CN104060102B - A kind of large-scale flash smelting furnace installation method - Google Patents
A kind of large-scale flash smelting furnace installation method Download PDFInfo
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- CN104060102B CN104060102B CN201410322544.XA CN201410322544A CN104060102B CN 104060102 B CN104060102 B CN 104060102B CN 201410322544 A CN201410322544 A CN 201410322544A CN 104060102 B CN104060102 B CN 104060102B
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Abstract
The invention discloses a kind of large-scale flash smelting furnace installation method, first comprehensive electronic simulation is carried out to flash smelting furnace entity, demonstrate all parts size and pre-assembled accuracy one by one, then install by the order of settling tank and stripping section, reaction tower, funnel uptake, electrode, other parts, trial run and examination; Stereoscopic logistic technology is adopted in installation process; In the bottom girder of settling tank and stripping section body of heater is installed, entirety takes reversible deformation measure, and with the welding of CO2 shielded welding, it is characterized in that: described in reaction tower is installed, and controls, adopt the method for locating holes after first installing to par cover levelness.The present invention has energy cross-operation and improves working efficiency, decreases working procedure, reduces labour cost and materials consumption, improve construction quality, shorten the construction period, saved the feature of general expenses.
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 is a kind of metallurgical technology processing powdery sulphide ores invented in earlier 1950s by Finland, its title origin is after material enters stove, just can complete the whole process of oxidation sweetening and melting in moment, there is lightening speed, therefore named Flash Smelting Furnace.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, the advantages such as level of automation is high, and environmental pollution is little, energy consumption is low.Nickel flash smelting stove is primarily of compositions such as reaction tower, settling tank and stripping section, funnel uptake, electrode, cooling water systems.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 improve working efficiency, decrease working procedure, reduce labour cost and materials consumption, improve construction quality, shorten the construction period, save the large-scale flash smelting furnace installation method of general expenses.
The large-scale flash smelting furnace installation method of one of the present invention, first comprehensive electronic simulation is carried out to flash smelting furnace entity, demonstrate all parts size and pre-assembled accuracy one by one, then install by the order of settling tank and stripping section, reaction tower, funnel uptake, electrode, other parts, trial run and examination, stereoscopic logistic technology is adopted in installation process, in the bottom girder of settling tank and stripping section body of heater is installed, entirety takes 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, again with spirit-leveling instrument by good for par trepanning position measure and control, then with strongback by good for semi-automatic cutting track installation, and semi auto cutting machine is cut chew adjust to drop-bottom at a certain angle, the perforate face of guarantee is parallel with furnace bottom, with the angle of furnace shell, par cover supporting plate and furnace shell are fitted tightly, the distortion caused due to loading level is there is not during welding, ensure that the reference for installation level that par overlaps meets the requirements.
Above-mentioned large-scale flash smelting furnace installation method, wherein: described stereoscopic logistic technology: annular outrigger platform is set in main span flash smelting furnace side, flash smelting furnace workshop, outrigger platform utilizes electric flat carriage carry out the horizontal transport of body of heater component; On furnace roof top, each layer arranges electric single beam crane respectively.
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, entirety takes reversible deformation measure, and weld with CO2 shielded welding: the first step, adopt suitable partition member method, carry out field weld respectively, make widget free shrink, and the unlikely one-piece construction that causes is out of shape; Second step, adopts reversible deformation measure, faces down on bottom girder, places backing plate in the middle part of segmentation bottom girder, adds counterweight respectively simultaneously, make its bottom girder become upper arcuation at the girder of bottom girder and secondary beam direction; 3rd step, adopts CO2 shielded welding weldprocedure to carry out non-concentrated skip welding to bottom girder and fills welding, weld complete be cooled to normal temperature after get except counterweight, bottom girder integral solder deflection reaches ± 4mm.
Above-mentioned large-scale flash smelting furnace installation method, wherein: described settling tank and stripping section parts install erection sequence: parts check and accept → parts hoisting transportation → basic repetition measurement → cushion block installs → furnace bottom laterally, longitudinal beam installs → bottom girder installs → drop-bottom installs → column, → grit installed by end carriage, longitudinal post, furnace shell is installed → copper water jacket installs → furnace roof is hung and → explosionproof hole installed by furnace roof operator's console, low nickel banish export, slag notch cooler installs.
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 → fixing ring header → soft copper band → brasses → holding ring → band-type brake → tightness system → electrode shell → trial run.
