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粒子钢压块成型生产线

钢销、钢渣粒子钢液压压制成型系统技术说明

Technical Description of Hydraulic Pressing Forming System for Steel Pin and Slag Particle Steel

一、项目背景

  Project Background

宏观层面看,《“十二五”循环经济发展规划》明确指出,发展循环经济是我国经济社会发展的重大战略任务,是推进生态文明建设、实现可持续发展的重要途径和基本方式。因此,全国钢铁企业必须围绕提高资源产出率,健全激励约束机制,构建循环型产业体系,推动再生资源利用产业化,推行绿色消费,加快形成覆盖全社会的资源循环利用体系。从中微观层面看,未来钢厂对钢渣处置利用将提出更高的价值诉求,钢渣循环再利用产业化势在必行。

Macroscopically, the 12th Five-Year Plan for the Development of Circular Economy clearly points out that the development of circular economy is an important strategic task for Chinas economic and social development and an important way and basic way to promote the construction of ecological civilization and achieve sustainable development. Therefore, the national iron and steel enterprises must focus on improving the resource output rate, improving the incentive and restraint mechanism, building a circular industrial system, promoting the industrialization of renewable resources utilization, promoting green consumption, and speeding up the formation of a resource recycling system covering the whole society. From the micro and meso level, steel mills will put forward higher value demands for the disposal and utilization of steel slag in the future, and it is imperative to industrialize the recycling and reuse of steel slag.

国际形势来看,一些发达国家利用节能环保方面的技术优势,已在国际贸易中制造了较高的绿色技术壁垒。国内形势来看,面对严峻资源环境约束,“十三五”时期是我国节能环保产业发展难得的历史机遇期,发展前景广阔。据有关部门测算,到2016年节能潜力超过4亿吨标准煤,可带动上万亿元投资;节能服务总产值可突破3000亿元;产业废物循环利用环境服务总产值将达5000亿元规模。

 

In the international situation, some developed countries have created high green technical barriers in international trade by taking advantage of their technological advantages in energy conservation and environmental protection. In view of the domestic situation, facing the severe resource and environment constraints, the 13th Five-Year Plan period is a rare historical opportunity for the development of energy-saving and environmental protection industry in China, with broad prospects for development. According to estimates by relevant departments, by 2016, the energy-saving potential will exceed 400 million tons of standard coal, which will lead to trillion yuan of investment; the total output value of energy-saving services will exceed 300 billion yuan; and the total output value of environmental services for industrial waste recycling will reach 500 billion yuan.

钢铁工业“十三五”发展规划也明确指出:“要加快钢铁行业资源能源回收利用产业发展;促进钢铁与其他产业的融合,发展循环经济;开展能源审计、清洁生产审核和清洁生产方案的实施”。可见,钢渣处理生产将面临达标排放的刚性需求。

 

The thirteenth five-year development plan of iron and steel industry also clearly points out that "the development of energy recovery and utilization industry in iron and steel industry should be accelerated; the integration of iron and steel with other industries should be promoted to develop circular economy; and the implementation of energy audit, cleaner production audit and cleaner production plan should be carried out". It can be seen that steel slag treatment production will face the rigid demand of meeting the discharge standards.

二、钢销、钢渣粒子钢液压压制成型技术介绍

Introduction of Hydraulic Pressing Technology for Steel Pin and Slag Particle Steel

唐山市鑫虎冶金科技有限公司,经过大量研发和科研实验,研究成功将钢销、钢渣粒子钢、钢渣精粉、高品位铁粉还原等通过液压压制成型的设备,现已经批量投入生产使用

Tang Shan  Xin Hu metallurgy Technology Co., Ltd. has successfully reduced steel pins, steel slag particle steel, steel slag powder and high-grade iron powder by hydraulic pressing through a large number of R&D and scientific research experiments. Now it has been put into production and use in batches.

