CN104060102A - Method for mounting large-sized flash smelting furnace - Google Patents
Method for mounting large-sized flash smelting furnace Download PDFInfo
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- CN104060102A CN104060102A CN201410322544.XA CN201410322544A CN104060102A CN 104060102 A CN104060102 A CN 104060102A CN 201410322544 A CN201410322544 A CN 201410322544A CN 104060102 A CN104060102 A CN 104060102A
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Abstract
The invention discloses a method for mounting a large-sized flash smelting furnace. The method comprises the following steps: performing comprehensive electronic simulation on the flash smelting furnace, verifying the accuracy of the design size and the preassembling of all parts one by one, mounting according to a sequence of a settling pond and depletion region, a reaction tower, an uptake flue, an electrode and other parts, performing pilot run, and checking and accepting; adopting a three-dimensional logistic technology in a mounting process; taking reversible deformation measures for the whole body during mounting of a bottom beam of a furnace body in the settling pond and depletion region, and welding by using CO2 gas shielded welding. The method is characterized in that the levelness of a flat water jacket is controlled during mounting of the reaction tower, and a method of mounting at first and then positioning and holing is adopted. The method has the characteristics that cross operation can be performed, the working efficiency is improved, construction steps are reduced, the labor cost and the material consumption are reduced, the project quality is improved, the construction cycle is shortened, and general expenses are saved.
Description
Technical field
The invention belongs to equipment field engineering field, specifically relate to a kind of large-scale flash smelting furnace installation method.
Background technology
Flash smelting technology Shi You Finland is in a kind of metallurgical technology of processing powdery sulphide ores of earlier 1950s invention, its title origin is that material enters after stove, in moment, just can complete the whole process of oxidation sweetening and melting, there is lightening speed, therefore named Flash Smelting Furnace.The advantages such as flash smelting technology is one of state-of-the-art technology of world today's pyrometallurgical smelting, and it is large that it has processing power, and level of automation is high, and environmental pollution is little, energy consumption is low.Nickel flash smelting stove is mainly comprised of reaction tower, settling tank and stripping section, funnel uptake, electrode, cooling water system etc.The installation work workload of the large-scale flash smelting furnaces such as nickel flash smelting stove is large, working face is narrow and small, with high content of technology, difficulty of construction is large.In prior art, to the installation method of the large-scale flash smelting furnaces such as nickel flash smelting stove, working procedure is many, and the construction period is long, and labour intensity is large, and construction quality is poor, and cost is large.
Summary of the invention
The object of the invention is to overcome above-mentioned shortcoming and the cross-operation of a kind of energy be provided and improved working efficiency, reduce working procedure, reduced labour cost and materials consumption, improved construction quality, shorten the construction period, saved the large-scale flash smelting furnace installation method of general expenses.
A kind of large-scale flash smelting furnace installation method of the present invention, first flash smelting furnace entity is carried out to comprehensive electronic simulation, verified one by one all parts size and pre-assembled accuracy, then by the order of settling tank and stripping section, reaction tower, funnel uptake, electrode, other parts, trial run and examination, installed, in installation process, adopt stereoscopic logistic technology, in the bottom girder of settling tank and stripping section body of heater is installed, integral body is taked reversible deformation measure, and weld with CO2 shielded welding, wherein: described in reaction tower is installed, par cover levelness is controlled, adopt the method for locating holes after first installing: first by after furnace shell installation qualification, with spirit-leveling instrument, par trepanning position measure and control is good again, then with strongback, semi-automatic cutting track is installed, and by semi auto cutting machine cut chew adjust to drop-bottom at a certain angle, the perforate face of assurance is parallel with furnace bottom, angle with furnace shell, par cover supporting plate and furnace shell are fitted tightly, during welding, there is not the distortion causing due to loading level, the reference for installation level that has guaranteed par cover meets the requirements.
Above-mentioned large-scale flash smelting furnace installation method, wherein: described stereoscopic logistic technology: in main span flash smelting furnace side, flash smelting furnace workshop, annular outrigger platform is set, on outrigger platform, utilizes electric flat carriage to carry out the horizontal transport of body of heater member; On furnace roof top, each layer arranges respectively electric single beam crane.
