无缝钢管用喷硼砂系统的关键技术研究
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摘要
热连轧无缝钢管内氧化铁皮的产生严重影响了管材的合格率。喷硼砂系统就是用于去除毛管内氧化铁皮的装置。此装置的工作原理就是借助氮气将硼砂颗粒吹到毛管内壁,在高温下,产生化学反应,使氧化铁皮脱落,并在毛管内注满氮气,防止氧气与毛管的进一步接触来达到抗氧化效果。为了优化设备除氧化铁皮效果,本论文以此套设备为研究对象,对现有设备的关键技术进行创新改进,从而进一步提高无缝钢管的成品率。
论文对抗氧化系统工作原理进行总结。结合引进的国外设备现状,解决了硼砂喷吹量的控制、密封件寿命、抗氧化物料的供给方式、工位转换阀角度、设备的运行状态的监测及装机水平等几个方面的问题。
喷嘴是抗氧化系统喷吹单元的一部分,直接影响着系统的喷吹效果。论文通过以往经验取值对喷嘴进行改进设计,建立了五种型号的喷嘴物理模型。结合系统关键技术参数合理确定初始条件和边界条件,借助CFD软件仿真新型喷嘴内部流场,确定硼砂经喷嘴喷出是否产生旋流,进而验证喷嘴的设计是否合理。
论文还建立了不同叶片摆放角度的模型,并对其仿真。通过对比喷嘴出口速度矢量图,得到各型号喷嘴的最佳叶片摆放角度范围。论文还在已确定最佳角度范围的基础上,根据系统提供的压力范围确定了各型号喷嘴出口扩散角的最大最小值,从而得到各型号喷嘴对应的钢管管径范围。
最后借助wincc界面所采集数据,对比新旧喷嘴耗硼砂量的多少,验证新型喷嘴的可行性
本论文为企业委托项目,通过对喷嘴的仿真分析与现场采集数据对比,为企业优化改进喷硼砂系统提供了参考依据。
The iron oxide scale which produced in the hot rolling seamless pipe have a serious impact on the pipe qualified rate. Spraying borax system is a kind of device,used for removing iron oxide scale. It's working principle is blowing nitrogen gas to the pipe inner wall with borax particles, at high temperatures, borax and iron oxide scale will produce chemical reaction,and then the oxidation iron sheet off, the steel pipe filled with nitrogen.In this Situation,the gas nitrogen prevent the oxygen further exposure to the steel pipe. In order to optimize the effect of removing iron oxide scale,this thesis sets of equipment as the research object, innovation and improvement the key technology of the exist equipment, so as to further enhance the rate of finished products of seamless tube.
The working principle of spraying borax system were summarized in this paper. With the current situation of this foreign equipment,we solved many key technology problems.Such as:the borax injection quantity control, the service life of the sealing elements, antioxidative materials supply mode, position changeover valve angle, the equipment running status monitoring and assembly level.
Blowing is one of unit of the antioxidant system,and the nozzle is a part of the blowing unit.It directly influences the blowing effect of the system. This paper based on the past experience value,made some new improved design on the nozzle.Set up five kinds of physical model. Combined with the key technology parameters of the system, determined the reasonable initial conditions and boundary conditions, use CFD simulated the internal flow field of the nozzle, make sure whether borax produce cyclonewhen it sprayed out through nozzle, so as to verify whether the design is reasonable.
The paper has also established and simulated the model with different vane angles. Got the optimum vane angle range by comparing the nozzle outlet velocity vectors. Based on the optimum vane angle range, identified maximum and minimum values of the nozzle outlet diffusion angle, according to the system pressure range.and thus get the corresponding pipe diameter range.
Finally according to the WinCC interface data, verified the feasibility of new nozzle by comparing the consumption amount of borax.
This thesis optimized for the enterprise improve spraying borax system offers the theoretical basis.
This paper is commissioned project by enterprise.It provides reference for the enterprise to optimize and improve spraying borax system which through simulation and analysis of the nozzle.