1.本系统设计依照的基本原则是:

  (1)采用先进的低能耗装备。

2)坚持可持续发展战略,提高能源,资源的利用效率。

3)以环境效益和综合经济效益为中心,实现企业的清洁生产。

4)优化工艺方案,总体布局紧凑合理,工艺流程简洁顺畅。

5)厉行节约,降低投资。

 客户生产出的产品.jpg

1.     The basic principles of the system design are:

(1)  Use advanced low-energy equipment.

(2)  Adhere to the strategy of sustainable development and improve the utilization efficiency of energy and resources.

(3)  Centering on the environmental and comprehensive economic benefits, the clean production of enterprises.

(4)  Optimizing process plan, compact and reasonable overall layout, simple and smooth process.

(5)  Strictly economize and reduce investment.

2、钢销、钢渣粒子钢、钢渣精粉、高品位铁粉还原等液压压制成型系统工艺流程

 

2.     Process flow of hydraulic pressing forming system for steel pin, steel slag particle steel, steel slag concentrate powder and reduction of high-grade iron powder

    工艺流程描述

Process description

钢销、钢渣粒子钢、钢渣精粉、高品位铁粉还原等液压压制成型系统工艺是将钢销、钢渣粒子钢由上料机加入到系统设备,由低温对流烘干器和精确调温器进行温度控制,对钢渣粒子钢进行烘干,然后经中间转运器输送到液压成型机,经液压按需求调整液压压力(0-315bar动态可调)压制成型后将压制好的粒子钢块由装载机吊运至成品库,期间部分热量由高效换热器进行回收利用,设计有除尘系统对生产过程中产生的废气、粉尘等污染进行环保处理。

Steel pin, steel slag particle steel, steel slag powder, high-grade iron powder reduction and other hydraulic pressing forming system technology is to add steel pin and steel slag particle steel to the system equipment by feeder, temperature control by low-temperature convection dryer and precise thermostat, drying steel slag particle steel, and then conveyed to the hydraulic forming machine through intermediate conveyor, hydraulic pressure adjusted according to demand (0. - 315bar dynamic adjustable) After pressing, the pressed steel particles are hoisted from loader to finished product warehouse, during which part of the heat is recovered and utilized by high efficiency heat exchanger, and a dust removal system is designed to deal with environmental pollution such as waste gas and dust produced in the production process.

    工艺流程图

Process flow chart

 粒子钢压块生产线工艺流程图.jpg


⑶主要设备部件包括钢渣粒子钢上料机、低温对流烘干器、精确调温烘干器、余热回收、除尘器、中间转运器、液压成型机、循环风机、成品输送设备、管道、自动控制系统等。

    The main equipment components include steel slag particle feeder, low temperature

convection dryer, precise temperature regulating dryer, waste heat recovery, dust collector, intermediate transporter, hydraulic forming machine, circulating fan, finished product conveying equipment, pipeline, automatic control system, etc.

3、安全可靠、优势明显

Safety, reliability and obvious advantages

A、渣钢根据粒度不同以不同方式回收利用

Slag steel is recycled in different ways according to its particle size.

 1A1级渣钢,TFe80%,粒度>75mm)为初选渣钢,经电磁除铁器选出,供给转炉炼钢使用。

Grade A1 slag steel with TFe (> 80%) and particle size > 75 (mm) is the primary slag steel seleced by electromagnetic iron remover and supplied to converter steelmaking.

2A2级渣钢,TFe80%,粒度10-75mm2#棒磨机提纯后,进入2#振动筛,筛上产物,供给转炉炼钢使用。

Class A2 slag steel with TFe (> 80%) and particle size of 10-75 (mm) 2 # bar mill is purified, and then it enters 2 # vibrating screen. The products are screened and supplied to converter steelmaking.

3B1级磁选粉,TFe80%,粒度5-75mm),经2#棒磨机提纯后,进入2#振动筛,筛下产物,再进行二次筛分,筛上产物,供给转炉炼钢使用。

Level B1 magnetic separator powder, TFe (> 80%) and particle size 5-75 (mm), purified by 2# bar mill, enters 2# vibrating screen, sieves the product, then carries on the second sieve, sieves on the product, supplies the converter steelmaking use.

