Furnace structure analysis for copper flash continuous smelting based on numerical simulation

According to the innate characteristic of four types of furnace, the copper flash continuous smelting （CFCS） furnace can be considered a synthetic reactor of two relatively independent processes： flash matte smelting process （FMSP） and copper continuous converting process （CCCP）. Then, the CFCS thermodynamic model was proposed by establishing the multi-phase equilibrium model of FMSP and the local-equilibrium model of CCCP, respectively, and by combining them through the smelting intermediates. Subsequently, the influences of the furnace structures were investigated using the model on the formation of blister copper, the Fe3O4 behavior, the copper loss in slag and the copper recovery rate. The results show that the type D furnace, with double flues and a slag partition wall, is an ideal CFCS reactor compared with the other three types furnaces. For CFCS, it is effective to design a partition wall in the furnace to make FMSP and CCCP perform in two relatively independent zones, respectively, and to make smelting gas and converting gas discharge from respective flues.

Modeling and Simulation of Heat Transfer in Loaded Continuous Heat Treatment Furnace

Continuous furnaces are widely used in the heat treatment of mass-produced parts. However, the heating up process of parts in continuous furnace is still decided by experience. In this paper the heat transfer in the continuous furnace is formulated firstly. The heat balance in each zone is discussed and equations are given. Coupled with the model for heat transfer between workpieces and furnace and the heat transfer in the workload as well presented in the former developed CHT-6/ for batch furnaces, a program CHT- for continuous furnaces was developed. The model deals with two typical movements of parts: continuous or step by step. The moving speed of parts and load pattern can be optimized based on the calculated temperature distributions and curves, especially, the fastest heated and slowest-heated temperature-distance profiles. A case study is carried out for the heat treatment of a kind of hook-shaped part. The calculated results are analyzed and in good agreement with the measured ones.

Detection and analysis of gas tightness of continuous annealing furnaces

When a cold rolled strip is being treated in a continuous annealing furnace which is full of protective gas, the gas tightness of the furnace body, the connected facilities and the gas channels become an important indicator that directly affects the product＇s surface quality and shows the technical level of the design, the manufacture and the installation. By considering the problems of the gas tightness of a vertical annealing furnace in the installation and maintenance, this thesis evaluates the gas tightness indicator and gas tightness related level of the furnace body and the circulation duct, while studying and analyzing the technologies of negative-pressure leak detection and sealing.

Cause analysis of and solution to furnace roller pick-up in the high strength automotive steel sheet processing line

Cold-rolled high strength steel sheets for automobiles contain more Mn and Si based alloy elements, which, under the reducing atmosphere in the annealing furnace, will get enriched on the strip surface. Since the furnace rollers and the strips contact frequently, alloy elements on the roller surface will form hard protuberance. We call this protuberance ＂pick-up＂. In addition, with the increase of the amount of dust in the furnace atmosphere, the occurrence of furnace roller pick-up will also increase. Through chemical reaction and physical accumulation analysis combined with practical experience, the causes of pick-up in different furnace sections were analyzed. Methods of preventing furnace roller pick-up in the high strength steel sheet processing line were discussed and solutions to improving the strip surface quality in the continous annealing furnace were provided.

Theoretical Derivation of Thermal Value Equations for Heating Furnaces

Based on thermal value theory, the aim of this paper is to deduce the theoretical formulas for evaluating the energy effective utilization degree in technological pyrological processes exemplified by metallurgical heating furnaces. Heat transfer models for continuous heating furnaces, batch-type heating furnaces, and regenerative heating furnaces are established, respectively. By analyzing the movement path of injected infinitesimal heat attached on steel or gas, thermal value equations of continuous, batch-type, and regenerative heating furnaces are derived. Then the influences of such factors as hot charging, gas preheating and intake time of heat on energy effective utilization degree are discussed by thermal value equations. The results show that thermal value rises with hot charging and air preheating for continuous heating furnaces, with shorter intake time when heat is attached on steel or longer intake time when heat is attached on gas for batch-type heating furnaces and that with more heat supply at early heating stage or less at late stage for regenerative heating furnaces.

Characteristic Analysis and Comprehensive Control for the Horizontal Stripes of High-Grade Automotive Panels in Continuous Annealing

As to the horizontal stripes defect which exist on the surface of the high-grade automotive panels in continuous annealing process, an effective comprehensive control method is proposed on the basis of full consideration of the equipment and technological features of continuous annealing line. With five field tests as basis, the generation mechanism of the defect was analysised in detail and the comprehensive control measures were put forward. According to actual situation, a detailed technical plan was worked out .Then the relevant technologies were applied to a 1850 continuous annealing line. The statistics shows that this program acquired good effects. The incidence of horizontal stripes defect decreased from 100% to 2.78%. Meanwhile, the surface quality of strip also improved effectively, which created a larger economic benefit.

