CN103333979A - 电煤法熔分还原炼铁系统及其工艺流程 - Google Patents
电煤法熔分还原炼铁系统及其工艺流程 Download PDFInfo
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- CN103333979A CN103333979A CN2013100865030A CN201310086503A CN103333979A CN 103333979 A CN103333979 A CN 103333979A CN 2013100865030 A CN2013100865030 A CN 2013100865030A CN 201310086503 A CN201310086503 A CN 201310086503A CN 103333979 A CN103333979 A CN 103333979A
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- ironmaking
- coal method
- molten
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- iron production
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- 230000001603 reducing Effects 0.000 title claims abstract description 62
- 239000003245 coal Substances 0.000 title claims abstract description 52
- 238000000034 method Methods 0.000 title claims abstract description 22
- 238000003723 Smelting Methods 0.000 title claims abstract description 15
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound 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[C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 59
- 238000004519 manufacturing process Methods 0.000 claims abstract description 44
- 239000002893 slag Substances 0.000 claims abstract description 40
- 239000008188 pellet Substances 0.000 claims abstract description 31
- 238000003860 storage Methods 0.000 claims abstract description 21
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- UGFAIRIUMAVXCW-UHFFFAOYSA-N carbon monoxide Chemical compound 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[O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 abstract description 3
- 239000003546 flue gas Substances 0.000 abstract description 3