Above-mentioned large-scale flash smelting furnace installation method, wherein: during the bottom girder of described settling tank and stripping section body of heater is installed, integral body is taked reversible deformation measure, and weld with CO2 shielded welding: the first step, adopt suitable partition member method, carry out respectively field weld, make widget free shrink, and unlikelyly cause one-piece construction distortion; Second step, adopts reversible deformation measure, will on bottom girder, face down, and in the middle part of segmentation bottom girder, places backing plate, and girder and the secondary beam direction at bottom girder adds respectively counterweight simultaneously, makes its bottom girder become upper arcuation; The 3rd step, adopts CO2 shielded welding weldprocedure to carry out non-concentrated skip welding to bottom girder and fills welding, welds completely to get except counterweight after being cooled to normal temperature reach ± 4mm of bottom girder integral solder deflection.
Above-mentioned large-scale flash smelting furnace installation method, wherein: described settling tank and stripping section parts are installed erection sequence: parts examinations → parts hoisting transportation → basic repetition measurement → cushion block installations → furnace bottom is laterally, longitudinal beam installations → bottom girder installation → drop-bottom installation → column, end carriage, longitudinal post installation → grit, furnace shell installation → copper water jacket installation → furnace roof hangs and furnace roof operator's console installation → explosionproof hole, low nickel are banished outlet, slag notch cooler installation.
Above-mentioned large-scale flash smelting furnace installation method, wherein: described reaction tower erection sequence: upper furnace shell → middle part box hat peace water jacket → profile of tooth water jacket → tower top hanging → reaction tower periphery furnace roof.
Above-mentioned large-scale flash smelting furnace installation method, wherein: described funnel uptake erection sequence: suspension rod hanging → smoke outlet device → flue skeleton and flue coaming plate → water jacket → flue furnace roof, secondary smoke outlet → manhole door, explosionproof hole.
Above-mentioned large-scale flash smelting furnace installation method, wherein: described electrode erection sequence: lifting device → electrode casing, mobile ring header → fixedly ring header → soft copper band → brasses → holding ring → band-type brake → tightness system → electrode shell → trial run.
The present invention compares with prior art, has obvious beneficial effect, from above scheme,
1 stereoscopic logistic technology: choose 6 meters of steel platforms outside main span flash smelting furnace side, flash smelting furnace workshop arranges, utilize electric flat carriage to carry out the horizontal transport of body of heater member, both solved old factory building space little, horizontal throw is long, solve again the problem that truck crane cannot efficiently utilize, shortened greatly transportation, hoisting cycle.On furnace roof top, each layer is provided with respectively electric single beam crane, a comprehensive difficult problem that solves the three-dimensional lifting of factory building inner member, has realized little space lifting machineization and lifting without the operation at dead angle, has reduced workmen, saved the time, effective guarantee construction safety.
2 arrange annular outrigger platform in stove week: obtained one and arranged the effect of multiple-effect, realized the accurately fixing and location of 66 10 ° inclination angles " movable " body of heater columns, made verticality of stand column degree reach 2mm.Realize body of heater high-altitude free of discontinuities operation around, both met working aloft requirement, avoided again setting up the little problem in stove week operating space after scaffolding.Realize the Placement Problems of installing after the advanced factory of part member, thoroughly solved the long yielding difficult problem of stove week suspension element.Realize the isolation of body of heater cross-operation around, both facilitated operation, guaranteed again construction safety.
3 bottom girder integral body are taked reversible deformation measure, and weld with CO2 shielded welding: the first step, adopt suitable partition member method, and carry out respectively field weld, make widget free shrink, and unlikelyly cause one-piece construction distortion; Second step, adopts reversible deformation measure, will on bottom girder, face down, and in the middle part of segmentation bottom girder, places the backing plate that thickness is 40mm, and girder and the secondary beam direction at bottom girder adds respectively counterweight simultaneously, makes its bottom girder become upper arcuation; The 3rd step, adopts CO2 shielded welding weldprocedure to carry out non-concentrated skip welding to bottom girder and fills welding, has reduced welding stress and bottom girder deflection, has also reduced to greatest extent the weldquality instability problem that site welding occurs simultaneously.Weld and completely get except counterweight after being cooled to normal temperature, reach ± 4mm of bottom girder integral solder deflection.
4 par cover levelness measure of control: the method that adopts locating holes after first installing.First by after furnace shell installation qualification, with spirit-leveling instrument, par trepanning position measure and control is good again, then with strongback, semi-automatic cutting track is installed, and semi auto cutting machine is cut to chew and adjust to the angle that becomes 1100 with drop-bottom, the perforate face of assurance is parallel with furnace bottom, becomes 1100 angle with furnace shell, and par cover supporting plate and furnace shell are fitted tightly, during welding, there is not the distortion causing due to loading level, guaranteed that the reference for installation level of par cover meets the requirements.