论文对抗氧化系统工作原理进行总结。结合引进的国外设备现状,解决了硼砂喷吹量的控制、密封件寿命、抗氧化物料的供给方式、工位转换阀角度、设备的运行状态的监测及装机水平等几个方面的问题。
喷嘴是抗氧化系统喷吹单元的一部分,直接影响着系统的喷吹效果。论文通过以往经验取值对喷嘴进行改进设计,建立了五种型号的喷嘴物理模型。结合系统关键技术参数合理确定初始条件和边界条件,借助CFD软件仿真新型喷嘴内部流场,确定硼砂经喷嘴喷出是否产生旋流,进而验证喷嘴的设计是否合理。
论文还建立了不同叶片摆放角度的模型,并对其仿真。通过对比喷嘴出口速度矢量图,得到各型号喷嘴的最佳叶片摆放角度范围。论文还在已确定最佳角度范围的基础上,根据系统提供的压力范围确定了各型号喷嘴出口扩散角的最大最小值,从而得到各型号喷嘴对应的钢管管径范围。
最后借助wincc界面所采集数据,对比新旧喷嘴耗硼砂量的多少,验证新型喷嘴的可行性
本论文为企业委托项目,通过对喷嘴的仿真分析与现场采集数据对比,为企业优化改进喷硼砂系统提供了参考依据。
The iron oxide scale which produced in the hot rolling seamless pipe have a serious impact on the pipe qualified rate. Spraying borax system is a kind of device,used for removing iron oxide scale. It's working principle is blowing nitrogen gas to the pipe inner wall with borax particles, at high temperatures, borax and iron oxide scale will produce chemical reaction,and then the oxidation iron sheet off, the steel pipe filled with nitrogen.In this Situation,the gas nitrogen prevent the oxygen further exposure to the steel pipe. In order to optimize the effect of removing iron oxide scale,this thesis sets of equipment as the research object, innovation and improvement the key technology of the exist equipment, so as to further enhance the rate of finished products of seamless tube.
The working principle of spraying borax system were summarized in this paper. With the current situation of this foreign equipment,we solved many key technology problems.Such as:the borax injection quantity control, the service life of the sealing elements, antioxidative materials supply mode, position changeover valve angle, the equipment running status monitoring and assembly level.
Blowing is one of unit of the antioxidant system,and the nozzle is a part of the blowing unit.It directly influences the blowing effect of the system. This paper based on the past experience value,made some new improved design on the nozzle.Set up five kinds of physical model. Combined with the key technology parameters of the system, determined the reasonable initial conditions and boundary conditions, use CFD simulated the internal flow field of the nozzle, make sure whether borax produce cyclonewhen it sprayed out through nozzle, so as to verify whether the design is reasonable.
The paper has also established and simulated the model with different vane angles. Got the optimum vane angle range by comparing the nozzle outlet velocity vectors. Based on the optimum vane angle range, identified maximum and minimum values of the nozzle outlet diffusion angle, according to the system pressure range.and thus get the corresponding pipe diameter range.
Finally according to the WinCC interface data, verified the feasibility of new nozzle by comparing the consumption amount of borax.
This thesis optimized for the enterprise improve spraying borax system offers the theoretical basis.
This paper is commissioned project by enterprise.It provides reference for the enterprise to optimize and improve spraying borax system which through simulation and analysis of the nozzle.
引文
[1]张敏健.喷嘴研究发展概述[J].电站系统工程,2008.1.
[2]殷国茂,杨仙.中国无缝钢管技术装备的现状分析[J].河北科技大学学报,2005.12.
[3]曾良平.毛管吹氮喷硼砂装置的技术关键[J].钢铁技术,2005.4：12-13.
[4]周华,范明豪,杨华勇.旋芯喷嘴高效雾化特性测量研究[J].机械工程学报2004.8.
[5]赵艳萍等.应用于油气钻采的磨料水射流喷嘴优化设计与试验研究[J].流体机械.2010.38(10).
