CN114480764B - Preparation method and system of blast furnace tuyere with heat insulation coating - Google Patents
Preparation method and system of blast furnace tuyere with heat insulation coating Download PDFInfo
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- CN114480764B CN114480764B CN202111636470.3A CN202111636470A CN114480764B CN 114480764 B CN114480764 B CN 114480764B CN 202111636470 A CN202111636470 A CN 202111636470A CN 114480764 B CN114480764 B CN 114480764B
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Abstract
The invention discloses a preparation method of a blast furnace tuyere with a heat insulation coating, which comprises the following steps: fixing the tuyere body on a rotary table, preheating the tuyere body through an induction coil arranged at the periphery of the tuyere, and preheating the tuyere body to a temperature of more than 600 ℃; rotating the tuyere body at a constant speed, and simultaneously performing surfacing welding on the inner wall of the tuyere body by using a plasma welding gun; the welding gun is always positioned above the inner wall of the tuyere and is vertical to the inner wall of the tuyere in direction; the thickness of the heat insulation coating is controlled to be 2-3mm; after one circle of overlaying is finished, the plasma welding gun advances for a certain distance and then continues the next circle of overlaying. The invention aims to reduce the heat taken away by cooling water from hot air at the air port and improve the air temperature, thereby reducing the coke ratio, realizing energy conservation and reducing carbon emission.
Description
Technical Field
The invention relates to blast furnace smelting, in particular to a blast furnace tuyere.
Background
With the deepening of people's understanding of global warming problems, the reduction of greenhouse gas emission and low-carbon production become increasingly the focus of social attention. As a high-energy-consumption and high-pollution industry, the steel industry is one of the major households with greenhouse gas emission. The carbon emission of the steel industry in China accounts for about 16% of the total carbon emission of the whole world, wherein blast furnace iron making is the largest process of carbon emission in the total flow of steel production and accounts for 70% -90% of the total emission. Therefore, the development and application of the blast furnace low-carbon smelting technology and the realization of energy conservation and emission reduction of the blast furnace process are important tasks in the steel industry in China.
The heat of the blast furnace is mainly derived from the combustion heat of fuel such as coke in the tuyere raceway and the physical heat brought in by hot air. The hot air provides 15-20% of heat input by the blast furnace, the temperature of the hot air not only affects the heat system in the blast furnace, but also affects the consumption of raw fuel, and researches show that the iron-coke ratio per ton can be reduced by 2.8% when the air temperature is increased by 100 ℃, so that the improvement of the air temperature of the blast furnace is an important way for realizing low-carbon production of the blast furnace. The hot-blast output of following the hot-blast furnace, then carry in the blast furnace through the blast furnace tuyere, however, the blast furnace tuyere is through-flow red copper material, and water-cooling intensity is big, inevitably can take away partly hot-blast heat, reduces the wind-warm syndrome to the use amount of blast furnace fuel coke has been improved. Therefore, the reduction of the heat loss of the hot air at the air inlet of the blast furnace has important significance for improving the air temperature of the blast furnace and realizing energy conservation and emission reduction.
Therefore, those skilled in the art have been devoted to developing a low-carbon energy-saving blast furnace tuyere.
Disclosure of Invention
In view of the above defects of the prior art, the invention provides a blast furnace tuyere with a heat insulation coating, namely the inner wall of the tuyere is coated with the heat insulation coating with the heat conductivity coefficient lower than that of red copper, and the invention aims to reduce the heat taken away by hot air by cooling water, improve the air temperature, reduce the coke ratio, realize energy conservation and reduce carbon emission. The coating mode can be various surface engineering technologies such as electroplating, spraying, surfacing and the like, and the coating material can be pure metal with lower heat conductivity than copper, alloy consisting of multiple elements, ceramic thermal barrier coating and the like.
The details will be described below by taking as an example the plasma deposition of the Ni60A alloy coating on the inner wall of the tuyere. The Ni60A alloy is a nickel-based alloy, the chemical component of the Ni60A alloy is Ni-15Cr-3.5B-4Si-8Fe-0.8C, the main component of the material is Ni which can be infinitely mutually dissolved with Cu of a tuyere, and the melting point (1026 ℃) of the coating material is also close to that of red copper (1083 ℃), so that the coating material can be melted with the copper in the surfacing process, metallurgical bonding is favorably formed, and the coating is not easy to peel off. Cr is formed in the coating during the overlaying process 23 C 6 And ceramic phases such as CrB, the thermal conductivity coefficient is remarkably reduced and is about 15W/(M.K), and the thermal conductivity coefficient is far lower than that of red copper and is 400W/(M.K). A numerical control plasma surfacing machine (PTA-400A) with low cost and high automation degree is selected as surfacing equipment, a tuyere is preheated to about 600 ℃ by induction heating equipment before surfacing so as to reduce heat loss of plasma arc heat, and the Ni60A heat insulation coating is deposited on the inner wall of the tuyere of the blast furnace by adopting an edited surfacing program.