- 239000000446 fuel Substances 0.000 abstract description 3
- 239000004568 cement Substances 0.000 abstract description 2
- 238000004939 coking Methods 0.000 abstract description 2
- 238000011084 recovery Methods 0.000 abstract description 2
- 239000003638 reducing agent Substances 0.000 abstract description 2
- 230000002829 reduced Effects 0.000 description 13
- 239000000428 dust Substances 0.000 description 7
- 230000005611 electricity Effects 0.000 description 7
- 239000003795 chemical substances by application Substances 0.000 description 6
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Abstract
本发明涉及一种电煤法熔分还原炼铁系统及其工艺流程。高炉炼铁是炼铁生产的主体，对冶金焦的强烈依赖，需采用其他非焦煤燃料代替冶金焦降低炼铁成本。本发明所述的电煤法熔分还原炼铁系统，依序包含有大倾角金属球团热送装置、保温储料仓、水平金属球团热送装置、电煤法熔分还原炼铁炉体和倾炉平台，利用电煤法进行熔分还原炼铁。本发明优化能源和原料结构，合理利用资源，设计了独特的炉体结构、采用了高温烟气和CO回收综合利用技术，可以利用余热，CO的回收可以用作还原金属化球团的还原剂，采用水焠渣，水焠渣可以综合利用作为制作水泥的原料，有效降低了炼铁成本。
Description
电煤法熔分还原炼铁系统及其工艺流程
技术领域
[0001] 本发明涉及一种非高炉炼铁的冶金设备，具体涉及一种电煤法熔分还原炼铁系统及其工艺流程。
背景技术
[0002] 高炉炼铁是炼铁生产的主体。经过长时期的发展，它的技术已经非常成熟。但它也存在着固有的不足。即其对冶金焦的强烈依赖。随着焦煤资源的日渐贫乏，冶金焦的资源价格越来越高。与此相反，蕴藏丰富的廉价非焦煤资源在炼铁生产中则得不到充分的利用。为了降低炼铁成本，人们一直在不断努力寻求以其他非焦煤燃料代替冶金焦的途径。
[0003] 此外，我国高炉炼铁所需的优质铁矿石长期依赖进口，并经常受国外供应商的制约。如何开发利用我国储量丰富的贫铁矿资源生产铁水，越来越成为我国钢铁生产迫切需要解决的课题。因此，我国乃至世界上发展非高炉炼铁生产的要求也越来越迫切。为此，经过冶金工作者长期的研究和开发，至今已初步形成了以直接还原和熔分还原为主体的现代化非高炉炼铁技术。但是，目前国内外的非高炉炼铁技术和设备还普遍存在着工艺复杂、投资大、能耗闻等诸多问题。
[0004] 我国具有发展非高炉炼铁的迫切需要和优越条件。如何针对我国煤炭和铁矿石资源的现实条件，研制、开发以非焦煤燃料代替冶金焦生产的金属化球团为原料，通过熔分还原工艺生产铁水，工艺适用、投资少见效快、能耗低的熔分还原设备，具有十分重要的现实意义和广阔前景。
发明内容
[0005] 本发明的目的是提供一种采用气基或煤基直接还原铁矿石生产的金属化球团作为原料、通过电弧加热和加入还原剂将金属化球团熔化、还原和渣铁分离生产液态生铁的电煤法熔分还原炼铁系统及其工艺流程。
[0006] 本发明所采用的技术方案是:
电煤法熔分还原炼铁系统，其特征在于:
所述的系统中依序包含有大倾角金属球团热送装置、保温储料仓、水平金属球团热送装置、电煤法熔分还原炼铁炉体和倾炉平台。
[0007] 所述的大倾角金属球团热送装置的输送通道为从低位到高位的传送带，传送带全程设置密封的保护罩，低位置处设置驱动装置和链板机，高位置处设置氮气保护装置向输送通道中输送氮气。