[6]王晓倩等.雾化喷嘴及其设计浅谈[J].哈尔滨：煤矿机械,2008.29(3).
[7]Marco Ghisolfi.现代化无缝钢管生产技术.SMS lnnse, milano, Italy.
[8]周晓锋,张宝惠,张传友,史庆志.除氧化物剂和芯棒润滑对热连轧无缝钢管产生内结疤缺陷的影响分析[J].钢管,2010.39(3).
[9]包头钢铁稀土公司稀土研究院.全自动热轧无缝钢管粉状润滑剂喷射装置[J].CN2220908 1996-02-08.
[10]金如崧译注：穿孔工艺的发展和锥辊式穿孔机的复出.钢管,2002.12.
[11]付曙光.高压水除鳞喷嘴射流特性的CFD仿真[D].武汉科技大学,2007.
[12]梁荣,党新安,赵小娟.超声波雾化喷嘴的设计[J].上海有色金属,2006.12.
[13]周月桂,曹威城,柳瑶斌,章明川.大流量单混合孔 Y型喷嘴的雾化特性[J].动力工程,2007.12.
[14]吕群,魏宁,余立伟.两相流雾化喷嘴在烟气喷雾增湿示范工程中的应用[J].电力环境保护,2001.17(3)：20—22.
[15]闫云飞,张力.低压旋流雾化喷嘴的雾化性能[J].化工学报,2009.5.
[16]李晓红.从无缝钢管生产格局和出口依存度现状分析我国淘汰落后无缝钢管装备的必要性[J].钢管,2009.1.
[17]林龙辉等.中国无缝钢管在美国市场竞争力的实证研究[J].国际商务研究,2010.2.
[18]A. Demetriades, Stabilization of a nozzle boundary layer by local surface heating, AIAA Journal 34 (12) (1996) 2490-2495.
[19]Zhou L X and Huang X Q. Numerical and experiments studies on a gas-particle two-phase flowjet,3th Asian Congressof Fluid Mechanism, Japan,1986.
[20]Yuu-S, Umekage-T,Tabuchi-M. Direct numerical simulation forthree-dime -nsional gas-solid two-phase jet uding two-way method and experimental-verificatio-n. JSMEInternationalJournal,1996, B39(2):230-238.
[21]曾卓雄,姜培正.喷嘴雾化粒径的实验研究[J].西安交通大学学报,2000.3.
[22]刘联胜,吴晋湘.气泡雾化喷嘴喷雾平均直径在下游流场中的分布[J].燃烧科学与技术,2001.9.
[23]龚景松,傅维镳.旋转型气-液雾化喷嘴的雾化特性研究[J].热能动力工程,2006.6.
[24]安爱英.采煤机喷雾系统喷嘴喷雾仿真分析研究[D].太原理工大学,2010.
[25]杜厚益.俄罗斯钢管工业的现状和发展前景(111)[J].钢管,2006.6.
[26]谢立维.热连轧带钢高压水除鳞系统介绍[J].涟钢科技与管理,2010.1.
[27]王毅.高压除鳞喷嘴流场三维数值模拟与试验研究[D].武汉科技大学,2008.
[28]徐刚.CFD在旋流喷嘴设计中的应用研究[D].上海交通大学,2008.
[29]J. D. Hoffman, Approximate analysis of nonisentropic flow in conical nozzles, Journal of Spacecraft and Rockets 6(11) (1969)1329-1337.
[30]李勇,艾信友,肖春华.气力输送原理在喷砂和除尘装置中的应用[J].《机械制造》1999.11.
[31]梁晓燕,卢平,章名耀.气泡雾化喷嘴及其喷雾特性[J].能源研究与利用,2004.2.
[32]Thomas A. Taylor. Surface roughening of metallic substrates by high pressur epur-ewaterjet. Surface and Coating Technology 76-77 (1995) 95-100.
[33]李晓红.我国无缝钢管供需市场分析与前景展望[J].钢管,2006.35(2).
