CN113699474A - 一种无底渣生产合金化热镀锌ga产品的方法 - Google Patents
一种无底渣生产合金化热镀锌ga产品的方法 Download PDFInfo
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Abstract
本发明涉及带钢连续热镀锌技术领域,且公开了一种无底渣生产合金化热镀锌GA产品的方法,包括以下内容:先对带钢进行清洗,然后进行基板退火处理,接着浸入锌锅的锌液中进行热浸镀,在进行热浸镀的时候,将锌液的有效铝含量控制在0.135%‑0.145%之间,再经气刀控制镀层重量后进入镀层合金化退火段进行镀层合金化退火处理,然后进行水冷、平整等后处理,生产出镀层铁含量大于等于7%的合金化热镀锌GA产品,最终实现无底渣生产合金化热镀锌GA产品;本发明可以大幅度的降低GA产品的生产成本,极大的提升产品竞争力,可以在新建机组或者对原有机组进行适应性改造后推广应用,且非常具有推广应用前景。
Description
技术领域
本发明涉及带钢连续热镀锌技术领域,具体为一种无底渣生产合金化热镀锌GA产品的方法。
背景技术
为了提高带钢的耐蚀性能,可以对带钢进行热镀锌处理。热镀锌有很多种镀层产品,但在汽车板领域,目前热镀锌使用量最多的镀层产品主要有三种:热镀纯锌镀层产品(以下简称GI镀层产品)、合金化热镀锌镀层产品(以下简称GA镀层产品)和热镀低铝锌铝镁镀层产品(以下简称ZAM镀层产品)。其中,GA镀层产品以其优良的耐蚀性、焊接性、涂装性、抗石击性、可制造性和节约锌资源等优点,在日系汽车中得到普遍应用。传统的GA镀层产品的生产方法是将带钢11在清洗段12清洗后进入基板退火处理段13进行基板退火处理,然后从炉鼻子14浸入锌锅15的锌液中进行热镀锌,经气刀16控制镀层重量后进入合金化加热段17、合金化均热段18和合金化冷却段19进行镀层合金化退火处理(以下简称GA处理),接着经普通喷气冷却段20进行喷气冷却,然后经最终水冷段21进行水冷,最后进行平整22等后处理,生产出GA镀层产品(如图1所示)。在带钢浸入锌锅的锌液中进行热镀锌时,锌液的有效铝含量(即锌液中的总铝含量-锌液中的铁含量)通常控制在0.135%以下,传统方法生产GA镀层产品,在锌锅的锌液底部会有锌渣逐渐沉积,生产到一定时间(通常20天左右)后,通常有两种处理办法。第一种,停机进行捞底渣作业,将底渣捞除后再进行GA镀层产品生产。例如专利CN200510024112.1给出了一种锌锅底渣清理装置,用于提高锌锅底渣清理效率。第二种,向锌锅中添加高铝锌锭,将锌液总铝含量提升到0.15%以上,通常是提升到0.20%左右生产GI镀层产品,在锌液铝含量提升过程中和GI镀层产品生产期间,锌锅中的底渣逐渐转变为悬浮渣和浮渣,被镀层带走或者被从锌锅中捞除。第一种方法,处理时间长,GA无法连续生产,且锌渣捞除造成的锌液损失大,造成生产成本高。第二种方法,在切换期间仅能生产表面质量要求相对较低的产品,如彩涂基板、建筑板等,需要配套建设彩涂机组或者生产低盈利产品,不利于提升企业竞争力。专利CN200710148463.2给出了一种无底渣热镀锌生产工艺用的镀锌液,该镀锌液含0.151%-0.179%的铝和一些铅、锑等元素,铅、锑等属于有害元素,显然不适合用于生产GA产品。而专利US6177140(B1)给出了一种同时生产GI和GA产品的方法,要求锌液温度控制在440-450℃,显然此锌液温度控制范围不利于镀层合金化退火。无论是停机捞底渣,还是切换提升锌液铝含量生产GI产品,都不利于GA产品长期稳定生产,无形中抬升了GA产品的生产成本。
发明内容
(一)解决的技术问题
针对现有技术的不足,本发明提供了一种无底渣生产合金化热镀锌GA产品的方法,解决了上述背景技术中所提出的问题。
(二)技术方案
