富氧侧吹熔池熔炼炉炼铜的生产实践

富氧侧吹熔池熔炼炉集物料的干燥、焙烧和熔炼于一炉。富氧侧吹熔池熔炼工艺投产后,对工艺控制参数和工艺的可变性及相应的控制方法进行了试验和摸索,试生产中出现了烟气中单体硫含量高、余热锅炉振动大、富氧侧吹熔池熔炼炉风眼砖和炉墙腐蚀严重、出口垂直烟道结渣及余热锅炉烟尘烧结等问题,通过分析提出了解决的方法,并对工艺的进一步优化提出建议。     

无人驾驶捅风眼机电气设计与应用

本文介绍了江铜贵溪冶炼厂捅风眼机全部升级为无人驾驶捅风眼机的创新过程和使用情况,通过使用多种电气控制技术,完成了捅风眼机的自动控制。有效的解决了人工操作水平差异大,导致的对不准风眼,捅风眼效率差,烧钎严重的问题,以及降低了炉后作业时的高温、烟气、粉尘对人体的伤害。     

卧式转炉捅风眼机自控改进研究与应用

针对传统卧式转炉捅风眼机人工手动操作设备故障率高、送风系统有损伤、转炉作业率受影响等问题,通过优化传动方式,采用PLC控制系统实现捅风眼机自动捅打,使风眼机故障率降低了68%,实现经济效益279.26万元/a。     

转炉作业的自动捅风眼机

前言日本矿业公司佐贺关熔炼精炼厂冶炼能力为原料含铜量300,000吨/年。用两座闪速炉生产,冰铜品位一般为62%。其冰铜用六台在整个冶炼作业中起关键作用的转炉进一步熔炼。通常,用两台转炉吹炼,两台转炉保温,一台转炉备用,一台转炉维修。现在每台转炉上都安装了专利的日本Mining型自动捅风眼机(NAP)。该机渊源于Gaspe型捅风眼机。     

金川二期转炉机械化捅风眼机的攻关改造

通过对转炉送风、风眼消音器、风眼机行走机构、捅打机构、供电和控制系统、钎子加工等装置的攻关改造,使闲置了六年的机械化捅风眼机成功应用于生产,改善了转炉的送风条件,提高了转炉的生产能力,同时也降低了工人的劳动强,取得了较好的社会经济效益。     

金川二期转炉机械化风眼机的改造应用

金川公司第一冶炼厂的技术人员，通过对转炉送风结构、风眼消音器、风眼机行走机构、捅打机构、供电和控制系统、钎子加工装置等进行了大量合理的改造，使闲置了六年的机械化捅风眼机应用于生产，改善了转炉的送风条件，提高了转炉的生产能力，同时也降低了工人的劳动强度，取得了较好的社会经济效益。     

典型铜冶炼行业基准排气量的比较与分析

针对2010年环境保护部发布的《铜、镍、钴工业污染物排放标准》(GB 25467-2010)中关于单位产品基准排气量的规定,结合《铜、镍、钴工业污染物排放标准》(征求意见稿)编制说明》,界定了纳入计算的废气种类,比较和分析了闪速炉、底吹炉、侧吹炉、白银炉、奥斯麦特炉、合成炉工艺的单位产品基准排气量,单位产品基准排气量从大到小排序为奥斯麦特炉、白银炉熔炼、底吹熔炼、合成炉熔炼、侧吹炉熔炼、闪速熔炼工艺。从环保角度,应推广闪速熔炼、合成炉熔炼和侧吹炉熔炼工艺等排气量小的工艺及其设备。     

贵溪冶炼厂自动捅风眼机的研发和设计

本文介绍了贵溪冶炼厂在研发转炉自动捅风眼机过程中遇到的问题和缺陷陷,通过对部分机械结构从新设计来实现整个捅风眼机机身在行走过程的启、停能完全符合电气控制的程序启、停的位置,进而来实现钎杆的精准定位,避免钎杆在捅的过程中钎杆捅不进去风眼。通过对部分机械结构从新设计能够完全配合和好电气程序的控制,达到自动捅风眼的功能。     