Below, by embodiment, further illustrate beneficial effect of the present invention.
Embodiment
A kind of large-scale flash smelting furnace installation method of the present invention, first flash smelting furnace entity is carried out to comprehensive electronic simulation, verified one by one all parts size and pre-assembled accuracy, then by the order of settling tank and stripping section, reaction tower, funnel uptake, electrode, other parts, trial run and examination, installed.
One settling tank and stripping section parts are installed
1 hanging device setting
Above flash smelting furnace body, ▽+11.3m absolute altitude steel column position arranges bracket along both sides, lays track, and two 10T single-beam cranes are installed; Two 10T single-beam cranes are installed at the bottom of ▽+15.5m platform above settling region, are met construction requirement.
Install 2 settling tanks and stripping section
Installation sequence
Parts examination → parts hoisting transportation → basic repetition measurement → cushion block installation → furnace bottom laterally, longitudinal beam installations → bottom girder installations → drop-bottom installations → column, end carriage, longitudinal post installation → grit, furnace shell installation → copper water jacket installation → furnace roof hangs and furnace roof operator's console installation → explosionproof hole, low nickel are banished outlet, slag notch cooler installation.
2) parts are checked and accepted
Settling tank and stripping section are before formal installation, the parts such as its bottom girder, drop-bottom, column, grit, furnace shell, end carriage, longitudinal beam, water jacket, pull bar, straining beam, spring, by schema requirement, check and accept successively, the parts of acceptance(check) are transported to field conduct by schedule in good time and install.
3) parts hoisting transportation and passage
A, body of heater transported in parts to be installed to the main span of flash smelting furnace workshop, flash smelting furnace workshop Q axle 8.-9. the platform of 6 meters is chosen outside installing in line absolute altitude+4.0m position, as the member main channel of stripping section and settling tank.
B, utilize 25T truck-mounted crane that member is hung in to the outer steel platform of 6 meters of choosing, the electric flatbed tricycle of recycling independent development is delivered to member in the working district of electric overhead travelling crane, realizes the hoisting transportation of each parts of body of heater.
4) basic repetition measurement
The setting of the datum mark of medullary ray, relief is one of important process in construction, and its accuracy requirement is high, and because of workshop light difference, construction has certain limitation, so survey crew must be measured operation daytime.
After each parts of A, flash smelting furnace are removed, body of heater is around cleaned out, surface of base and around must constructability.Before installing, by basic horizontal, the longitudinal cenlerline of Design Orientation requirements repetition measurement and absolute altitude, surface of base absolute altitude deviation is not more than 2mm, and marks the installation reference line of cushion block.
B, cushion block are processed and must to each cushion block position measurement, numbering, be determined required cushion block size, and cushion block is numbered according to the concrete elevation dimension in basis, and the numbering of cushion block Position Number and cushion block must be consistent.
5) cushion block is installed
A, by the reference line pulling in advance carry out in place after, then carry out integral body and measure.
B, to overproof basis sign record, as required overproof basis or cushion block are processed, repeatedly adjust, whole measurement, guarantee that every cushion block end face absolute altitude deviation is within the scope of (2～+ 2) mm.
C, cushion block must be placed firmly and weld with the pre-embedded steel slab of basic end face.
6) bottom girder is installed
A, bottom girder are one group (a slice) by three of technical requirementss, form altogether eight, install after being transported to scene.
B, bottom girder measure and adjust absolute altitude and level with spirit-leveling instrument after installing three, qualified rear little joist steel between three is connected, to both sides, be in place again gradually simultaneously, and finally carry out integral body adjustment, until qualified.
After C, leveling, the secondary beam connecting is welded, guarantee that each node must be smooth.
D, finally remaining contact beam is carried out to integral solder, adopt little electric current, backstep sequence welding, strictly control heat input, prevent welding distortion.
E, local welding distortion position is processed, adjust.
F, bottom girder welding set adopt KR-500 type CO2 gas shielded welding machine.
G, bottom girder are installed as and stop examining, and the self check of installation teams and groups is qualified and can carry out next procedure construction after the assay was approved through supervising engineer.
7) drop-bottom is installed
Before A, installation, body of heater medullary ray is identified on drop-bottom, and carries out protection.
B, base plate must be placed on bottom girder stably, and keep level, if find, between base plate and bottom girder, have gap, must levelling, pad.The local continuous length that its gap is greater than 2mm must not be greater than 200mm, and must not there be gap at every base plate two ends, and the gap that is greater than 2mm pads with corresponding steel plate, and parallels is carried out to spot welding and fix.