为实现上述目的,本发明提供如下技术方案:一种无底渣生产合金化热镀锌GA产品的方法,包括以下内容:先对带钢进行清洗,然后进行基板退火处理,接着浸入锌锅的锌液中进行热浸镀,在进行热浸镀的时候,将锌液的有效铝含量控制在0.135%-0.145%之间,再经气刀控制镀层重量后进入镀层合金化退火段进行镀层合金化退火处理,然后进行水冷、平整等后处理,生产出镀层铁含量大于等于7%的合金化热镀锌GA产品,最终实现无底渣生产合金化热镀锌GA产品。
优选的,所述基板退火处理采用直火加热+辐射管加热的方法对带钢进行加热及均热处理,且直火加热采用预氧化工艺,辐射管加热和均热段采用还原工艺对带钢进行预氧化还原处理,在基板表面生成一层还原铁,然后进行热浸镀和镀层合金退火处理。
优选的,所述直火加热的直火燃烧的空气过剩系数控制在0.93-0.97,且直火加热燃烧的燃料为人造天然气或常规开采得到的天然气或液化石油气。
优选的,所述基板退火处理时,将辐射管加热段和辐射管均热段的露点控制在-40-0℃之间,进一步抑制硅、锰等元素向基板表面富集。
优选的,所述热浸镀时,锌液的温度控制在460-475℃之间。
优选的,所述热浸镀前,对带钢的入锌锅温度进行精确控制,带钢入锌锅温度控制在460-515℃之间,且大于等于锌液温度。
优选的,所述气刀控制镀层重量,镀层单面重量控制在30-72g/m2,进一步优选控制在30-60g/m2之间。
优选的,所述镀层合金化退火处理,采用电磁感应加热+直火加热组合的方法或采用直火燃烧废气+电辐射管加热组合的方法加热镀层或采用气雾冷却+高速喷气冷却的方法冷却镀层,进行镀层合金化退火处理。
(三)有益效果
本发明提供了一种无底渣生产合金化热镀锌GA产品的方法,具备以下有益效果:
本发明可以大幅度的碱度GA产品的生产成本,极大的提升产品竞争力,可以在新建机组或者对原有机组进行适应性改造后推广应用,且非常具有推广应用前景。
附图说明
图1为传统生产合金化热镀锌产品方法示意图;
图2为本发明生产合金化热镀锌产品方法示意图。
图中:11、带钢;12、清洗段;13、基板退火处理段;14、炉鼻子;15、锌锅;16、气刀;17、合金化加热段;18、合金化均热段;19、合金化冷却段;20、普通喷气冷却段;21、最终水冷段;22、平整段;23、直火燃烧废气预热段;24、直火加热段;25、辐射管加热段;26、辐射管均热段;27、缓冷段;28、快冷段;29、均衡段。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1
基板主要成分质量百分含量为0.0012%C、0.0015%Si、0.12%Mn、0.006%P和0.002%S的带钢11先在清洗段12进行清洗,具体包括碱喷淋、碱刷洗、电解清洗、热水刷洗、热水漂洗和烘干,然后进入3%H2和97%N2的保护性气氛退火炉进行基板退火处理,基板退火处理包括进入直火燃烧废气预热段23进行直火废气预热、再进入到直火加热段24进行直火加热、再进入到辐射管加热段25进行辐射管加热、再进入到辐射管均热段26进行辐射管均热、再进入到缓冷段27进行缓冷、再进入到快冷段28进行快冷、最后进入到均衡段29进行均衡处理,然后进行热浸镀;直火加热时采用自然开采的天然气,将直火燃烧空气过剩系数控制在0.93,将带钢11加热带680℃,然后进入到辐射管加热段25,继续加热到830℃,然后进入辐射管均热段26,在830℃下进行均热处理40s,接着进入到缓冷段27缓冷到670℃,再进入到快冷段28快冷到475℃,并进入到均衡段29在475℃进行均衡处理,以475℃的带钢11入锌锅15浸入460℃的锌液中进行热浸镀;辐射管加热段25和辐射管均热段26的露点都控制在-40℃,缓冷段27、快冷段28、均衡段29的露点都控制在-45℃以下;本实施例中,锌锅15内锌液的有效铝含量控制在0.145%;带钢11热浸镀后经气刀16将上下表面的锌层重量控制在72/72g/m2,然后进入电磁感应加热+直火加热的组合加热合金化加热段17进行镀层合金化退火加热处理,将带钢11加热到480℃,然后进入直火燃烧废气+电辐射管加热的组合均热合金化均热段18在480℃左右进行镀层合金化退火均热处理,接着进入气雾冷却+高速喷气冷却的组合冷却合金化冷却段19进行冷却,将带钢冷却到300℃,然后继续进入到普通喷气冷却段20和最终水冷段21进行喷气冷却+最终水冷,最后进入平整段22进行平整等后处理;本实施例中镀层铁含量基本控制在10.5%左右,长时间生产,锌锅15的锌液中无底渣沉积。