侧吹炉炉体设计优化与实践

随着侧吹熔池熔炼工艺的广泛应用,侧吹炉不断地向大型化发展,同时侧吹熔炼炉的结构及熔炼技术也在不断改进。为了保障侧吹炉的安全稳定运行,针对侧吹炉出现热损失偏高,二次风口处结瘤、烟道与锅炉接口处结瘤,排放速度有限导致紧急排空困难以及炉体保温等问题,从操作、结构设计等方面提出了优化改进措施。     

侧吹顶吹一体化连续炼铜炉的设计与实践探讨

针对目前铜火法冶金在两个独立的装置中完成存在的不利情况,提出了侧吹顶吹一体化连续炼铜炉,并对其炉体结构形式、技术参数、生产操作、炉体监控等方面进行了阐述。通过优化设计和生产控制,侧吹顶吹一体化连续炼铜炉建成投产后应能达到节省投资、减少操作、降低运行成本、节能和环保的预期效果,能充分发挥侧吹炉熔炼工艺的优势。     

密闭侧吹熔炼炉处理CRT含铅玻璃工业可行性研究

在密闭侧吹熔炼炉内开展CRT含铅玻璃替代炼铅原料的配比工业试验。结果表明,CRT含铅玻璃可以替代部分铅矿石和硅石作为密闭侧吹熔炼炉炼铅的原料,在CRT含铅玻璃23.2%配比条件下,铅回收率最高。     

管链输送机在铅冶炼行业中的应用

华东某再生铅冶炼厂利用侧吹炉处理废旧铅酸蓄电池过程中,侧吹熔炼车间产生的环集烟气经布袋除尘后送往脱硫系统,除尘器捕集的铅环集烟尘采用管链输送机输送到原料库的烟尘仓并返回侧吹炉系统。管链输送机的结构简单紧凑,可以水平、垂直、弯曲和三维布置,具有广泛的应用前景。     

一种同时炼铅锌的新技术

开发了一种同时炼铅锌的新技术,利用富氧侧吹(或底吹)炉和密闭富氧侧吹炉代替了传统技术中使用的烧结机和密闭鼓风炉。该技术改善了传统技术中存在的高焦率、低空污染、烟气含硫低、大量返尘等问题,具有可行性和潜在市场。     

水钢1350m^3高炉炉缸侧壁温度升高的治理实践

水钢1350m^3高炉大修后,经2年强化冶炼,炉缸西铁口下方侧壁温度上升至623℃,通过控制冶炼强度、钛矿护炉、休风堵风口、降低生铁锰、改变出铁方式,炉缸灌浆等措施,侧壁温度得到有效控制,并降低至500℃以下。侧壁温度稳定后,采取坚持钛矿护炉,逐步加氧强化冶炼,实现技术指标改善,侧壁温度稳定在安全水平,最大限度实现安全生产、增产降耗的目标。     

A novel method to detect the water leakage from tuyere nose cooling circuit in blast furnace

The water cooled tuyere noses, through which hot blast is blown into the furnace, are exposed to very high temperature region of raceway inside the furnace. As a result the chances of rupture of cooling pipes within the tuyere nose are significantly high. The rupture causes water dripping into the furnace and if it continues and unnoticed for a prolonged period it lowers down the local raceway temperature and thus adversely affects the product hot metal and slag quality. Moreover, with heavy water leakage, there is a danger of explosion; monitoring of the cooling water is therefore essential. Despite the availability of water flow metre at each tuyere it is difficult to identify the leaking tuyere at the early stage unless the rupture size grows bigger and so the leakage. In several cases the furnace is forced to shut down to manually inspect the leakage occurring without prior knowledge of the exact tuyere number. Identification of water leakage at an early stage is therefore necessary to prevent process disturbances due to chilling of the furnace and avoid the unscheduled downtime for tuyere replacement. This paper presents a method to identify the water leakage from tuyere nose cooling circuit in blast furnace and the adverse effect of water leakage on the performance of the blast furnace. A system called water leak detection system is developed for different blast furnaces in Tata Steel Jamshedpur to monitor the water leakage through tuyere nose and identify the exact leaking tuyere based on a dimensionless number called leak detection factor.     