C, drop-bottom are installed rear and bottom girder tack weld, after body of heater is built by laying bricks or stones, cut open again.
The position of D, base plate piece (20mm) must, on beam, be laid before base plate cover stitches plate and foreign material in gap must be cleaned out.
8) column is installed
When A, base plate are installed, 4, the end angle positioning vertical column of reaction tower side is installed.
After four jiaos of locating dowels (8) of B, body of heater are proofreaied and correct, measure and coordinate centering post after, verticality, the diagonal lines of body of heater is checked, qualified rear at column bottom, middle part and top, arrange temporarily temporary fixed, to prevent that column from toppling over.Mounting block and column and bottom girder weld temporarily.On the cylinder of top, column inclined-plane, 100mm place arranges datum mark.Temporary supporting mainly adopts stove week to face to arrange platform.
C, column erection sequence are: from stripping section orientation angle to 9. axis, install, be mounted to 9. axis feeding-passage place and stop, then install to reaction tower direction from stripping section K axle orientation angle for one group; Another Zu Cong reaction tower district Q axle orientation angle is installed to funnel uptake direction, is mounted to 8. axis feeding-passage place and stops, and Zai Cong reaction tower district K axle orientation angle is installed to stripping section direction.
D, column are installed rear its perpendicularity deviation overall height < 5mm, adjacent upright posts deviation of centre distance < 5mm, column inside dimensions deviation ± 2mm, column end face absolute altitude deviation ± 5mm.
9) grit, furnace shell are installed
A, by design working drawing, carry out grit installation, this operation precision prescribed is high, need repeatedly adjust and can reach design requirements, must well-organized construction.
After B, grit install, carry out furnace shell installation, furnace shell and grit must be fitted closely, local gap < 3mm.Adjust in limit of error, take temporary fixed after, by grit above with the furnace shell weldering of break, every 300mm, weld 200mm.
C, measurement coordinate installs all gusset and supporting plate, carries out integral solder after installing, and takes correct welding sequence to control welding distortion in welding process.
After D, grit, furnace shell are installed welding, carry out again integral body adjustment, guarantee each size conforms design requirements.
10) straining beam assembly, top longitudinal beam, transverse beam are installed
A, top longitudinal beam are installed: top longitudinal beam divides two portions to make in source mill, the two joist steel 500mm that staggers while simultaneously noting splicing, the straightening of every joint member palpus, splice in suitable place at the scene, splice point is because vertical position welding is more with overhead welding, in splice point, must increase stiffening plate, then integral hoisting.
B, upper lateral beam are installed: employing translation Method for Installation in place carries out.
C, straining beam assembly adopt the construction of complete installation method.
11) copper water jacket is installed
Two kinds of A, flash smelting furnace settling tank and stripping section furnace shell copper water jacket employing copper coin boring water jacket and red copper pipe laying casting water jackets, installation form is level or vertical.
B, water jacket carry out pressure testing one by one by design requirements before installing, test pressure 0.6MPa, and pressurize 30 minutes, must not have seepage.After pressure testing is qualified, can install.
After C, water jacket stand the test, must keep properly, water pipe part especially, its outer end must screw on nut or tube stub, in order to avoid the threaded portion of water pipe distortion or damage, water pipe should be not stressed, in order to avoid root junction leaks.
D, furnace shell plate install, after each size conforms design requirements, by design working drawing requirement shape, size, installation site carry out water jacket installation.Vertical water jacket is first installed, rear installation par cover, bottom-up carrying out.
When E, par cover are installed, must check water spot position, guarantee that water spot is positioned at outside column.
The installation of F, water jacket pipe connecting is undertaken by the requirement of design working drawing.
G, water jacket install and carry out Hydrostatic test, and settling tank top and top, stripping section hanging water jacket test pressure are 0.6MPa, and other water jacket test pressure is 0.45MPa, and continuing all must not have seepage in 30 minutes.
Reaction tower is installed
The main installation parts of reaction tower is transported to after the main span of flash smelting furnace workshop, utilizes 50T mobile crane to choose platform outside a ▽+4.0 meter absolute altitude hangs in, the reaction tower below that recycling electric flatbed tricycle is transported to.
1 erection sequence
Upper furnace shell → middle part box hat peace water jacket → profile of tooth water jacket → tower top hanging → reaction tower periphery furnace roof.
2 reaction tower parts are checked and accepted
Reaction tower arranges 2-4 people to check that the part quality such as each single-piece box hat, water jacket meet design requirements before installing.