The present invention, compared with prior art, has obvious beneficial effect, from above scheme,
1 stereoscopic logistic technology: choose 6 meters of steel platforms outside arranging in main span flash smelting furnace side, flash smelting furnace workshop, electric flat carriage is utilized to carry out the horizontal transport of body of heater component, both old hall space had been solved little, horizontal throw is long, solving again truck crane cannot the problem of efficiency utilization, shortens transport, hoisting cycle greatly.On furnace roof top, each layer is provided with electric single beam crane respectively, the comprehensive difficult problem solving the lifting of factory building inner member solid, the operation achieving little space lifting machineization and lift without dead angle, decreases workmen, save the time, effective guarantee construction safety.
2 arrange annular outrigger platform in stove week: achieve an effect arranging multiple-effect, achieve the accurately fixing of 66 10 ° inclination angle " movable " body of heater columns and location, make verticality of stand column degree reach 2mm.Achieve free of discontinuities operation in high-altitude around body of heater, both met working aloft requirement, turn avoid and set up the little problem in the operating space of stove week after scaffolding.The Placement Problems installed after achieving the advanced factory of part component, thoroughly solves the long yielding difficult problem of stove week suspension element.Achieve the isolation of cross-operation around body of heater, both facilitated operation, in turn ensure that construction safety.
3 bottom girder entirety take reversible deformation measure, and weld with CO2 shielded welding: the first step, adopt suitable partition member method, carry out field weld respectively, make widget free shrink, and the unlikely one-piece construction that causes is out of shape; Second step, adopts reversible deformation measure, faces down on bottom girder, and placing thickness in the middle part of segmentation bottom girder is the backing plate of 40mm, adds counterweight respectively simultaneously, make its bottom girder become upper arcuation at the girder of bottom girder and secondary beam direction; 3rd step, adopts CO2 shielded welding weldprocedure to carry out non-concentrated skip welding to bottom girder and fills welding, reduce welding stress and bottom girder deflection, also decrease the weldquality instability problem that site welding occurs simultaneously to greatest extent.Weld complete be cooled to normal temperature after get except counterweight, bottom girder integral solder deflection reaches ± 4mm.
4 par cover levelness measure of control: the method adopting locating holes after first installing.First by after furnace shell installation qualification, again with spirit-leveling instrument by good for par trepanning position measure and control, then with strongback by good for semi-automatic cutting track installation, and semi auto cutting machine is cut the angle chewed and adjust to become with drop-bottom 1100, the perforate face of guarantee is parallel with furnace bottom, becomes the angle of 1100 with furnace shell, and par cover supporting plate and furnace shell are fitted tightly, there is not the distortion caused due to loading level during welding, ensure that the reference for installation level that par overlaps meets the requirements.
Below by way of embodiment, further illustrate beneficial effect of the present invention.
Embodiment
The large-scale flash smelting furnace installation method of one of the present invention, first comprehensive electronic simulation is carried out to flash smelting furnace entity, demonstrate all parts size and pre-assembled accuracy one by one, then install by the order of settling tank and stripping section, reaction tower, funnel uptake, electrode, other parts, trial run and examination.
One settling tank and stripping section parts are installed
1 hanging device is arranged
Above flash smelting furnace body, ▽+11.3m absolute altitude steel column locations arranges bracket along both sides, lays track, installs two 10T single-beam cranes; Above settling region, at the bottom of ▽+15.5m platform, two 10T single-beam cranes are installed, meet construction requirement.
2 settling tanks and stripping section are installed
Installation sequence
Parts examination → parts hoisting transportation → basic repetition measurement → cushion block installation → furnace bottom transverse direction, the hanging of longitudinal beam installation → bottom girder installation → drop-bottom installation → column, end carriage, longitudinal post installation → grit, furnace shell installation → copper water jacket installation → furnace roof and furnace roof operator's console installations → explosionproof hole, low nickel banish outlet, slag notch cooler installation.
2) parts are checked and accepted
Settling tank and stripping section are before formally installing, the parts such as its bottom girder, drop-bottom, column, grit, furnace shell, end carriage, longitudinal beam, water jacket, pull bar, straining beam, spring, check and accept successively by schema requirement, the parts of acceptance(check) are transported to field conduct by schedule in good time and install.
3) parts hoisting transportation and passage
After A, body of heater transported in parts to be installed to flash smelting furnace workshop main span, flash smelting furnace workshop Q axle 8.-9. line absolute altitude+4.0m position the outer platform choosing 6 meters is installed, as the component main channel of stripping section and settling tank.