[0008] 所述的保温储料仓自上而下设置有出料仓、振动给料装置和称量仓，振动给料装置下端设置有冷却装置，称量仓中设置有称量装置。
[0009] 所述的保温储料仓由钢支架支撑。
[0010] 所述的水平金属球团热送装置的核心部件为具有驱动装置的螺旋进料装置，螺旋进料装置置于余热除尘复合通道中，螺旋进料装置出口处设置有保温装置；余热除尘复合通道的下端也同时作为复合输料除尘管道。
[0011] 所述的电煤法熔分还原炼铁炉体的底部为球形底，球形底上部为直边筒体，直边筒体上盖有水冷炉盖，整体密封；直边筒体的上部设置有水冷密排盘管；
水冷炉盖为无缝钢管密排焊接而成的管式水冷结构，由炉盖本体和炉盖本体上部的上中心盖组成，上中心盖顶部设置有除尘管道和加料溜管；
炉体下部设置有低位长糟的出铁槽和高位短糟的出渣槽。
[0012] 所述的电煤法熔分还原炼铁炉体内设置有搅拌枪。
[0013] 所述的电煤法熔分还原炼铁炉体整体安装在倾炉平台上；
倾炉平台设置有两个半圆弧形支架，支架下方设置有有支撑滚轮，支架一侧的底部设置有倾炉油缸，另一侧设置有水平支撑。
[0014] 所述的电煤法熔分还原炼铁系统的工艺流程，其特征在于:
步骤一:大倾角金属球团热送装置从用气基出口处接受高温金属化球团，并在非氧化性气氛条件下将高温金属化球团由低位送到高位的保温储料仓中，全程密封；
步骤二:保温储料仓对高温金属化球团进行重量称量后，通过振动给料装置将高温金属化球团送入水平金属球团热送装 步骤三:高温金属化球团通过水平金属球团热送装置送入电煤法熔分还原炼铁炉体中，电弧加热熔化，期间用搅拌枪喷碳，搅拌熔池熔渣；
步骤四:在冶炼过程中通过多次工艺性的扒渣来减少渣层高度；随着金属化球团的连续加入和喷煤粉的连续进行，电极进入渣层按照冶炼模型设定的功率输入进行埋弧、长弧冶炼加热，同时伴随着煤粉的氧化燃烧发热，再通过搅拌枪的喷吹搅拌进行成分、温度的均匀，最终将原料球团进行升温、熔化，实现渣、铁的分离；
步骤五:在炉内的铁水量达到预定目标值时，将要进行出铁操作，出铁前为防止渣层过高侵蚀炉体上部耐材及设备，需要出渣，一般出渣至留渣量为5% ；
步骤六:冶炼生成的铁水量达到目标值后进行出渣操作，出渣完成后进行出铁，将目标数量的铁水通过出铁口流入铁水包，通过天车或运输车离开，进行下一个工艺工程。
[0015] 本发明具有以下优点:
I)优化能源和原料结构，合理利用资源:
本发明的熔分还原以普通煤炭和电能(电弧加热)作为主要能源生产铁水，炉料可以大量或全部(100 %)采用以我国蕴藏量丰富的贫铁矿资源生产的全铁含量(TFe)S 70%的一般品位金属化球团作为主要原料。采用金属化球团热送、热装技术，储料仓和螺旋送料机构的保温和非氧化性气氛保护技术，减少了金属球团的二次氧化，降低能耗节约能源。根据热平衡计算，金属球团物料的温度每升高100°c可以节约电能〜23Kw.ho
[0016] 2)本发明采用了独特的炉体结构。
[0017] 本发明的搅拌枪枪体可以上下、左右摆动和前进后退搅拌熔池，搅拌枪并可喷碳粉进行还原和增碳，另外碳粉燃烧产生的热能也是一种辅助能源；出渣或者出铁过程中采用了固定托轮和炉体滚动倾动，在不破坏熔分炉还原气氛条件实现连续加料；在炉体上设置炉衬和熔池的观察监控装置，对接合部的密封进行精细设计采用了水封、气封等多种结构，确保在炉内和熔池表面保持强还原气氛，还原效率高；将加料和排烟孔合二为一布置在同一通道，降低了热量损失，同时利用高温烟气可以预热金属化球团和其他炉料。[0018] 3)本发明采用了高温烟气和CO回收综合利用技术，可以利用余热，CO的回收可以用作还原金属化球团的还原剂；采用水烊渣，水烊渣可以综合利用作为制作水泥的原料。
附图说明
[0019] 图1为系统平面布置图。
[0020] 图2为系统立面布置图。
[0021] 图3为大倾角金属球团热送装置结构图。
[0022] 图4为保温储料仓结构图。
[0023] 图5为水平金属球团热送装置结构图。