3 foundation beam repetition measurements and reaction tower center check
1) top box hat carries out repetition measurement to the absolute altitude of original Civil Specialities octagon collar tie beam, center, roughness before installing, be not more than ± the 10mm of absolute altitude deviation of its upper surface (area supported), be not more than ± 5mm of beam width between centers deviation, be not more than ± 5mm of the roughness of collar tie beam upper surface.
2) front inspection reaction tower center is installed and whether aims at settling tank center, be not more than ± 10mm of the deviation of two central vertical projections.
4 box hat transportations and lifting
1) top box hat tonnage weight, diameter is large, and transport difficulty is large.Whole welding utilizes flatbed trailer to be transported to flash smelting furnace workshop main span after being shaped, and that utilizes that 50T overhead traveling crane hangs in meter absolute altitude place, ▽+4.0 adopts electric flat carriage to be transported into reaction tower central position after choosing platform outward.
Utilize the newly-increased uninstalled time of anistree beam, with the monorail crane of two 10T under 21.70 meters of platforms of ▽, carry out two-shipper cooperation lifting, slowly rise while winching to 15.50 meters of about 500mm in platform top of ▽ and stop lifting by crane, start monorail crane moves to top box hat on the platform between reaction tower and Q axis simultaneously, and top box hat is paved to 500mm on platform, fulcrum area is wanted large and is wanted stressed even.
2) box hat parts, because diameter is large, easily produce distortion while directly lifting, and therefore, when lifting, adopt the angle steel of ∠ 100 * 10 to make temporary supporting.
5 top box hats are installed
1) the reaction tower medullary ray of take on drop-bottom to be identified is benchmark, the installation level attitude of centering top box hat.
2) between top box hat and octagon collar tie beam, with the teflon gasket of different thickness, adjust absolute altitude and the levelness of box hat.Be not more than ± the 10mm of absolute altitude deviation of box hat, the water level gauge levelling of the upper surface of box hat.
3) top box hat carries out two-shipper cooperation lifting with two 10T monorail cranies under 21.70 meters of platforms of ▽, from the platform of putting in advance, sling, slowly rise while winching to 15.50 meters of about 100mm in platform top of ▽, installation personnel carries out top box hat and beam centre line aligning, after while centering, slow decreasing is to installed height mark again, carries out smart centering after in place again.Two 10T monorail crane material arranged under 21.70 meters of platforms of ▽ adopt 40b joist steel.
4) the mounting center perpendicularity deviation <3mm of top box hat.
5) take the medullary ray of top box hat is benchmark centering top box hat, perpendicularity deviation <5mm.
6) the installation ring-type levelness deviation <3mm of top box hat.
7) take the installation ovality that the inner circle of top box hat is benchmark centering top box hat, the installation ovality deviation <5mm of centering upper back box hat.
8) top box hat installs after each portion is of the required size and is connected and fixed.
6 middle part box hat peace water jackets are installed
1) top box hat installs, and utilizes original 2 10T monorail cranies, adopts 4 suspension centres to lift by crane active job platform, and active job platform is the circle of Ф 7700mm.Middle part steel ring and par cover are put to active job platform and are lifted by crane installation.Recycling interim active job platform installs downwards successively.
2) monolithic par cover must carry out the water test before installing one by one, and test pressure and time length must meet design requirements.
3) every layer of par be enclosed within the water test qualified after, by design working drawing requirement, carry out pre-installation, then water jacket is numbered one by one.
4) when every layer of par cover is with the assembling of middle part box hat, position and numbering definite during according to water jacket pre-installation are fixed every water jacket and box hat with bolt, and monolithic water jacket lifting rope is selected flexible ropes.
5) in middle part box hat hoisted in position process, must there is special messenger to command, avoid colliding water jacket.During lifting, wireline suspension centre place must add soft liner.
6) each tie point of water jacket connects under the state of natural centering, forbids to apply external force and connects by force.
7) installation of water jacket pipe connecting is carried out referring to settling tank and stripping section water jacket installation requirement.
8) after water jacket installation, integral body is carried out pressure testing, notes the exhaust of every water jacket in pressure testing process, prevents from forming air chamber, affects cooling performance.
9) water jacket test pressure 0.45MPa, keeping pressure time is 30 minutes.
10) water jacket body and each tie point, if any seepage, must ascertain the reason and conscientiously process.
7 profile of tooth water jackets are installed
1) after par cover and middle part box hat installation, carry out the installation of profile of tooth water jacket.