4B2级磁选粉,TFe42%,粒度<5mm),经2#棒磨机提纯后,进入2#振动筛,筛下产物,再进行二次筛分,筛下产物,返烧结使用。

B2 grade magnetic separator powder, TFe (> 42%) and particle size (< 5 mm), purified by 2 # bar mill, enters 2 # vibrating screen, sieves the product, then sieves the product twice, sieves the product, and returns to sintering.

(5)   尾渣,MFe<3%,粒度<10mm),经破碎、磁选、提纯后的产物。

Tailings, MFe < 3%, particle size < 10 (mm), after crushing, magnetic separation, purification products.

B、 小颗粒渣钢烧结和直接入炉的弊端

Disadvantages of Sintering and Direct Furnace Entry of Small Particle Slag Steel

●烧结设备大型化和自动化,投资和运行费用较高

Large-scale and automation of sintering equipment, high investment and operation costs

●由于煤中含硫,所以烧结会排放出有害气体产物二氧化硫,必须进行烟气脱硫处理。

Because of the sulfur content in coal, sulfur dioxide, a harmful gas product, will be discharged from sintering, so flue gas desulfurization must be carried out.

●由于烧结温度很高,烧结矿不能热送高炉,即使回收部分余热,还是要排出大量废热

Because of the high sintering temperature, sinter can not be hot-fed to blast furnace. Even if part of the waste heat is recovered, a large amount of waste heat must be discharged.

 ●氧化铁皮为片状形态,在烧结过程中影响料层的透气性,从而降低烧结产量。并且细小的颗粒容易被气流抽走增加除尘系统负荷。

The sheet shape of iron oxide sheet affects the permeability of the material layer during sintering process, thus reducing the sintering output. And fine particles are easily sucked away by airflow to increase the load of dust removal system.

●粒子钢直接加入转炉产生较大的火焰和喷溅,存在人员和设备的安全隐患。

Particle steel directly added into converter produces larger flame and splash, which has potential safety hazards for personnel and equipment.

三、原料供应

Raw Material Supply

1、 原料:钢渣选出的粒子钢、锯口屑、各种小颗粒、钢销、钢屑、氧化铁

Raw materials: particulate steel, sawdust, various small particles, steel pins, steel chips and iron oxide seleced from steel slag

2、 粒度分级:0.5mm--30mm(按不同原料比例调配)成分:待测

Particle size grading: 0.5mm-30mm (dispensing according to different raw material proportions) Composition: to be measured

四、处理目的

Purpose of treatment

将钢渣粒子钢在0-315bar动态可调的液压压力下,液压压制成粒子钢块。钢渣粒子钢经过本设备的液压压制成型后的成品指标为:Si1.25%P0.15%S0.07%C2.5%,单质铁≥90%,密度为6.5g/cm3,此产品能有效降低炼钢成本,提高钢产量。

The steel slag particle steel was pressed into the particle steel block under the dynamic adjustable hydraulic pressure of 0-315 bar. The finished product index of steel slag particle steel after hydraulic pressing is: Si < 1.25%, P < 0.15%, S < 0.07%, C < 2.5%, elemental iron (>90%) and density 6.5g/cm. This product can effectively reduce steelmaking cost and increase steel output.

五、钢销、钢渣粒子钢烘干液压成型系统组件

Components of Hydraulic Forming System for Steel Pin and Slag Particle Steel Drying

 钢渣粒子钢烘干液压成型系统主要设备及部件包括:上料机、低温对流烘干器、精确调温设备、余热回收换热器、除尘器、中间转运器、液压成型机、排烟机、循环风机、成品输送设备、管道、自动控制系统。

The main equipments and components of the steel slag particle steel drying hydraulic forming system include feeder, low temperature convection dryer, precise temperature regulating equipment, waste heat recovery heat exchanger, dust collector, intermediate transporter, hydraulic forming machine, smoke exhaust machine, circulating fan, finished product conveying equipment, pipeline and automatic control system.