B, utilize 25T truck-mounted crane component to be hung in the outer steel platform choosing 6 meters, component is delivered in the working district of electric overhead travelling crane by the electric flatbed tricycle of recycling independent development, 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 carry out measurement operation daytime.
The each parts of A, flash smelting furnace are cleaned out around body of heater after removing, surface of base and around palpus constructability.By Design Orientation requirement repetition measurement basis transverse direction, longitudinal cenlerline and absolute altitude before installing, surface of base absolute altitude deviation is not more than 2mm, and marks the installation reference line of cushion block.
The processing of B, cushion block according to the concrete elevation dimension in basis, to each cushion block position measurement, numbering, must be determined required cushion block size, and is numbered cushion block, and cushion block Position Number must be consistent with the numbering of cushion block.
5) cushion block is installed
A, by the reference line pulled in advance carry out in place after, then carry out entirety measure.
B, to overproof basis mark and record, as required overproof basis or cushion block are processed, repeatedly adjust, overall to measure, ensure that every block 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 technical requirements three, form eight altogether, install after being transported to scene.
After B, bottom girder install three, with spirit-leveling instrument absolute altitude and level measured and adjust, qualifiedly rear little joist steel between three to be connected, being in place to both sides more gradually simultaneously, finally carrying out integrated regulation, until qualified.
After C, leveling, the secondary beam connected is welded, ensure that each node must be smooth.
D, finally integral solder is carried out to remaining connection beam, adopt small area analysis, backstep sequence welding, strictly control heat input, prevent welding distortion.
E, welding distortion position, local to be processed, adjustment.
F, bottom girder welding set adopt KR-500 type CO2 gas shielded welding machine.
G, bottom girder are installed as and stop examining, and it is qualified and can carry out next procedure construction after the assay was approved through supervising engineer to install teams and groups self-inspections.
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 there is gap between base plate and bottom girder, 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 block base plate two ends, and the gap being greater than 2mm pads with corresponding steel plate, and carries out spot welding to parallels and fix.
C, drop-bottom install rear and bottom girder tack weld, cut open after body of heater is built by laying bricks or stones again.
Foreign material in gap on beam, must must be cleaned out before laying base plate cover seam plate by the position of D, base plate piece (20mm).
8) column is installed
While A, base plate are installed, 4, the end angle positioning vertical column of reaction tower side is installed.
After the corner locating dowel (8) of B, body of heater corrects, measure and coordinate centering post after, verticality, the diagonal lines of body of heater is checked, qualifiedly arrange temporary fixed at column bottom, middle part and top afterwards temporarily, topple over to prevent column.Mounting block and column and bottom girder temporary weld.On the cylinder of top, column inclined-plane, 100mm place arranges datum mark.Temporary support mainly adopts stove week to face to arrange platform.
C, column erection sequence are: one group, from stripping section orientation angle to 9. axis installation, is mounted to 9. axis feeding-passage place and stops, then install to reaction tower direction from stripping section K axle orientation angle; Another group is installed from reaction tower district Q axle orientation angle to funnel uptake direction, is mounted to 8. axis feeding-passage place and stops, then install to direction, stripping section from reaction tower district K axle orientation angle.
Rear its perpendicularity deviation overall height < 5mm installed by D, column, 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, carry out grit installation by design working drawing, this procedure calls precision is high, repeatedly need adjust and can reach design requirements, must well-organized construction.
Carry out furnace shell installation after B, grit install, furnace shell and grit must be fitted closely, local gap < 3mm.Adjust in limit of error, take temporary fixed after, will grit above carry out disconnected weldering with furnace shell, every 300mm weldering 200mm.
C, measurement coordinate all gussets of installation and supporting plate, carry out integral solder, take correct welding sequence to control welding distortion in welding process after installing.
After D, grit, furnace shell erecting and welding, carry out integrated regulation again, ensure the size conforms design requirements of each portion.
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, when noting splicing, two joist steel stagger 500mm simultaneously, often save the straightening of component palpus, place suitable is at the scene spliced, splice point is due to vertical position welding and weld in the overhead position more, 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
A, flash smelting furnace settling tank and stripping section furnace shell copper water jacket adopt copper coin to hole water jacket and red copper pipe laying casting water jacket two kinds, and installation form is level or vertical.
B, water jacket carry out pressure testing by design requirements, test pressure 0.6MPa before installing one by one, and pressurize 30 minutes, must not have seepage.Can install after pressure testing is qualified.