Study of solid mushroom formation in direct iron ore smelting reduction process using low temperature water model

Abstract

In the direct iron ore smelting reduction process, molten iron near the bottom blowing gas tuyere is cooled by low temperature/endothermic gas and forms a mushroom shaped solid on top of the tuyere. The formation of an appropriate solid mushroom, which covers the tuyere, can protect the tuyere and the surrounding refractory. In the present study, a water model with a low temperature gas system was established to investigate formation of the solid mushroom and the effects of operating conditions on its shape and dimensions. Transparent acrylic was used to construct the water model, which was 40% of the size of the actual furnace. Water was used to simulate the molten iron. Low temperature air, obtained by passing air through a heat exchanger cooled by liquid nitrogen, was blown into the water bath through a bottom tuyere. The air temperature was able to reach-188±1°C. In the water model experiments, water near the tuyere was cooled, and formed an ice mushroom surrounding the tuyere. The effects of operating conditions, mainly gas flowrate and mould material surrounding the tuyere, on the parameters of the solid mushroom were investigated. The parameters of the solid mushroom included whether it could be formed and duration of the solid mushroom, as well as the shape, dimensions, and weight of the solid mushroom. Attempts were also made to relate the temperature-time and pressure-time relationships of the blown gas to the parameters of the solid mushroom. With copper used as mould material surrounding the tuyere, the water model experiments were conducted with flowrate of the bottom blown gas set in the range 30-90 NL min^-1. The results show that as the gas flowrate was increased, the highest water temperature which allowed the solid mushroom to form in the water model was increased. Three different types of pressure-time curve were obtained under different gas flowrates in the present study. They also corresponded to different forms of solid mushroom. As peaks appeared in the pressure-time curve, they revealed ice capsulation and subsequent bursting to release the pressure. A gas flowrate of 80 NL min^-1 and water temperature of 19·2°C with copper plate as the bottom material are considered to be optimal conditions of the water model for growth of the appropriate ice mushroom. These data are rather consistent with the gas flowrate and superheat for the actual direct iron ore smelting reduction unit, which are 2700 NL min^-1 and 120°C (equivalent to 70 NL min^-1 and 22·7°C in the water model).     

冶金焦的本质特性与现代高炉冶炼的对应关系

 在对鞍钢焦炭质量现状进行科学分析的基础上,研究了焦炭强度、热态性能、化学组成、粒度及质量波动等对高炉冶炼的影响规律,并通过对高炉风口焦炭的实际取样与研究加以验证,指导高炉操作实践;同时,系统地掌握焦炭质量、焦炭质量对高炉冶炼的影响、焦炭质量的评价方法等;尤其是利用“风口取样”,掌握焦炭在炉内的变化规律和炉缸工作状况,为高炉操作提供技术支持,同时为焦化厂低成本生产出符合高炉运行要求的焦炭提供了依据。     

高风温在攀钢二高炉的生产实践

高炉冶炼过程中提高风温使得煤气发生量减少,理论燃烧温度增加,风口前燃烧的固定碳减少,从而降低焦比,优化高炉各项技术指标。攀钢二高炉通过2007年的年修,对热风炉进行改造,使风温从年修前的1190℃增加到目前的1230℃左右,风温长期维持在较高水平,促进了高炉各项技术经济指标的进步,使得钒钛磁铁矿冶炼技术得到提高。     

铅锌密闭鼓风炉风口喷吹技术应用探讨

分析了铅锌密闭鼓风炉的冶炼特点及风口喷煤冶炼的特征,指出了提高喷煤量的途径。介绍了ISP生产厂家风口喷吹浮渣等二次物料及粉煤的基本情况,提出了今后的研究方向。