Through ANSYS numerical simulation, the temperature of cooling water at a water outlet of the tuyere with the Ni60A coating deposited on the inner wall is reduced by about 3 ℃ compared with that of a common tuyere without deposited coating, so that the heat taken away by the cooling water is obviously reduced, namely the heat loss of hot air at the tuyere is effectively reduced by the novel low-carbon energy-saving tuyere.
Based on the numerical simulation results, the energy-saving effect and the carbon emission reduction effect of the tuyere with the Ni60A heat-insulating coating deposited thereon are calculated:
specific heat capacity C of circulating water p The temperature is 4.1868 kJ/(kg. DEG C), and if the cooling water quantity m of each tuyere is 28 tons/hour and the temperature drop Delta T of the water outlet of the tuyere is 3 ℃, the heat quantity of hot air which is reduced and taken away by each tuyere per hour is as follows: q = C p ·m·ΔT＝4.1868×28×1000×3＝351691.2KJ。
Assuming that the tuyeres operate for 365 days per year, the heat loss per tuyere per year is reduced: q General assembly ＝351691.2×24 ×365＝3.08×10 9 KJ。
The heat value of standard coal per kilogram stipulated in China is 7000 kilocalories, namely 7000 multiplied by 4.18585=29300.95KJ, and the heat loss reduced per year of each tuyere is converted into 3.08 multiplied by 10 of standard coal 9 /29300.95＝1.05×10 5 Kg。
3200m with 32 tuyeres 3 Blast furnaces are taken as an example, and each blast furnace can save standard coal by 1.05 multiplied by 10 every year 5 × 32＝3.36×10 6 Kg, converted into coke saving of 3.63X 10 6 ×0.9714＝3.263904×10 6 Kg =3264 ton.
In addition, the amount of carbon dioxide discharged by the blast furnace can be reduced by 8160 tons every year by calculating 2.5 tons of carbon dioxide discharged by one ton of coke through the tuyere on which the Ni60A heat insulation coating is deposited.
Specifically, the invention firstly provides a preparation method of a blast furnace tuyere with a heat insulation coating, which comprises the following steps:
fixing the tuyere body on a rotary table, preheating the tuyere body through an induction coil arranged at the periphery of the tuyere, and preheating the tuyere body to a temperature of more than 600 ℃;
rotating the tuyere body at a constant speed, and simultaneously performing surfacing welding on the inner wall of the tuyere body by using a plasma welding gun; the welding gun is always positioned above the inner wall of the tuyere and is vertical to the inner wall of the tuyere in direction; the thickness of the heat insulation coating is controlled to be 2-3mm;
after one circle of overlaying is finished, the plasma welding gun advances for a certain distance and then continues the next circle of overlaying.
Furthermore, the induction coil uses a copper tube with an insulation sleeve of 8mm, and the number of turns is based on the standard that the tuyere body can be preheated to more than 600 ℃.
Furthermore, a square linear sliding rail is arranged on the center line of the air port, a square sliding block is arranged on the square linear sliding rail, and the welding gun is fixed on the lower end face of the square sliding block.
Furthermore, the square slide block is a linear motor.
Furthermore, a scraping cutter with adjustable height is arranged on the upper end face of the square sliding block, and the thickness of the coating can be controlled by adjusting the height of the scraping cutter; when the tuyere device works, the welding gun at one end of the square sliding block carries out overlaying welding on the protective coating on the inner wall of the tuyere body along with the rotation of the tuyere body, and the scraping cutter at the other end of the square sliding block scrapes the protective coating so as to ensure the uniformity and surface smoothness of the coating.
Further, at the front end of the linear guide rail, a purge fan is provided for purging coating debris generated by scraping.
The invention also provides a preparation system of the blast furnace tuyere with the heat insulation coating, which comprises a turntable for fixing the tuyere body, an induction coil wound on the periphery of the tuyere body for preheating, a square linear slide rail arranged on the central line of the tuyere, a square slide block arranged on the square linear slide rail, a welding gun fixed on the lower end surface of the square slide block, and a scraping cutter arranged on the upper end surface of the square slide block and with adjustable height.
Furthermore, the square slide block is a linear motor.
Further, the air conditioner also comprises a sweeping fan arranged at the front end of the linear guide rail.
Furthermore, the induction coil uses a red copper tube with an insulation sleeve of 8mm, and the number of turns is standard to preheat the tuyere to be above 600 ℃.