[34]周庆杰,朱景清.我国无缝钢管生产的现状、问题、对策与展望[J].钢管,2000.29(1).
[35]D. Vlassov, G. I. Mazing, About losses in rough surface nozzles, Journal of Machin-ery Construction (in Russian) 9 (1987)81-85.
[36]深入浅出西门子S7-300PLC[M].北京：北京航空航天大学出版社,2004.8.
[37]U. S. Burreau of Mines. Novel Foam Application Reduces Longwall Dust. Technol. News. No.326. March1989.
[38]严卫群等.提高热轧钢管除鳞效率的途径[J].冶金设备,2008.3.
[39]WSheldon. The design and evaluation of hydrome-chanical descaling nozzl-es. Hydraulic Descaling In Rolling Mills 1995(9).
[40]DavidT. Blazevic, Mechanicsof Descaling, Descaling Technology Seminar, Bejing, China,1998(5).
[41]王峰.氧化皮对热轧盘条耐蚀性能影响的研究[D].湖南大学,2009.
[42]S. T. Bonnington, Water Driven Air Ejectors, BHRA Fluid Engnf RR664,1960.
[43]G. E. Reisman, Y. C. Wang, C. E. Brennen, Observations of shock waves in cloud cavit-ation.J.Fluid Mech.,1988,355:255-283.
[44]于云,许振明,李建国.单火孔预混鼓风式煤气燃烧器喷头的设计原理[J].工业加热,2003.2.
[45]Heidt, Viktor. Influence of Running Water on the Heat Transfer in Continuous Casting. Steel Research,1983(3):157～164.
[46]夏先平等.三次氧化铁皮缺陷的成因分析[J].宝钢技术,2002.4.
[2]殷国茂,杨仙.中国无缝钢管技术装备的现状分析[J].河北科技大学学报,2005.12.
[3]曾良平.毛管吹氮喷硼砂装置的技术关键[J].钢铁技术,2005.4：12-13.
[4]周华,范明豪,杨华勇.旋芯喷嘴高效雾化特性测量研究[J].机械工程学报2004.8.
[5]赵艳萍等.应用于油气钻采的磨料水射流喷嘴优化设计与试验研究[J].流体机械.2010.38(10).
[6]王晓倩等.雾化喷嘴及其设计浅谈[J].哈尔滨：煤矿机械,2008.29(3).
[7]Marco Ghisolfi.现代化无缝钢管生产技术.SMS lnnse, milano, Italy.
[8]周晓锋,张宝惠,张传友,史庆志.除氧化物剂和芯棒润滑对热连轧无缝钢管产生内结疤缺陷的影响分析[J].钢管,2010.39(3).
[9]包头钢铁稀土公司稀土研究院.全自动热轧无缝钢管粉状润滑剂喷射装置[J].CN2220908 1996-02-08.
[10]金如崧译注：穿孔工艺的发展和锥辊式穿孔机的复出.钢管,2002.12.
[11]付曙光.高压水除鳞喷嘴射流特性的CFD仿真[D].武汉科技大学,2007.
[12]梁荣,党新安,赵小娟.超声波雾化喷嘴的设计[J].上海有色金属,2006.12.
[13]周月桂,曹威城,柳瑶斌,章明川.大流量单混合孔 Y型喷嘴的雾化特性[J].动力工程,2007.12.
[14]吕群,魏宁,余立伟.两相流雾化喷嘴在烟气喷雾增湿示范工程中的应用[J].电力环境保护,2001.17(3)：20—22.
[15]闫云飞,张力.低压旋流雾化喷嘴的雾化性能[J].化工学报,2009.5.
[16]李晓红.从无缝钢管生产格局和出口依存度现状分析我国淘汰落后无缝钢管装备的必要性[J].钢管,2009.1.
[17]林龙辉等.中国无缝钢管在美国市场竞争力的实证研究[J].国际商务研究,2010.2.