连续热电偶检定炉的设计与研制

连续热电偶是基于塞贝克效应制成的一种新型温度传感器。在校准连续热电偶时,热电偶检定炉是较为重要的热源之一。该研究在传统检定炉的基础之上设计四温区检定炉,通过对炉体和温度控制的改造,对多种控温模式的设计,研制出能够适用连续热电偶等多种高温传感器校准的热源。

推舟式连续热处理炉内温度场数值模拟与系统优化

为了提高连续式热处理炉内部温度场的温度均匀性及加热效率,以一种推舟式连续热处理炉为参考进行建模,采用ANSYS FLUENT软件模拟了稳态条件下连续炉内部温度场的分布规律,并将模拟结果与实测结果进行对比分析,最大误差在10%以内。在此基础上,研究加热管直径、管排间距和进气口位置对炉体内部温度均匀性及加热效率的影响,并以此优化加热系统。结果表明,低温加热段适当将上排加热管下移和侧面进气口上移可提高炉体内部温度均匀性和加热效率,改变加热管径对低温段系统影响不大;高温段适当改变管截面尺寸和上移侧面进气口可有效提高炉体内部温度均匀性和加热效率,改变管排间距则对高温段系统影响不大。具体优化方案为:低温加热段加热管直径ϕ60 mm,上排加热管下移300 mm,侧面进气口上移400 mm;高温加热段加热管截面尺寸8 mm×28 mm,侧面进气口上移100 mm。优化后低温段加热工件中心与边缘平均温差由原来的48.5℃降低到30.8℃;高温段由原来的140.8℃降低到16.1℃,显著提高了炉体内部温度均匀性和加热效率。

14Mn5Nb无缝钢管“鱼鳞”形外折分析与控制

某厂14Mn5Nb连铸圆坯(Φ330 mm)轧制成无缝钢管(Φ323.8 mm×8.3 mm)后表面出现大量“鱼鳞”状外折缺陷,影响成材率,成为亟须解决的问题。采用缺陷金相分析,“刻槽”试验,铸坯酸洗确定钢管表面“鱼鳞状”缺陷是由连铸圆坯表面横裂纹造成。采用扫描电镜检测,钢种热溯性分析以及现场数据统计,确定铸坯表面横裂纹产生原因为:Φ330 mm圆坯在当前工艺参数下铸坯进拉矫温度在900~950℃,处于第III脆性区转变温度940℃附近;表面存在较多Nb(C、N)析出物,增加了钢种的裂纹敏感性。通过调整钢种Ti含量至0.02%~0.03%,保护渣碱度由0.97提高至1.14,降低结晶器水量,调整二冷水量配比以确保进拉矫温度≥970℃等措施,有效避免了铸坯横裂纹和无缝钢管鱼鳞外折的产生。

武钢废钢全流程一体化协同管控系统的建设

随着国家大力推进智慧制造,借助数字化转型来推动钢铁企业废钢管理升级优化,是钢铁企业降低生产成本、实现绿色低碳发展的必然选择。建立了武钢废钢全流程一体化协同管控系统,支撑废钢全流程管控精细化,实现物流、质检、库区岗位操作智能化,建立废钢计划需求及区间配送调度模型,全流程全要素可视化,实现管理岗位决策智慧化。

特征标记下的蓄热式连续加热炉炉管安全VR检测技术

蓄热式连续加热炉炉管开展安全检测时,若采集的炉管损伤图像质量差,会直接降低后续的安全检测精度。为了提升安全检测精度,提出特征标记下的蓄热式连续加热炉炉管安全VR检测技术。该方法首先使用红外热成像技术获取炉管红外图像,并利用双层小波系数对图像展开去噪处理;完成图像去噪后,利用VR技术对去噪图像实施目标重现;结合差分卷积模板,对炉管图像的温度特征实施标记处理,完成温度特征标签化;最后,将温度标签作为模型参数,基于人工神经网络建立安全检测模型,完成蓄热式连续加热炉炉管的安全状态检测。实验结果表明,使用该方法开展炉管安全检测时,炉管红外图像处理效果较好,安全检测精度和效率均较高。

回转炉应用于粉状五氧化二钒连续化生产的研究

介绍了偏钒酸铵制备粉状五氧化二钒的制备工艺,对传统设备与新型回转炉设备的运行参数进行了优劣对比,并对进料系统、炉管、原料回收及尾气处理系统的优化设计及连续化生产应用进行阐述。片状五氧化二钒为生产钒合金的原料,而粉状五氧化二钒则是片状五氧化二钒的直接原料,间接影响钒合金的性能。目前批量生产方式较为落后,其整体生产效率低、自动化水平低,导致运营成本居高不下。连续制备粉状五氧化二钒的回转炉装备主要优点在于:物料破碎充分,螺旋进料顺畅;设备连续批量产出高质量粉状五氧化二钒,产量达到340 kg/h以上;尾气中回收物料可再次作为原料进行利用,尾气处理后达到国家排放标准。连续式回转炉可实现粉钒连续化制备,对钒氮行业具有积极意义。