2) monolithic profile of tooth water jacket must carry out the water test before installing one by one, and test pressure and time length meet design requirements.
3) water test qualified after, by design working drawing requirement, carry out pre-installation, then water jacket is numbered one by one.
4) while formally installing, definite position and numbering are applied mechanically bolt by every water jacket and box hat and par and are fixed during according to water jacket pre-installation.
5) installation of water jacket pipe connecting is carried out referring to settling tank and stripping section water jacket installation requirement.
6) after water jacket installation, carry out whole pressure testing, test pressure 0.6MPa, continuing must not have Seepage in 30 minutes.
7) after reaction tower box hat and water jacket install, be not more than ± 3mm of the perpendicularity deviation on overall height.
Funnel uptake is installed
Funnel uptake transported in parts to be installed, to the main span of flash smelting furnace workshop, utilizes the outer platform of choosing of 50T overhead traveling crane meter absolute altitude from ▽+9.6 to be transported into, and recycling flat-bed trailer is transported to funnel uptake central position.2 5T windlasss are set and lift, first lift smoke outlet side, then epimere skeleton, the coaming plate of the side of lifting length respectively, after hypomere skeleton, coaming plate are installed, finally lift short side.Finally utilize the attached installation that realizes other parts of top across original two electric overhead travelling cranes of top in workshop.
1 erection sequence
Suspension rod hanging → smoke outlet device → flue skeleton and flue coaming plate → water jacket → flue furnace roof, secondary smoke outlet → manhole door, explosionproof hole.
2 install main points and requirement
1) funnel uptake organizes 3 people to carry out an acceptance inspection to all parts of flue before installing, and checks that the quality such as each single-piece suspension rod, girder steel, coaming plate, water jacket meet design requirements.
2) funnel uptake must be measured and confirm that the position of funnel uptake medullary ray is accurate before installing, and the position of civil engineering girder steel must meet the requirements.
3) before flue is installed, conscientiously check that flue support section and body of heater relative position must meet design requirements.
4) flue skeleton is respectively by long side and the supply of material of short side split merogenesis.
5) while installing, first carry out top suspension bracket installation, then carry out the following part skeleton of suspension bracket and install.The place of skeleton and settling tank impact, cut skeleton at scene.
6) when flue skeleton is installed, utilize the nut of suspension rod to adjust absolute altitude and verticality.
7) water jacket must be built temporary steel platform before installing.Water jacket is installed content referring to installation, the pressure testing requirement of the flat water sleeve profile of tooth of reaction tower water jacket.
8) rear funnel uptake center line of discharge position deviation is installed and is not more than 5mm, outlet end absolute altitude deviation is not more than 5mm, and the height tolerance of outlet is not more than 5mm, and width difference is not more than 5mm.
Electrode is installed
1 hanging device setting
With workshop, ▽+26.00m absolute altitude place 5T overhead traveling crane, upper band-type brake, bearing and electrode shell are placed on from erection opening is sling on the platform of ▽+21.70m, lower band-type brake, lifting table and lifting device from slinging, are put into erection opening to ▽+15.50m platform, ▽+21.7m absolute altitude place above platform electrode lift cylinders, if two mutually perpendicular horizontal and vertical i-beam tracks (36# joist steel), each installs a 5T electric block, the parts such as installing electrodes lifting device.
2 erection sequences
Lifting device → electrode casing, mobile ring header → fixedly ring header → soft copper band → brasses → holding ring → band-type brake → tightness system → electrode shell → trial run.
3 Electrode Fluctuations, lifting device are installed
1) all kinds of hydraulic rams must purge, clean before installing, and do not allow there are any foreign material.
2) oil cylinder installation site is correct, enters oil extraction position, direction palpus correctly, and each interconnecting piece must be connected firmly, and meets the requirements.
3) each cylinder seal is good, has not allowed obvious oil impregnate phenomenon.
4) after friction plate is installed, consistent with the gap adjustment of electrode shell surrounding.
4 electric installations and electrode sealing are installed
1) mobile ring header, fixedly ring header installation
Position deviation < ± the 3mm of A, all conjunction planes of mobile ring header, will note protecting all finished surfaces in transportation and installation process, must not collide with.
B, fixedly the polishing that will eliminate rust of all conductive contact surfaces is bright before ring header assembling.During installation installation site, each size after all meeting the requirements fixedly ring header hanging be welded on civil engineering beam pre-embedded steel slab and be fixed, when hanging is installed, according to field condition, determine the length of hanging.Fixedly ring header only takes off pressing plate after installing, and only centre three row's bolts is unclamped, and the soft band of copper is installed, and the bolt on both sides must not become flexible, and must not become flexible gland bolt.