According to the invention, the Ni60A heat insulation coating with low heat conductivity coefficient is added on the inner wall of the tuyere, so that the heat loss of hot air at the tuyere can be reduced, and the energy consumption is saved; meanwhile, after the temperature of hot air is increased, the usage amount of coke required by blast furnace smelting can be obviously reduced, the smelting cost is saved, and carbon emission caused by coke combustion is reduced.
The conception, the specific structure and the technical effects of the present invention will be further described with reference to the accompanying drawings to fully understand the objects, the features and the effects of the present invention.
Drawings
FIG. 1 is a schematic view illustrating a process of preheating a tuyere of a blast furnace by using an induction coil according to a preferred embodiment of the present invention;
FIG. 2 is a schematic view of a plasma weld of the blast furnace tuyere of FIG. 1;
FIG. 3 is a schematic diagram of the winding of the induction coil of FIG. 1;
FIG. 4 is a schematic view of the tuyere inner wall overlay in FIG. 1;
FIG. 5 is a schematic illustration of another embodiment of the present invention with simultaneous scraping of the coating during the weld overlay process;
FIG. 6 is an axial view of the embodiment of FIG. 5;
FIG. 7 is a temperature field distribution cloud chart of a water inlet and a water outlet of a common blast furnace tuyere;
FIG. 8 is a cloud chart of the temperature field distribution of the water inlet and the water outlet of the blast furnace tuyere with the thermal insulation coating.
In the figure: 1-tuyere body, 2-induction coil for preheating, 3-plasma welding gun support rod, 4-plasma welding gun, 5-thermal insulation coating, 6-tuyere center line, 7-water inlet, 8-water outlet, 9-square linear guide rail, 10-square slide block, 11-scraping cutter and 12-purging fan.
Detailed Description
The technical contents of the preferred embodiments of the present invention will be made clear and easily understood by referring to the drawings attached to the specification. The present invention may be embodied in many different forms of embodiments and the scope of the invention is not limited to the embodiments set forth herein.
The preparation method of the blast furnace tuyere with the heat insulation coating comprises the following steps: as shown in fig. 1 and 3, the tuyere body 1 needs to be fixed on the rotary table, and since the red copper tuyere has excellent thermal conductivity, the tuyere needs to be preheated before surfacing, so that the heat loss of plasma arc is reduced, and the occurrence of the incomplete penetration phenomenon is prevented. The preheating adopts an induction preheating mode, and the induction coil 2 is wound on the periphery of the tuyere and used for surfacing welding of the inner wall of the tuyere body 1, as shown in fig. 2 and 4. The induction coil uses a copper tube with an 8mm insulating sleeve, the number of turns is based on the standard that the tuyere can be preheated to more than 600 ℃, and meanwhile, the induction coil also needs to be matched with the power of induction heating equipment.
The overlaying mode of the tuyere is as follows: the induction coil is fixed, the welding gun 4 is always positioned above the inner wall of the tuyere and is vertical to the inner wall of the tuyere in direction, the tuyere is in a constant-speed rotation state, as shown in figure 4, the thickness of the heat-insulating coating 5 is generally controlled to be about 2-3mm, and the thickness of the coating can be controlled by controlling the powder feeding amount in the plasma surfacing equipment. The proper increase of the thickness is beneficial to reducing the heat loss of the hot air, but the excessive thickness may be unfavorable to the melting loss resistance of the tuyere and needs to be determined according to actual conditions.
In order to control the thickness and uniformity of the coating 5 more accurately and improve the smoothness of the surface of the coating 5 to reduce the wind resistance to the high-speed hot wind in the tuyere as much as possible, as shown in fig. 5 to 6, a square linear slide rail 9 is arranged on the center line of the tuyere, and a square slide block 10 is arranged on the square linear slide rail 9. In a further embodiment, the slider 10 can also be provided as a linear motor of the square linear slide rail 9. The welding gun 4 is fixed on the lower end face of the square slider 10, the height-adjustable scraping tool 10 is arranged on the upper end face of the square slider 10, and the thickness of the coating 5 can be controlled by adjusting the height of the scraping tool 10. When the tuyere device works, the welding gun 4 at one end of the square sliding block 10 carries out overlaying welding on the protective coating 5 on the inner wall of the tuyere body 1 along with the rotation of the tuyere body 1, and the scraping cutter 10 at the other end of the square sliding block 10 scrapes the protective coating 5 so as to ensure the uniformity and the surface smoothness of the coating 5. The scraping tool 10 is behind the welding torch 4 by a distance of one turn in the direction of the centre line. After one circle of overlaying, the square slider 10 is controlled to advance for a set distance, and the next circle of overlaying and scraping is started. At the front end of the linear guide 9, a fan 12 is provided for blowing away coating debris generated by the scraping so as not to affect the weld deposit.