[0024] 图6为电煤法熔分还原炼铁炉体结构图。
[0025] 图7为倾炉平台结构图。
[0026] 图8为搅拌枪结构图。
[0027] 图中，1-大倾角金属球团热送装置，2-保温储料仓，3-水平金属球团热送装置，4-电煤法熔分还原炼铁炉体，5-倾炉平台，6-传送带，7-保护罩，8-大倾角金属球团热送装置驱动装置，9-链板机，10-氮气保护装置，11-出料仓，12-振动给料装置，13-称量仓，14-称量装置，15-水平金属球团热送装置驱动装置，16-螺旋进料装置，17-余热除尘复合通道，18-复合输料除尘管道，19-保温装置，20-球形底，21-直边筒体，22-水冷炉盖，23-水冷密排盘管，24-炉盖本体，25-上中心盖，26-除尘管道，27-加料溜管，28-隔热材料，29-固定装置，30 -冷却装置，31-支架，32-支撑滚轮，33-倾炉油缸，34-水平支撑，35-钢支架，36-搅拌枪，37-切换阀，38-加料除尘旋转接口，39-填沙机构，40-搅拌枪驱动装置,41-耐材枪,42-调整装置。
具体实施方式
[0028] 下面结合具体实施方式对本发明进行详细的说明。
[0029] 本发明的电煤法溶分还原炼铁电炉(Smelting Reduction Electric IronmakingFurnace)简称SREIF炉是涉及一种非高炉炼铁的冶金设备，其以热(冷)金属化球团(直接还原铁)或者金属渣料为原材料，以电、煤为热力学和还原条件生产高纯度铁水或者生产高纯度的钒、镍、钛渣设备。本发明的电煤法SREIF-熔分还原炼铁电炉与转底炉、竖炉、回转窑等用煤基(气基)生产金属化球团(直接还原铁)设备双联，组成现代化非高炉炼铁生产新流程。
[0030] 同时本发明也适用于使用钢渣、铁渣、含铁粉尘为原料的炼铁(钢)工艺。
[0031] 本发明SREIF-熔分还原炼铁电炉为了解决上述背景技术中的不足之处，提供一种新型非高炉炼铁设备。其主要技术特征是:既抛开了通常使用电阻电弧加热的矿热炉熔分形式，采用电弧明弧加热熔分的电弧熔炼原理，但又有别于常规的炼钢电弧炉。在熔炼的炉料、冶炼的最终产品、炉体的结构、搅拌枪的设置、排烟烟道与加料孔的设置、炉料及还原剂的保温储存与输送方式、炉衬及熔池观察监控装置的设置等方面有独创技术和诀窍，SREIF-熔分还原炼铁电炉是一种新型的熔分还原炼铁电炉。
[0032] 本发明所述的电煤法熔分还原炼铁系统，依序包含有大倾角金属球团热送装置1、保温储料仓2、水平金属球团热送装置3、电煤法熔分还原炼铁炉体4和倾炉平台5。[0033] 大倾角金属球团热送装置I的输送通道为从低位到高位的传送带6，传送带全程设置密封的保护罩7，低位置处设置驱动装置8和链板机9，高位置处设置氮气保护装置10向输送通道中输送氮气。输送能力和转底炉的生产能力相匹配，并留有一定的富裕量，输送速度的控制采用VVVF控制。
[0034] 保温储料仓2自上而下设置有出料仓11、振动给料装置12和称量仓13，振动给料装置12下端设置有冷却装置30，称量仓13中设置有称量装置14。
[0035] 保温储料仓2由钢支架35支撑。
[0036] 水平金属球团热送装置3的核心部件为具有驱动装置15的螺旋进料装置16，螺旋进料装置16置于余热除尘复合通道17中，螺旋进料装置3出口处设置有保温装置19 ；
余热除尘复合通道17的下端也同时作为复合输料除尘管道18。
[0037] 电煤法熔分还原炼铁炉体4的底部为球形底20，球形底上部为直边筒体21，直边筒体21上盖有水冷炉盖22，整体密封；直边筒体21的上部设置有水冷密排盘管23 ；
水冷炉盖22为无缝钢管密排焊接而成的管式水冷结构，由炉盖本体24和炉盖本体上部的上中心盖25组成，上中心盖25顶部设置有除尘管道26和加料溜管27 ； 炉体下部设置有低位长糟的出铁槽和高位短糟的出渣槽。
