷却壁,消灭填料对炉缸传热的限制影响;对于大块炭砖结构的炉缸,先采用部分小块炭砖顶砌冷却壁,在小块与大块炭砖间使用填料,将填料向高炉内部推移约200mm以上,烘炉阶段为了将填料烘干,冷却壁断水烘炉是必需的,为了保证冷却壁的安全,同时讨论了冷却壁断水烘炉应注意的问题。     

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.     

高炉炉缸长寿认识及维护治理实践

炉缸寿命长短直接决定了高炉的一代炉役寿命,至关重要。结合京唐2座有效容积5 500 m 3 高炉的炉缸 构造及对2号高炉炉缸局部温度升高后的治理,浅谈对高炉炉缸长寿及维护的认识。     

Numerical modeling of multiphase flow,heat transfer and titanium flow behavior in blast furnace hearth

Understanding the complex phenomena in BF hearth is essential to increase furnace productivity and to extend furnace campaign.We have developed several continuum-based mathematical/numerical models to simulate the multi-phase flow,heat transfer and chemical reactions in the BF hearth.These models have generated an improved insight on the mechanisms for liquid drainage efficiency,lining erosion and wall protection in BF hearth under operational conditions.The current paper gives an overview of these studi...     

济钢1750m~3高炉炉役后期炉缸侵蚀分析及对策

炉役后期的护炉生产实践以及炉缸侵蚀模型表明,济钢2#1 750 m3高炉炉缸侧壁呈现为较大蘑菇型侵蚀。分析认为炉缸侵蚀的主要原因是铁水环流的影响以及炉缸局部热流强度过高;另外,90°的铁口夹角布置以及长期频繁使用洗炉剂也加剧了炉缸的侵蚀。通过改进灌浆操作,开发局部强化冷却技术,提高了炉缸的冷却效果。同时优化操作制度,有效减缓了砖衬的侵蚀,保证了炉役后期炉缸工作本质安全。     

高炉碳砖抗铁水溶蚀性能的研究

模拟高炉炉缸生产条件，研究了定量测定高炉碳砖的抗铁水溶蚀性能的方法。该方法实验证明，铁水温度升高、流动速度加快均能加速碳砖溶蚀，此外，碳砖质量对其溶蚀性能有极大的影响。提出了延长高炉寿命的措施。