本实施例与传统生产方法相比差异点主要在于:
本实施例与传统生产方法相比有点在于:
实施例2
基板主要成分质量百分含量为0.08%C、0.40%Si、2.1%Mn、0.009%P和0.003%S的带钢11先在清洗段12进行清洗,具体包括碱喷淋、碱刷洗、电解清洗、热水刷洗、热水漂洗和烘干,然后进入5%H2和95%N2的保护性气氛退火炉进行基板退火处理,基板退火处理包括进入直火燃烧废气预热段23进行直火废气预热、再进入到直火加热段24进行直火加热、再进入到辐射管加热段25进行辐射管加热、再进入到辐射管均热段26进行辐射管均热、再进入到缓冷段27进行缓冷、再进入到快冷段28进行快冷、最后进入到均衡段29进行均衡处理,然后进行热浸镀;直火加热时采用液化石油气,控制过剩系数控制在0.95,将带钢11加热带650℃,然后进入到辐射管加热段25,继续加热到800℃,然后进入辐射管均热段26,在800℃下进行均热处理50s,接着进入到缓冷段27缓冷到670℃,再进入到快冷段28快冷到515℃,并进入到均衡段29在515℃进行均衡处理,以515℃的带钢11入锌锅15浸入470℃的锌液中进行热浸镀;辐射管加热段25和辐射管均热段26的露点都控制在-20℃,缓冷段27、快冷段28、均衡段29的露点都控制在-45℃以下;本实施例中,锌锅15内锌液的有效铝含量控制在0.140%;带钢11热浸镀后经气刀16将上下表面的锌层重量控制在50/50g/m2,然后进入电磁感应加热+直火加热的组合加热合金化加热段17进行镀层合金化退火加热处理,将带钢11加热到500℃,然后进入直火燃烧废气+电辐射管加热的组合均热合金化均热段18在500℃左右进行镀层合金化退火均热处理,接着进入气雾冷却+高速喷气冷却的组合冷却合金化冷却段19进行冷却,将带钢冷却到320℃,然后继续进入到普通喷气冷却段20和最终水冷段21进行喷气冷却+最终水冷,最后进入平整段22进行平整等后处理;本实施例中镀层铁含量基本控制在11.5%左右,长时间生产,锌锅15的锌液中无底渣沉积。
本实施例与传统生产方法相比差异点主要在于:
本实施例与传统生产方法相比有点在于:
实施例3
基板主要成分质量百分含量为0.18%C、1.8%Si、2.25%Mn、0.007%P和0.001%S的带钢11先在清洗段12进行清洗,具体包括碱喷淋、碱刷洗、电解清洗、热水刷洗、热水漂洗和烘干,然后进入7%H2和93%N2的保护性气氛退火炉进行基板退火处理,基板退火处理包括进入直火燃烧废气预热段23进行直火废气预热、再进入到直火加热段24进行直火加热、再进入到辐射管加热段25进行辐射管加热、再进入到辐射管均热段26进行辐射管均热、再进入到缓冷段27进行缓冷、再进入到快冷段28进行快冷、最后进入到均衡段29进行均衡处理,然后进行热浸镀;直火加热时采用人造天然气,控制过剩系数控制在0.97,将带钢11加热带700℃,然后进入到辐射管加热段25,继续加热到850℃,然后进入辐射管均热段26,在850℃下进行均热处理60s,接着进入到缓冷段27缓冷到675℃,再进入到快冷段28快冷到500℃,并进入到均衡段29在500℃进行均衡处理,以500℃的带钢11入锌锅15浸入475℃的锌液中进行热浸镀;辐射管加热段25和辐射管均热段26的露点都控制在0℃,缓冷段27、快冷段28、均衡段29的露点都控制在-40℃以下;本实施例中,锌锅15内锌液的有效铝含量控制在0.135