[0038] 电煤法熔分还原炼铁炉体4内设置有搅拌枪36，搅拌枪(耐火材料自耗式)装置可以上下、左右、前进后退运动。依据工艺要求，为熔分还原提供化学反应的动力学条件一-熔`池搅拌。通过对熔池的搅拌，加强了渣中FeO的还原等各种化学反应；通过对熔池的搅拌，可以将金属球团均匀、集中分布在电弧的高温区，提高了熔融的热效率，避免或减少了金属球团的软融层，不使熔池形成搭桥现象；通过对熔池的搅拌，可以均匀渣的温度和铁水的温度和加强渣铁反应。搅拌枪装置可以通过载体气体向渣层或铁水喷入碳粉。依据工艺要求，碳粉作为还原剂可以为熔分还原(包括渣中FeO的还原)提供直接还原和间接还原(CO)所需要的还原剂；可以通过向铁水喷入碳粉实施铁水增碳；碳粉燃烧产生的热能也是一种辅助能源。
[0039] 搅拌枪根据工艺需要的数量安装在水冷炉盖或炉体上炉壳水冷壁上，通过法兰进行连接。穿过水冷壁上的开孔深入炉内进行搅拌。。
[0040] 电煤法熔分还原炼铁炉体4整体安装在倾炉平台5上；
倾炉平台5设置有两个半圆弧形支架31，支架31下方设置有有支撑滚轮32，支架31一侧的底部设置有倾炉油缸33，另一侧设置有水平支撑34。
[0041] 其他装置:
(I) TV观察监控装置
设备功能:在炉体的侧壁安装有多个TV观察监控装置，用以实现对“密封”的SREIF炉内工艺状态(泡沫渣的沸腾、渣液的流动、球团料的分布、炉衬的侵蚀等)全过程进行实时监控，为调整工艺操作提供实时、动态的依据。
[0042] TV观察监控装置由安装于频闪观察玻璃上方的TV长焦距摄像头(针孔)，水冷保护套及旋转支架、清扫机构、气体保护机构等组成。摄像装置摄像头可以旋转，当摄像头转离观察窗时，可进行人工观测。
[0043] 在炉体底部设有多点温度传感器用以监测炉衬状况。
[0044] (2) SREIF电炉变压器和电抗器设备功能:为确保SREIF炉的产能要求，依据不同工艺阶段为熔分还原炉(SREIF)提供最优化的能量供给方式。保证热力学条件之一的电能与金属球团的熔融和输送速度相适应，采用多档位二次电压电动有载调压电炉变压器。SREIF炉的供电制度采用高阻抗、长弧操作，为实现高阻抗、长弧操作，SREIF炉变压器带有电抗器。
[0045] (3) SREIF炉的三相电极升降电弧加热系统、大电流短网系统、高压系统和SREIF低压电控及PLC自动化控制系统，以及液压系统、手动集中润滑装置、带称量的出铁车及拖缆装置、水冷系统、气动系统、电极存放及联接装置等，与炼钢电弧炉相类似。
[0046] 总的工艺流程为:从转底炉或者竖炉、回转窑等用气基煤基直接还原设备生产的金属化球团/直接还原铁DRI出口处受料一用采用N2保护的大倾角金属球团热送装置将热金属球团900〜1000°C输送到SREIF炉的保温储料仓一称量、震动给料球团、还原剂、渣料一螺旋给料机连续输送物料进入炉内高温区一电弧加热熔化同时炉体搅拌枪喷碳一搅拌熔池熔渣喷碳粉还原一测温取样一工艺性扒渣一电弧加热熔化一工艺性扒渣一电弧加热熔化一测温取样温度、成分达标一出铁前扒渣、定量出铁留渣、留铁。
[0047] 具体步骤为:
步骤一:大倾角金属球团热送装置从用气基出口处接受高温金属化球团，并在非氧化性气氛条件下将高温金属化球团由低位送到高位的保温储料仓中，全程密封；
步骤二:保温储料仓对高温金属化球团进行重量称量后，通过振动给料装置将高温金属化球团送入水平金属球团热送装置；
步骤三:高温金属化球团通过水平金属球团热送装置送入电煤法熔分还原炼铁炉体中，电弧加热熔化，期间用搅拌枪喷碳，搅拌熔池熔渣；
步骤四:在冶炼过程中通过多 次工艺性的扒渣来减少渣层高度；随着金属化球团的连续加入和喷煤粉的连续进行，电极进入渣层按照冶炼模型设定的功率输入进行埋弧、长弧冶炼加热，同时伴随着煤粉的氧化燃烧发热，再通过搅拌枪的喷吹搅拌进行成分、温度的均匀，最终将原料球团进行升温、熔化，实现渣、铁的分离；
步骤五:在炉内的铁水量达到预定目标值时，将要进行出铁操作，出铁前为防止渣层过高侵蚀炉体上部耐材及设备，需要出渣，一般出渣至留渣量为5% ；
步骤六:冶炼生成的铁水量达到目标值后进行出渣操作，出渣完成后进行出铁，将目标数量的铁水通过出铁口流入铁水包，通过天车或运输车离开，进行下一个工艺工程。