Must keep properly after C, water jacket stand the test, especially water pipe sections, must screw on nut or tube stub in its outer end, in order to avoid the threaded portion distortion of water pipe or damage, water pipe should be not stressed, in order to avoid root junction leaks.
D, furnace shell plate install, after the size conforms design requirements of each portion, by design working drawing requirement shape, size, installation site carry out water jacket installation.First vertical water jacket is installed, rear installation par cover, bottom-uply carries out.
Water spot position must be checked when E, par cover is installed, 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
After the main installation parts of reaction tower is transported to flash smelting furnace workshop main span, 50T mobile crane is utilized to choose platform outside ▽+4.0 meters of absolute altitudes hang in, below the reaction tower 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) before the installation of top box hat, repetition measurement is carried out to the absolute altitude of original Civil Specialities octagon collar tie beam, center, roughness, the absolute altitude deviation of its upper surface (area supported) is not more than ± 10mm, beam width between centers deviation is not more than ± 5mm, and the roughness of collar tie beam upper surface is not more than ± 5mm.
2) check before installing whether reaction tower center is aimed at settling tank center, the deviation of two central vertical projections is not more than ± 10mm.
4 box hat transports and lifting
1) top box hat tonnage weight, diameter is large, and transport difficulty is large.Overall welding utilizes flatbed trailer to be transported to flash smelting furnace workshop main span after being shaped, utilize 50T overhead traveling crane to hang in ▽+4.0 meters of absolute altitude places outer choose platform after adopt electric flat carriage to be transported into reaction tower central position.
Utilize the newly-increased anistree beam uninstalled time, carry out two-shipper with the monorail crane of two 10T under ▽ 21.70 meters of platforms and coordinate lifting, slowly rise to winch to when ▽ 15.50 meters of platform upper are about 500mm and stop lifting, start monorail crane moves on the platform between reaction tower and Q axis by top box hat simultaneously, and top box hat is paved 500mm on platform, fulcrum area is wanted large and is wanted uniform force.
2) box hat parts are large due to diameter, directly easily produce distortion during lifting, therefore, adopt the angle steel of ∠ 100 × 10 to make temporary support when lifting.
5 top box hats are installed
1) with the reaction tower medullary ray that drop-bottom identifies for benchmark, the installation level attitude of centering top box hat.
2) between top box hat and octagon collar tie beam, absolute altitude and the levelness of box hat is adjusted with the teflon gasket of different thickness.The absolute altitude deviation of box hat is not more than ± 10mm, and the upper surface water level gauge of box hat is levelling.
3) two 10T monorail cranies under top box hat ▽ 21.70 meters of platforms carry out two-shipper and coordinate lifting, sling from the platform put in advance, slowly rise and winch to ▽ 15.50 meters of platform upper when being about 100mm, installation personnel carries out top box hat and beam centre line aligning, until centering after simultaneously, slowly drop to installed height mark again, after in place, carry out smart centering again.Two 10T monorail crane material arranged under ▽ 21.70 meters of platforms adopt 40b joist steel.
4) the mounting center perpendicularity deviation <3mm of top box hat.
5) with the medullary ray of top box hat for benchmark centering top box hat, perpendicularity deviation <5mm.
6) the installation ring-type levelness deviation <3mm of top box hat.
7) with the installation ovality of the inner circle of top box hat for 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.
In the middle part of in the of 6, box hat peace water jacket is installed
1) top box hat installs, and utilizes original 2 10T monorail cranies, and adopt 4 suspension centres to carry out lifting active job platform, active job platform is the circle of Ф 7700mm.Middle part steel ring and par cover put lifting installation to active job platform.Recycle template activity job platform to install 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, carry out pre-installation by design working drawing requirement, then water jacket be numbered one by one.
4) when every layer of par cover is assembled with middle part box hat, every block water jacket and box hat bolt are fixed according to the position determined during water jacket pre-installation and numbering, flexible ropes selected by monolithic water jacket lifting rope.
5) special messenger must be had to command in middle part box hat hoisted in position process, collision free 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 see settling tank and stripping section water jacket installation requirement.
8) after water jacket installation, entirety carries out pressure testing, notes the exhaust of every block water jacket in pressure testing process, prevents from forming air chamber, affects cooling performance.
9) water jacket test pressure 0.45MPa, keeps pressure time to be 30 minutes.
10) water jacket body and each tie point are if any seepage, must ascertain the reason and conscientiously process.