After C, installation, with the insulation resistance of all insulating point of Insulation Resistance Tester test electrode, its resistance meets design requirement.
2) copper strips is installed
A, being fixedly connected of ring header and short net bus adopts argon arc welding welding.The soft band of copper adopts tie-bolt to connect with mobile ring header, conducting copper belt with being connected of Conducting copper tile with ring header (fixing and mobile ring header), conducting copper belt.
When B, the soft band of copper and conducting copper belt transportation, to pack and prevent that bus from damaging with braid, and be put into the place that is difficult for wounding and deposit.During on-the-spot installation, if two ends copper strips has corrosion to use acid pickling and rust removing, clear water is installed on ring header after drying up after cleaning.
It is consistent that 8 soft copper band sinuousness of C, each electrode are wanted, and still needs to carry out treatment for correcting according to on-site actual situations, but will guarantee that copper strips knee must not jagged and crackle during installation.During lifting, must not injure copper strips.
Boring on D, copper strips makes aperture bright and clean by round file and flat file outshot wool thorn before installation.While installing on-the-spot, if two ends copper strips has corrosion to use acid pickling and rust removing, and clear water is cleaned and dried up, and is evenly coated with electric force compounded grease, overlaps holding bolt immediately contact surface is connected closely, and prevent that contact surface from falling into filth with the parts of regulation.Bore size on bolt specification, quantity and bus must not be changed arbitrarily, in order to avoid cause busbar shiplap joint bad and make joint area temperature rise too high.
E, conducting system will be paid special attention to when mounted the calibration of copper strips position and want accurately, guarantee the copper strips flexural deformation in process that moves up and down, and are not distorted.
3) oil cylinder must meet design requirements to casing, wedging water jacket to the insulation values of seal cartridge to wedging water jacket, brasses and mobile ring header.
4) wedging cylinder seal is good, does not reveal.Be connected reliably flexible movements with wedging cover.Wedging cover must level.Cylinder action is synchronous, and wedging cover should be basically identical to brasses wedging power.
5) Conducting copper tile must be connected closely with water-cooled tube, does not allow to reveal.Being connected with ring header should be firm.Brasses mounting height must be consistent.Weld bond is level and smooth, attractive in appearance.
6) electrode hole sealing-ring contacts with electrode is soft with the refractory fiber cloth that heat-resistant steel wire strengthens, and contact must be closely.
A, sealing bore basis must meet installation requirement.
B, each insulating part must meet requirement of withstand voltage.
C, electrode container are installed firmly and must be vertical, consistent with electrode centers.
D, electrode shell segmentation are installed, and upper-lower section gusset aligns rear firm welding.
After 7 electrodes install, water system carries out the water test of 0.35MPa; Oil system carries out the oil pressure test of 0.8MPa, in 30 minutes, all must not have Seepage, and each oil cylinder palpus flexible movements are reliable; Lifting device carries out 2～10 total travel to-and-fro movements under 0.63MPa oil pressure, must guarantee mobile steady, flexible.
After 8 electrodes are installed, integral body reaches following requirement:
1) electrode centers deviation <2mm.
2) central perpendicularity deviation <5mm.
3) the overall height inclination <5mm of casing.
4) electrode hole, electrode casing, band-type brake center and electrode centers deviation <2mm.
5) insulation resistance >=1M Ω of all insulating point of electrode.
Jinchuan Group company nickel flash smelting stove, is constructed and put into operation for 1992, is the world the 5th, Asia First nickel metallurgy flash smelting furnace.Jinchuan Group company installs in blowing out cold repair on May 25th, 2010, and planning total duration is 140 days.In Jinchuan Group company nickel flash smelting system cold repair technological transformation project flash smelting furnace installation work construction, the actual consumption that adopts the inventive method and project quota direct expenses contrast situation are in Table 1 and analysis conclusion:
Table 1 actual consumption and project quota direct expenses contrast table
| Project | Labour cost | Consumable material | Machinery takes | Total price (unit) |
| Actual consumption | 270173 | 140958 | 553551 | 964682 |
| Quota flat cost | 417901 | 149478 | 606299 | 1173678 |
| Saving rate | 35.35% | 5.7% | 8.7% | 17.81% |
1, Ф 6000mm flash smelting furnace completes installation for 50 days, and labor productivity is 28.1 tons/work day, than quota of budget, has improved 35.35%.