[0048] 电煤法SREIF炉主要技术经济指标见下表1:
表I主要技术经济指标
本发明的内容不限于实施例所列举，本领域普通技术人员通过阅读本发明说明书而对本发明技术方案采取的任何等效的变换，均为本发明的权利要求所涵盖。
Claims (9)
1.电煤法熔分还原炼铁系统，其特征在于: 所述的系统中依序包含有大倾角金属球团热送装置(I)、保温储料仓(2)、水平金属球团热送装置(3)、电煤法熔分还原炼铁炉体(4)和倾炉平台(5)。
2.根据权利要求1所述的电煤法熔分还原炼铁系统，其特征在于: 所述的大倾角金属球团热送装置(I)的输送通道为从低位到高位的传送带(6)，传送带全程设置密封的保护罩(7)，低位置处设置驱动装置(8)和链板机(9)，高位置处设置有向输送通道中输送氮气的氮气保护装置(10)。
3.根据权利要求1或2所述的电煤法熔分还原炼铁系统，其特征在于: 所述的保温储料仓(2)自上而下设置有出料仓(11)、振动给料装置(12)和称量仓(13)，振动给料装置(12)下端设置有冷却装置(30)，称量仓(13)中设置有称量装置(14)。
4.根据权利要求3所述的电煤法熔分还原炼铁系统，其特征在于: 所述的水平金属球团热送装置(3)设置有具有驱动装置(15)的螺旋进料装置(16)，螺旋进料装置(16 )置于余热除尘复合通道(17 )中，螺旋进料装置(3 )出口处设置有保温装置(19)； 余热除尘复合通道(17)的下端也同时作为复合输料除尘管道(18)。
5.根据权利要求4所述的电煤法熔分还原炼铁系统，其特征在于:· 所述的电煤法熔分还原炼铁炉体(4)的底部为球形底(20)，球形底上部为直边筒体(21 )，直边筒体(21)上盖有水冷炉盖(22)，整体密封；直边筒体(21)的上部设置有水冷密排盘管(23)； 水冷炉盖(22)为无缝钢管密排焊接而成的管式水冷结构，由炉盖本体(24)和炉盖本体上部的上中心盖(25)组成，上中心盖(25)顶部设置有除尘管道(26)和加料溜管(27)；炉体下部设置有低位长糟的出铁槽和高位短糟的出渣槽。
6.根据权利要求5所述的电煤法熔分还原炼铁系统，其特征在于: 所述的保温储料仓(2)由钢支架(35)支撑。
7.根据权利要求6所述的电煤法熔分还原炼铁系统，其特征在于: 所述的电煤法熔分还原炼铁炉体(4 )内设置有搅拌枪(36 )。
8.根据权利要求7所述的电煤法熔分还原炼铁系统，其特征在于: 所述的电煤法熔分还原炼铁炉体(4)整体安装在倾炉平台(5)上； 倾炉平台(5)设置有两个半圆弧形支架(31)，支架(31)下方设置有有支撑滚轮(32)，支架(31) —侧的底部设置有倾炉油缸(33)，另一侧设置有水平支撑(34)。
9.根据权利要求1所述的电煤法熔分还原炼铁系统的工艺流程，其特征在于: 步骤一:大倾角金属球团热送装置从用气基出口处接受高温金属化球团，并在非氧化性气氛条件下将高温金属化球团由低位送到高位的保温储料仓中，全程密封； 步骤二:保温储料仓对高温金属化球团进行重量称量后，通过振动给料装置将高温金属化球团送入水平金属球团热送装置； 步骤三:高温金属化球团通过水平金属球团热送装置送入电煤法熔分还原炼铁炉体中，电弧加热熔化，期间用搅拌枪喷碳，搅拌熔池熔渣； 步骤四:在冶炼过程中通过多次工艺性的扒渣来减少渣层高度；随着金属化球团的连续加入和喷煤粉的连续进行，电极进入渣层按照冶炼模型设定的功率输入进行埋弧、长弧冶炼加热，同时伴随着煤粉的氧化燃烧发热，再通过搅拌枪的喷吹搅拌进行成分、温度的均匀，最终将原料球团进行升温、熔化，实现渣、铁的分离； 步骤五:在炉内的铁水量达到预定目标值时，将要进行出铁操作，出铁前为防止渣层过高侵蚀炉体上部耐材及设备，需要出渣，一般出渣至留渣量为5% ； 步骤六:冶炼生成的铁水量达到目标值后进行出渣操作，出渣完成后进行出铁，将目标数量的铁水通过出铁 口流入铁水包，通过天车或运输车离开，进行下一个工艺工程。
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