Fig. 7 and 8 show the temperature field distribution of the water inlet 7 and the water outlet 8 of the tuyere before and after the Ni60A heat-insulating coating with 3mm of inner wall surfacing welding, respectively, the temperature of the cooling water at the water outlet after surfacing welding is reduced by about 3 ℃, and it can be seen that the heat taken away by the cooling water is significantly reduced, which indicates that the heat loss of the hot air at the tuyere can be effectively reduced by the blast furnace tuyere with the heat-insulating coating.
In fact, increasing the thickness of the thermal barrier coating, or using other coating materials with lower thermal conductivity, is expected to further reduce the temperature difference between the water inlet and the water outlet, i.e. further reduce the heat loss of the hot air. Meanwhile, the energy-saving effect and the carbon emission reduction effect of the corresponding tuyere can be estimated according to the actual temperature difference and the calculation method mentioned in the summary of the invention.
The foregoing detailed description of the preferred embodiments of the invention has been presented. It should be understood that numerous modifications and variations could be devised by those skilled in the art in light of the present teachings without departing from the inventive concept. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the prior art according to the concept of the present invention should be within the scope of protection defined by the claims.
Claims (3)
1. A preparation method of a blast furnace tuyere with a heat insulation coating is characterized by comprising the following steps:
fixing the tuyere body on a rotary table, preheating the tuyere body by an induction coil arranged at the periphery of the tuyere, and preheating the tuyere body to above 600 ℃;
rotating the tuyere body at a constant speed, and simultaneously performing surfacing welding on the inner wall of the tuyere body by using a plasma welding gun; the welding gun is always positioned above the inner wall of the tuyere and is vertical to the inner wall of the tuyere in direction; the thickness of the heat insulation coating is controlled to be 2-3mm;
after one circle of overlaying is finished, the plasma welding gun is made to advance for a certain distance and then the next circle of overlaying is continued;
wherein, a square linear slide rail is arranged on the center line of the tuyere, a square slide block is arranged on the square linear slide rail, and a welding gun is fixed on the lower end surface of the square slide block; the square sliding block is a linear motor; the upper end surface of the square sliding block is provided with a scraping cutter with adjustable height, and the thickness of the coating can be controlled by adjusting the height of the scraping cutter; when the tuyere device works, the welding gun at one end of the square sliding block carries out overlaying welding on the protective coating on the inner wall of the tuyere body along with the rotation of the tuyere body, and the scraping cutter at the other end of the square sliding block scrapes the protective coating so as to ensure the uniformity and surface smoothness of the coating.
2. The method for manufacturing a tuyere for a blast furnace having a thermal insulation coating according to claim 1, wherein the induction coil uses a 8mm copper tube with an insulation sleeve, and the number of turns is based on the criterion that the tuyere body can be preheated to 600 ℃ or more.
3. The method for manufacturing a blast furnace tuyere with a thermal barrier coating according to claim 1, wherein a blowing fan for blowing coating chips generated by scraping is provided at a front end of the linear guide.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JPS54158336A (en) * | 1978-06-05 | 1979-12-14 | Nippon Kokan Kk <Nkk> | Forming method for heat and wear resistant coating for blast furnace tuyere |
| EP1580283A1 (en) * | 2004-03-26 | 2005-09-28 | Paul Wurth S.A. | Method for protecting a tuyere assembly and a refractory lining of a furnace |
| CN101492749B (en) * | 2008-01-24 | 2010-09-08 | 宝山钢铁股份有限公司 | Surface coating for tuyeres of blast furnace and method for preparing the same |
| CN104404186B (en) * | 2014-11-24 | 2016-08-24 | 武汉钢铁(集团)公司 | Strengthen function the manufacture method of functionally gradient material (FGM) in a kind of air port |
| CN205852040U (en) * | 2016-06-23 | 2017-01-04 | 武汉钢铁股份有限公司 | A kind of blast-furnace tuyere inwall welder |
| JP7260732B2 (en) * | 2018-08-03 | 2023-04-19 | 日本製鉄株式会社 | Blast furnace tuyere and manufacturing method thereof |
| CN212885622U (en) * | 2020-08-18 | 2021-04-06 | 汕头市俊国机电科技有限公司 | Robot build-up welding device |
| CN113046744B (en) * | 2021-03-15 | 2023-03-28 | 上海大学 | Method for plasma cladding of WC (wolfram carbide) reinforced nickel-based alloy on surface of copper tube |
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