2, CO2 shielded welding, energy consumption is low, and the electric energy of every meter of weld seam consumption is the more than 40% of electrode arc welding.
3, the installation work of Jinchuan Group company nickel flash smelting system cold repair technological transformation project flash smelting furnace is owing to adopting the construction of this engineering method, manages properly, within 5 days in advance, goes into operation, for Jinchuan Group company creates 1.4 hundred million yuan of the output values, obtained good economic benefit.
4, by maintenance, flash smelting furnace output is brought up to 70,000 tons of nickel contents by 60,000 tons of former annual outputs, has obtained good social benefit.
The above, it is only preferred embodiment of the present invention, not the present invention is done to any pro forma restriction, any technical solution of the present invention content that do not depart from, any simple modification, equivalent variations and the modification above embodiment done according to technical spirit of the present invention, all still belong in the scope of technical solution of the present invention.
Claims (7)
1. one kind large-scale flash smelting furnace installation method, first flash smelting furnace entity is carried out to comprehensive electronic simulation, verified one by one all parts size and pre-assembled accuracy, then by the order of settling tank and stripping section, reaction tower, funnel uptake, electrode, other parts, trial run and examination, installed, in installation process, adopt stereoscopic logistic technology, in the bottom girder of settling tank and stripping section body of heater is installed, integral body is taked reversible deformation measure, and weld with CO2 shielded welding, it is characterized in that: described in reaction tower is installed, par cover levelness is controlled, adopt the method for locating holes after first installing: first by after furnace shell installation qualification, with spirit-leveling instrument, par trepanning position measure and control is good again, then with strongback, semi-automatic cutting track is installed, and by semi auto cutting machine cut chew adjust to drop-bottom at a certain angle, the perforate face of assurance is parallel with furnace bottom, angle with furnace shell, par cover supporting plate and furnace shell are fitted tightly, during welding, there is not the distortion causing due to loading level, the reference for installation level that has guaranteed par cover meets the requirements.
2. large-scale flash smelting furnace installation method as claimed in claim 1, it is characterized in that: described stereoscopic logistic technology: in main span flash smelting furnace side, flash smelting furnace workshop, annular outrigger platform is set, on outrigger platform, utilizes electric flat carriage to carry out the horizontal transport of body of heater member; On furnace roof top, each layer arranges respectively electric single beam crane.
3. large-scale flash smelting furnace installation method as claimed in claim 1 or 2, it is characterized in that: during the bottom girder of described settling tank and stripping section body of heater is installed, integral body is taked reversible deformation measure, and weld with CO2 shielded welding: the first step, adopt suitable partition member method, carry out respectively field weld, make widget free shrink, and unlikelyly cause one-piece construction distortion; Second step, adopts reversible deformation measure, will on bottom girder, face down, and in the middle part of segmentation bottom girder, places backing plate, and girder and the secondary beam direction at bottom girder adds respectively counterweight simultaneously, makes its bottom girder become upper arcuation; The 3rd step, adopts CO2 shielded welding weldprocedure to carry out non-concentrated skip welding to bottom girder and fills welding, welds completely to get except counterweight after being cooled to normal temperature reach ± 4mm of bottom girder integral solder deflection.
4. large-scale flash smelting furnace installation method as claimed in claim 1 or 2, is characterized in that: described settling tank and stripping section parts are installed erection sequence: parts examinations → parts hoisting transportation → basic repetition measurement → cushion block installations → furnace bottom laterally, longitudinal beam installations → bottom girder installation → drop-bottom installation → column, end carriage, longitudinal post installation → grit, furnace shell installation → copper water jacket installation → furnace roof hangs and furnace roof operator's console installation → explosionproof hole, low nickel are banished outlet, slag notch cooler installation.
5. large-scale flash smelting furnace installation method as claimed in claim 3, is characterized in that: described reaction tower erection sequence: upper furnace shell → middle part box hat peace water jacket → profile of tooth water jacket → tower top hanging → reaction tower periphery furnace roof.
6. large-scale flash smelting furnace installation method as claimed in claim 1 or 2, is characterized in that: described funnel uptake erection sequence: suspension rod hanging → smoke outlet device → flue skeleton and flue coaming plate → water jacket → flue furnace roof, secondary smoke outlet → manhole door, explosionproof hole.
7. large-scale flash smelting furnace installation method as claimed in claim 1 or 2, is characterized in that: described electrode erection sequence: lifting device → electrode casing, mobile ring header → fixedly ring header → soft copper band → brasses → holding ring → band-type brake → tightness system → electrode shell → trial run.
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