六、成本测算:

 Cost estimation:

1、钢销、钢渣粒子钢、钢渣精粉、高品位铁粉还原烘干液压成型系统运行费用(预估值 )

Operation cost of reduction drying hydraulic forming system for steel pin, steel slag particle steel, steel slag powder and high grade iron powder (estimated)

 

名称

消耗量/

单价

合计

电耗

15.5/

0.7

15.5

焦炉煤气

30-40m3

0.3

9-12

高炉煤气

100-120m3

0.1

10-12

天然气

10-12m3

3

30-36

人工费

10

10

10

机器磨损

3-5


3-5

用焦炉煤气合计

37.5-42.5/

用高炉煤气合计

38.5-42.5/

用天然气合计

68.5-66.5/

 

 

Item

Consumption  / ton

Unit Price

Total Amount

electricity

15.5RMB/ton

0.7RMB

15.5 RMB

coke oven gas

30-40m3

0.3 RMB

9-12 RMB

Blast furnace gas

100-120m3

0.1 RMB

10-12 RMB

Natural gas

10-12m3

3 RMB

30-36 RMB

Labor cost

10 RMB

10 RMB

10 RMB

Machine wear

3-5 RMB


3-5 RMB

Total with coke oven gas

37.5-42.5 RMB /ton

Total blast furnace gas

38.5-42.5 RMB / ton

Total with natural gas

68.5-66.5 RMB / ton

七、钢渣粒子钢液压压制成型系统的技术优势

Technical Advantages of Hydraulic Pressing Molding System for Steel Slag Particle Steel

 1粒子钢铁水降低率低

Low reduction rate of particulate molten iron and steel

系统采用特殊调节手段对粒子钢上料、液压压制成型等方面进行自动化精确控制,粒子钢在此过程中氧化率很低,因此与原料相比,粒子钢成型后含铁量降低幅度可以控制在2%以下。

Particle steel feeding and hydraulic pressing are controlled automatically and accurately by special adjusting means. The oxidation rate of particle steel is very low in this process. Therefore, compared with raw materials, the reduction of iron content after particle steel forming can be controlled below 2%.

 2粒子钢质量耗损率低

Low mass loss rate of particulate steel

此设备采用高效收尘措施,小粒级粒子钢直接返回烘干二段,且系统封闭性较好,因此,系统粒子钢几乎没有损耗。

This equipment adopts high efficiency dust collection measures, small particle steel directly returns to the second drying stage, and the system has good closure, so the system particle steel has almost no loss.

3系统降低能耗

System Reduction of Energy Consumption

系统采用全自动化进行精确控制,对生产过程中的各个环节进行精确控制和先进的液压伺服装置,在运行过程中电耗低,系统总功率比常规系统降低20%左右。

The system uses full automation for precise control, precise control of all links in the production process and advanced hydraulic servo device. In the operation process, the power consumption is low, and the total power of the system is reduced by about 20% compared with the conventional system.

4、系统造价较低

Lower system cost

系统设计中将烘干过程分级设计,系统尺寸大幅度降低,与常规设计相比,本系统造价降低约30%左右。

In the design of the system, the drying process is graded and the size of the system is greatly reduced. Compared with the conventional design, the cost of the system is reduced by about 30%.

5、系统事故率低

 Low system accident rate

通过模拟计算和自动化系统预警和调节,设备某一环节出现故障或系统检测传感器参数有异常时会及时进行报警和优化设备运行,系统作业率大幅度上升。

Through analog calculation and automatic system early warning and adjustment, the system will alarm and optimize the operation of the equipment in time when a fault occurs in a part of the equipment or the parameters of the system detection sensor are abnormal, and the operation rate of the system will increase greatly.

6、  系统流程简单,运行稳定性好

The system process is simple and the operation stability is good.

系统流程设计非常简洁、顺畅,调节手段灵活,系统运行稳定性很高。

  System flow design is very simple, smooth, flexible means of regulation, system operation stability is very high.

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