连续重整装置与抽提负荷不匹配问题分析及改造

某公司扩能升级改造后,为确保以最大能力为1.8MPa氢气系统供氢,要求重整联合装置须满负荷运行,凸显出现有工艺重整装置与芳烃抽提装置负荷不匹配问题。为彻底解决该负荷不匹配的难题,经分析提出在脱重组分塔之后增产二甲苯装置前新增一座脱庚烷塔的方案。使用Aspen HYSYS模拟软件模拟得到脱庚烷塔投用后热载体系统负荷、原料性质、物料参数及产品情况,并与无脱庚烷塔时重整装置满负荷运行方案效益进行对比,得出增设脱庚烷塔后,总效益增加3414元/h,全年产生效益2800万元。并以此为理论依据对增设脱庚烷塔前后的实际情况进行对比,得出优化后装置虽未能达到理论最优工况,但经济效益、操作灵活度得到了提升。该方法对新建装置效益评估具有一定的指导意义。

提高中间包连浇炉数的生产实践

通过对影响中间包连浇炉数的因素进行深入分析,结合湛江钢铁的合同结构、装备情况、生产物流特点,针对性地提出提升湛江钢铁连浇炉数的举措并进行落地。实践证明,通过采取提高耐材寿命、优化连铸机分工、提高钢种连浇炉数上限、优化合同结构和生产组织及强化现场操作管理等措施,钢种中间包连浇炉数上限最多提高60%,炼钢内部对中间包连浇炉数影响下降61.29%,2023年湛江钢铁中间包连浇炉数较2021年提升1.9炉/中间包,效果显著。

连续退火炉烧嘴燃烧系统管理优化解析与实践

烧嘴燃烧系统是冷轧连续退火炉的主体设备,冷轧连续退火炉的使用维护与燃烧控制直接影响备件成本和生产产品的性能是否达标。本文通过对冷轧厂连续退火炉烧嘴故障管理优化、烧嘴燃烧控制模式优化、烧嘴空燃比调整优化,为其后期退火炉烧嘴燃烧系统管理工作的开展提供相应的支持。

烟气连续监测系统在加热炉的运用探讨

描述了烟气连续监测系统在加热炉上的综合运用。为实现加热炉烟气中气态污染物(SO_(2)、NO_(X)、O_(2))和颗粒物浓度,温度、压力、流量和湿度等参数在操作台上在线监测,通过在烟气分析室内新增S7-300PLC系统建立通讯,实现烟气连续监测数据实时传输至上位机,在加热炉燃烧系统新增画面上显示及智能预警、报警,实现与加热炉的工艺燃烧的联锁控制。

Deviation Prevention Ability of Rollers in Continuous Annealing Furnace and Application

In order to reduce the strip deviation in the practical production procedure in the continuous annealing fur- nace, a dynamic simulation model was built through finite element method （FEM） to conduct the quantification cal- culation of the effect of regular roller contour types on strip deviation. The result reveals that comparing to the flat roller, forward roller contour can prevent the strip deviation to some degree. In terms of prevention ability, double- taper roller is the strongest, single-taper roller and crown roller are less stronger; and more roller contour values raise the prevention ability. Accordingly, optimization method was applied to continuous annealing furnace, and it largely reduced accidents such as strip break and limited speed that are caused by the deviation.

Modeling of Strip Heating Process in Vertical Continuous Annealing Furnace

The mechanism for heat transfer of radiation is usually adopted to heat strip in vertical continuous annealing furnace. The rate of heat transfer among strip and other objects can be hugely affected by the parameters of strip speed, geometry factors and radiating characteristic of surfaces of strip, radiating tubes and walls of furnace. A model including all parameters is proposed for calculating the heat transfer coefficient, predicting the strip tempera- ture and boundary temperature of strip through analyzing these parameters. The boundary temperature is a important datum and different from average arithmetic value of temperature of strip and temperature in furnace. Also, the model can be used to analyze the relation for temperature of strip and heat transfer coefficient, total heat transfer quantity and heating time. The model is built by using the radiating heat transfer rate, the Newtonrs law of cooling, and lumped system analysis. The results of calculation are compared to the data from production line. The comparisons indicate that the model can well predict the heating process. The model is already applied for process control in pro- duction line. Also, this research will provide a new method for analyzing the radiation heat transfer.

镀锌线薄板生产中退火炉的加热控制研究

基于对镀锌退火炉的加热控制功能的分析,结合生产线的实际情况,对不同规格的薄板制定出了不同的加热控制策略,即以不同的温度上升斜率来保证薄板升温过程的平稳进行。通过优化退火炉的加热控制策略,满足了镀锌薄板的生产需求。

一种铜液连续测控温度技术

介绍了开发铜液连续测控温的一种技术。铜/钢行业金属液测温难度大,多为人工用快速热偶间歇抽测的粗略方式;现开发了一种热偶护套管涂层制造技术,该热偶经实测铜液试验,达到了连续使用及耐热震基本要求;通过感应熔铸炉自动控温技术改造,铜液熔炼期及浇注期的过热度实现精确调控,提升了熔铸工艺温度控制技术水平和产品质量;该技术在铜液/钢液等金属液测控温技术领域,具有较广泛的推广应用价值。