7 profile of tooth water jackets are installed
1) installation of profile of tooth water jacket is carried out after par cover and middle part box hat installation.
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, carry out pre-installation by design working drawing requirement, then water jacket be numbered one by one.
4) formally according to the position determined during water jacket pre-installation and numbering, every block water jacket and box hat and par are applied mechanically bolt when installing and fix.
5) installation of water jacket pipe connecting is carried out see settling tank and stripping section water jacket installation requirement.
6) carry out overall pressure testing after water jacket installation, test pressure 0.6MPa, continue must not have Seepage in 30 minutes.
7), after reaction tower box hat and water jacket install, the perpendicularity deviation on overall height is not more than ± 3mm.
Funnel uptake is installed
After funnel uptake transported in parts to be installed to flash smelting furnace workshop main span, utilize 50T overhead traveling crane to be transported into from the outer platform of choosing of ▽+9.6 meters of absolute altitudes, recycling flat-bed trailer is transported to funnel uptake central position.Arrange 2 5T windlasss to lift, first lift smoke outlet side, then lift epimere skeleton, the coaming plate of long side respectively, after hypomere skeleton, coaming plate are installed, finally lift short side.Finally utilize the attached installation realizing 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 Installation features 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 before installing and confirm that the position of funnel uptake medullary ray is accurate, 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) first carry out top suspension bracket installation when installing, then carry out suspension bracket and install with lower part skeleton.The place of skeleton and settling tank impact, scene is cut skeleton.
6) nut adjustment absolute altitude and the verticality of suspension rod is utilized when flue skeleton is installed.
7) water jacket must build temporary steel platform before installing.Water jacket installs content see the installation of reaction tower flat water sleeve profile of tooth water jacket, pressure testing requirement.
8) after installing, funnel uptake center line of discharge position deviation is not more than 5mm, and 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 is arranged
With workshop, ▽+26.00m absolute altitude place 5T overhead traveling crane, upper band-type brake, bearing and electrode shell are placed on the platform of ▽+21.70m after erection opening is sling, lower band-type brake, lifting table and lifting device are put into ▽+15.50m platform after erection opening is sling, ▽+21.7m absolute altitude place above platform electrode lift cylinders, if two mutually perpendicular horizontal and vertical i-beam tracks (36# joist steel), each installation 5T electric block, the parts such as installing electrodes lifting device.
2 erection sequences
Lifting device → electrode casing, mobile ring header → fixing 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 ram must purge before installing, clean, and does not allow there are any foreign material.
2) oil cylinder installation site is correct, and entering oil extraction position, direction must be correct, 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, adjust consistent with electrode shell surrounding gap.
4 electric installations and electrode seal to be installed
1) mobile ring header, fixing ring header are installed
Position deviation < ± the 3mm of A, all conjunction planes of mobile ring header, will note protecting all finished surfaces in transport and installation process, must not collide with.
Before B, the assembling of fixing ring header, the polishing that will eliminate rust of all conductive contact surfaces is bright.During installation, the hanging of fixing ring header to be welded on civil engineering beam pre-embedded steel slab after all meeting the requirements and to be fixed by installation site, each portion size, determines the length of hanging when hanging is installed according to field condition.Pressing plate only takes off after installing by fixing ring header, and namely only bolt is arranged in centre three and unclamp, install copper soft ribbons, the bolt on both sides must not loosen, and namely must not loosen 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, fixing ring header adopt argon arc welding to weld with the connection of short net bus.The connection of copper soft ribbons and ring header (fixing and mobile ring header), conducting copper belt and mobile ring header, conducting copper belt and Conducting copper tile adopts tie-bolt to connect.
Packing with braid during the transport of B, copper soft ribbons and conducting copper belt prevents bus from damaging, and is put into the place of not easily wounding and deposits.During in-site installation, if two ends copper strips has corrosion, use acid pickling and rust removing, clear water is installed on ring header after drying up after cleaning.
8 soft copper band sinuousness of C, each electrode want consistent, still need to carry out treatment for correcting according to on-site actual situations, but will ensure that copper strips knee must not jagged and crackle during installation.Copper strips must not be injured during lifting.
Boring on D, copper strips makes aperture bright and clean by round file and flat file outshot wool thorn in a pre-installation.If two ends copper strips has corrosion during in-site installation, use acid pickling and rust removing, clear water is cleaned and is dried up, and is evenly coated with electric force compounded grease, overlaps holding bolt immediately and contact surface is connected closely, and prevent 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.