%;带钢11热浸镀后经气刀16将上下表面的锌层重量控制在30/30g/m2,然后进入电磁感应加热+直火加热的组合加热合金化加热段17进行镀层合金化退火加热处理,将带钢11加热到510℃,然后进入直火燃烧废气+电辐射管加热的组合均热合金化均热段18在510℃左右进行镀层合金化退火均热处理,接着进入气雾冷却+高速喷气冷却的组合冷却合金化冷却段19进行冷却,将带钢冷却到350℃,然后继续进入到普通喷气冷却段20和最终水冷段21进行喷气冷却+最终水冷,最后进入平整段22进行平整等后处理;本实施例中镀层铁含量基本控制在11.0%左右,长时间生产,锌锅15的锌液中无底渣沉积,不影响机组长时间生产GA产品。
本实施例与传统生产方法相比差异点主要在于:
本实施例与传统生产方法相比有点在于:
需要说明的是,在本文中,诸如第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来,而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且,术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含,从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素,而且还包括没有明确列出的其他要素,或者是还包括为这种过程、方法、物品或者设备所固有的要素。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (8)
1.一种无底渣生产合金化热镀锌GA产品的方法,其特征在于:包括以下内容:先对带钢进行清洗,然后进行基板退火处理,接着浸入锌锅的锌液中进行热浸镀,在进行热浸镀的时候,将锌液的有效铝含量控制在0.135%-0.145%之间,再经气刀控制镀层重量后进入镀层合金化退火段进行镀层合金化退火处理,然后进行水冷、平整等后处理,生产出镀层铁含量大于等于7%的合金化热镀锌GA产品,最终实现无底渣生产合金化热镀锌GA产品。
2.根据权利要求1所述的一种无底渣生产合金化热镀锌GA产品的方法,其特征在于:所述基板退火处理采用直火加热加辐射管加热的方法对带钢进行加热及均热处理,且直火加热采用预氧化工艺,辐射管加热和均热段采用还原工艺对带钢进行预氧化还原处理,在基板表面生成一层还原铁,然后进行热浸镀和镀层合金退火处理。
3.根据权利要求2所述的一种无底渣生产合金化热镀锌GA产品的方法,其特征在于:所述直火加热的直火燃烧的空气过剩系数控制在0.93-0.97,且直火加热燃烧的燃料为人造天然气或常规开采得到的天然气或液化石油气。
4.根据权利要求3所述的一种无底渣生产合金化热镀锌GA产品的方法,其特征在于:所述基板退火处理时,将辐射管加热段和辐射管均热段的露点控制在-40-0℃之间,进一步抑制硅、锰等元素向基板表面富集。
5.根据权利要求1所述的一种无底渣生产合金化热镀锌GA产品的方法,其特征在于:所述热浸镀时,锌液的温度控制在460-475℃之间。
6.根据权利要求1所述的一种无底渣生产合金化热镀锌GA产品的方法,其特征在于:所述热浸镀前,对带钢的入锌锅温度进行精确控制,带钢入锌锅温度控制在460-515℃之间,且大于等于锌液温度。
7.根据权利要求1所述的一种无底渣生产合金化热镀锌GA产品的方法,其特征在于:所述气刀控制镀层重量,镀层单面重量控制在30-72g/m2,进一步优选控制在30-60g/m2之间。
8.根据权利要求1所述的一种无底渣生产合金化热镀锌GA产品的方法,其特征在于:所述镀层合金化退火处理,采用电磁感应加热+直火加热组合的方法和直火燃烧废气+电辐射管加热组合的方法加热镀层以及采用气雾冷却+高速喷气冷却的方法冷却镀层,进行镀层合金化退火处理。
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