[18]A. Demetriades, Stabilization of a nozzle boundary layer by local surface heating, AIAA Journal 34 (12) (1996) 2490-2495.
[19]Zhou L X and Huang X Q. Numerical and experiments studies on a gas-particle two-phase flowjet,3th Asian Congressof Fluid Mechanism, Japan,1986.
[20]Yuu-S, Umekage-T,Tabuchi-M. Direct numerical simulation forthree-dime -nsional gas-solid two-phase jet uding two-way method and experimental-verificatio-n. JSMEInternationalJournal,1996, B39(2):230-238.
[21]曾卓雄,姜培正.喷嘴雾化粒径的实验研究[J].西安交通大学学报,2000.3.
[22]刘联胜,吴晋湘.气泡雾化喷嘴喷雾平均直径在下游流场中的分布[J].燃烧科学与技术,2001.9.
[23]龚景松,傅维镳.旋转型气-液雾化喷嘴的雾化特性研究[J].热能动力工程,2006.6.
[24]安爱英.采煤机喷雾系统喷嘴喷雾仿真分析研究[D].太原理工大学,2010.
[25]杜厚益.俄罗斯钢管工业的现状和发展前景(111)[J].钢管,2006.6.
[26]谢立维.热连轧带钢高压水除鳞系统介绍[J].涟钢科技与管理,2010.1.
[27]王毅.高压除鳞喷嘴流场三维数值模拟与试验研究[D].武汉科技大学,2008.
[28]徐刚.CFD在旋流喷嘴设计中的应用研究[D].上海交通大学,2008.
[29]J. D. Hoffman, Approximate analysis of nonisentropic flow in conical nozzles, Journal of Spacecraft and Rockets 6(11) (1969)1329-1337.
[30]李勇,艾信友,肖春华.气力输送原理在喷砂和除尘装置中的应用[J].《机械制造》1999.11.
[31]梁晓燕,卢平,章名耀.气泡雾化喷嘴及其喷雾特性[J].能源研究与利用,2004.2.
[32]Thomas A. Taylor. Surface roughening of metallic substrates by high pressur epur-ewaterjet. Surface and Coating Technology 76-77 (1995) 95-100.
[33]李晓红.我国无缝钢管供需市场分析与前景展望[J].钢管,2006.35(2).
[34]周庆杰,朱景清.我国无缝钢管生产的现状、问题、对策与展望[J].钢管,2000.29(1).
[35]D. Vlassov, G. I. Mazing, About losses in rough surface nozzles, Journal of Machin-ery Construction (in Russian) 9 (1987)81-85.
[36]深入浅出西门子S7-300PLC[M].北京：北京航空航天大学出版社,2004.8.
[37]U. S. Burreau of Mines. Novel Foam Application Reduces Longwall Dust. Technol. News. No.326. March1989.
[38]严卫群等.提高热轧钢管除鳞效率的途径[J].冶金设备,2008.3.
[39]WSheldon. The design and evaluation of hydrome-chanical descaling nozzl-es. Hydraulic Descaling In Rolling Mills 1995(9).
[40]DavidT. Blazevic, Mechanicsof Descaling, Descaling Technology Seminar, Bejing, China,1998(5).
[41]王峰.氧化皮对热轧盘条耐蚀性能影响的研究[D].湖南大学,2009.
[42]S. T. Bonnington, Water Driven Air Ejectors, BHRA Fluid Engnf RR664,1960.
[43]G. E. Reisman, Y. C. Wang, C. E. Brennen, Observations of shock waves in cloud cavit-ation.J.Fluid Mech.,1988,355:255-283.
[44]于云,许振明,李建国.单火孔预混鼓风式煤气燃烧器喷头的设计原理[J].工业加热,2003.2.
[45]Heidt, Viktor. Influence of Running Water on the Heat Transfer in Continuous Casting. Steel Research,1983(3):157～164.
[46]夏先平等.三次氧化铁皮缺陷的成因分析[J].宝钢技术,2002.4.