The calibration that E, conducting system will pay special attention to copper strips position is when mounted wanted accurately, ensures that copper strips moves up and down flexural deformation in process, is 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.Overlapping with wedging is connected reliably, flexible movements.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) refractory fiber cloth that electrode hole sealing-ring heat-resistant steel wire strengthens contacts with electrode is soft, 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, all must not have Seepage in 30 minutes, and the flexible movements of each oil cylinder palpus are reliable; Lifting device carries out 2 ~ 10 total travel to-and-fro movements under 0.63MPa oil pressure, must ensure mobile steady, flexible.
After 8 electrodes are installed, entirety 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 plan total lever factor 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 of the inventive method and project quota direct expenses is adopted to contrast situation in table 1 and analyze 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 in 50 days, and labor productivity is 28.1 tons/work day, improves 35.35% than quota of budget.
2, CO2 shielded welding, energy consumption is low, and the electric energy of every meter of weld seam consumption is 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 constructed owing to adopting this engineering method, manages proper, within 5 days in advance, goes into operation, for Jinchuan Group company creates the output value 1.4 hundred million yuan, achieves good economic benefit.
4, by maintenance, flash smelting furnace output brought up to 70,000 tons of nickel contents by former annual output 60000 tons, achieved good social benefit.
The above, it is only preferred embodiment of the present invention, not any pro forma restriction is done to the present invention, anyly do not depart from technical solution of the present invention content, the any simple modification done above embodiment according to technical spirit of the present invention, equivalent variations and modification, all still belong in the scope of technical solution of the present invention.
Claims (5)
1. one kind large-scale flash smelting furnace installation method, first comprehensive electronic simulation is carried out to flash smelting furnace entity, demonstrate all parts size and pre-assembled accuracy one by one, then install by the order of settling tank and stripping section, reaction tower, funnel uptake, electrode, other parts, trial run and examination, stereoscopic logistic technology is adopted in installation process, in the bottom girder of settling tank and stripping section body of heater is installed, entirety takes 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, again with spirit-leveling instrument by good for par trepanning position measure and control, then with strongback by good for semi-automatic cutting track installation, and semi auto cutting machine is cut chew adjust to drop-bottom at a certain angle, the perforate face of guarantee is parallel with furnace bottom, with the angle of furnace shell, par cover supporting plate and furnace shell are fitted tightly, the distortion caused due to loading level is there is not during welding, ensure that the reference for installation level that par overlaps meets the requirements,
Wherein: described stereoscopic logistic technology: annular outrigger platform is set in main span flash smelting furnace side, flash smelting furnace workshop, outrigger platform utilizes electric flat carriage carry out the horizontal transport of body of heater component; On furnace roof top, each layer arranges electric single beam crane respectively;
Wherein: during the bottom girder of described settling tank and stripping section body of heater is installed, entirety takes reversible deformation measure, and welds with CO2 shielded welding: the first step, adopt suitable partition member method, carry out field weld respectively, make widget free shrink, and the unlikely one-piece construction that causes is out of shape; Second step, adopts reversible deformation measure, faces down on bottom girder, places backing plate in the middle part of segmentation bottom girder, adds counterweight respectively simultaneously, make its bottom girder become upper arcuation at the girder of bottom girder and secondary beam direction; 3rd step, adopts CO2 shielded welding weldprocedure to carry out non-concentrated skip welding to bottom girder and fills welding, weld complete be cooled to normal temperature after get except counterweight, bottom girder integral solder deflection reaches ± 4mm.
2. large-scale flash smelting furnace installation method as claimed in claim 1, is characterized in that: described settling tank and stripping section parts install erection sequence: parts check and accept → parts hoisting transportation → basic repetition measurement → cushion block installs → furnace bottom laterally, longitudinal beam installs → bottom girder installs → drop-bottom installs → column, → grit installed by end carriage, longitudinal post, furnace shell is installed → copper water jacket installs → furnace roof is hung and → explosionproof hole installed by furnace roof operator's console, low nickel banish export, slag notch cooler installs.
3. large-scale flash smelting furnace installation method as claimed in claim 1, 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.
4. large-scale flash smelting furnace installation method as claimed in claim 1, 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.
5. large-scale flash smelting furnace installation method as claimed in claim 1, is characterized in that: described electrode erection sequence: lifting device → electrode casing, mobile ring header → fixing ring header → soft copper band → brasses → holding ring → band-type brake → tightness system → electrode shell → trial run.
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