加压气化炉关键件制造工艺研究
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摘要
我国是以煤为主要能源的国家，资源十分丰富，已探明的地质储量达7700亿吨，居世界第三位。但把固态煤转化为气体燃料，目前化工合成原料率的水平还比较低。因此，依托河南省义马煤气化工程，对鲁齐加压气化炉关键技术进行科技攻关，做到对鲁齐加压气化炉的自行开发、设计和制造，用以代替进口整机和备件，可为国家节省大量外汇，其意义是十分重大的。
河南义马煤气化工程，采用德国鲁齐加压气化技术，引进鲁齐公司MARK—Ⅳ/4型φ3800mm炉技术软件，由哈尔滨锅炉厂有限责任公司承担制造任务。该产品集大型(重120吨)，双夹套结构等特点为一身，按照德国鲁齐和GB150工程规范进行设计制造和验收，在制造过程中简体冷卷成形结合冷精校压制成型，整体深内腔炉蓖面机加和大直径阀门密封面堆焊工艺等均为新的制造工艺，制造难度大。
本文主要工作有以下几个方面：
1．通过借助于计算机模拟方法，采用ANSYS程序，用其强大的前处理及后处理功能对大直径薄壁简体卷制过程进行模拟，并采取冷卷成形结合冷精校压制成型技术，保证简体环形水冷夹套内外间隙的装配要求。
2．产品整体热处理后要求保证炉篦两传动轴套与炉篦支撑面的垂直度要求90°±1′，炉体上下法兰密封面与炉体中心线的垂直度要求90°±5′。鉴于产品属大型(重120吨)，结构复杂，通过机械加工方法的研究并结合无接触三坐标测量技术，为大型石化设备、核电产品整体机械加工提供了宝贵的经验和依据。
3．气化炉的煤锁上、下阀门密封面要求堆焊硬质合金，堆焊面积大，硬度高，质量要求极其严格。通过工艺试验，在国内首次采用等离子弧自动堆焊的方法，使产品的堆焊及加工质量完全满足图纸和技
哈尔滨工程大学硕士学位论文
术条件的要求。
4.采用ANSYS程序对气化炉关键件的温度场、应力场进行应力分
析，并按JB4732一95《钢制压力容器分析设计标准》进行应力评定，
从而更深入的洞察材料在塑性成形过程中发生的变形、微观组织的变
化，为探索新的塑性成形工艺打下基础。
用于制取城市煤气和化工合成气的鲁齐加压气化炉是国际上公认
的成熟而先进的煤制气设备。但从目前情况看，我国煤炭加压气化的
理论研究，气化炉制造技术研究等方面和鲁齐公司相比仍有较大差距。
因此，开展鲁齐加压气化炉关键件技术攻关工作是十分必要的。
In our country, the main energy depends on the coal fuel, the coal resource is very rich, the geologic reserves of the coal proved up at present has reached to the amount of 7700 hundred millions of tons, the reserves of the coal is the third in the world. But it is lower capacity to converse solid coal into the gas fuel and chemical combination synthetical material, so, it is very important that solve the key technology of Lurgi pressure gasifier for Yima coal gas project in Henan province, to exploit, design and fabricate independently in stead of importation of the whole and spare parts, so as to save a large amount of foreign exchange
Yima coal gas project in Henan province adopt the technology of Lurgi, introduce the technology software of MARK-IV/4 type of Lurgi corporation,
Into our country, the manufacture is being in charge of by Harbin Boiler Works co. , Ltd. this product both are large ( the weight of more than 120 tons) and double sleeve shells, designed .manufactured and accepted ace. to the engineering specifications of lurgi in Germany and GB150, the new technology such as : the cold bending and cold press sizing of the shells, the whole machining of the surface for deep depth lumen and the larger valve sealing surface depositing, are very difficulty.
Primary research items are as follows :
1.By means of computer simulate of ANSYS program, using its powerful treatment function, simulate the process of the bending
of the larger and thin-walled shells, adopt the process of the cold bending and cold press sizing of the shells, and the clearance between the 2 sleeves of the shell circle for fit up ensured
2. After the whole PWHT , the product has to be machined to the requirements of the perpendicularity 90°±1' of the 2 drive axes sleeves to supporting surface, and the perpendicularity 90
°±5' of the upper and lower flanges sealing surface to the axes of shell, due to being heavy product (the weight of 120 tons) ,and structure complex, machining study and non touch 3 coordinate measure,lay the foundation of machining of petroleum and chemical combination equipments and nuclear products.
3. The sealing surface of the upper & lower valves of the coal lock hopper, required to deposit horniness alloy metal, the depositing area larger , the depositing metal high hardness, and the most strict requirements in quality. The technology test performed, the first process of automatic plasma arc welding used, and deposit quality meets the requirements of the drawing & the specification.
4.Stress analyzed on the temperature & the Stress distributing for the key pieces of the gasifier by using ANSYS program, and Stress qualified according to the specification of
JB4732-955 《specification for Stress analyzing design of steel pressure vessel》 , the shape distortion, microcosmic organism change of the materials can be observed deeply, and the foundation of exploring new forming technology can he laid.
The Lurgi pressure gasifier for coal gas & synthetical gas
are the recognized, mature & advanced equipments. But, in our country, compared with Lurgi company , a great difference existed on the theory study of the coal pressure gasified & its manufacture technology study at present .So it is necessary to tackle key technical problem for the Lurgi pressure gasifier.
河南义马煤气化工程，采用德国鲁齐加压气化技术，引进鲁齐公司MARK—Ⅳ/4型φ3800mm炉技术软件，由哈尔滨锅炉厂有限责任公司承担制造任务。该产品集大型(重120吨)，双夹套结构等特点为一身，按照德国鲁齐和GB150工程规范进行设计制造和验收，在制造过程中简体冷卷成形结合冷精校压制成型，整体深内腔炉蓖面机加和大直径阀门密封面堆焊工艺等均为新的制造工艺，制造难度大。
本文主要工作有以下几个方面：
1．通过借助于计算机模拟方法，采用ANSYS程序，用其强大的前处理及后处理功能对大直径薄壁简体卷制过程进行模拟，并采取冷卷成形结合冷精校压制成型技术，保证简体环形水冷夹套内外间隙的装配要求。
2．产品整体热处理后要求保证炉篦两传动轴套与炉篦支撑面的垂直度要求90°±1′，炉体上下法兰密封面与炉体中心线的垂直度要求90°±5′。鉴于产品属大型(重120吨)，结构复杂，通过机械加工方法的研究并结合无接触三坐标测量技术，为大型石化设备、核电产品整体机械加工提供了宝贵的经验和依据。
3．气化炉的煤锁上、下阀门密封面要求堆焊硬质合金，堆焊面积大，硬度高，质量要求极其严格。通过工艺试验，在国内首次采用等离子弧自动堆焊的方法，使产品的堆焊及加工质量完全满足图纸和技
哈尔滨工程大学硕士学位论文
术条件的要求。
4.采用ANSYS程序对气化炉关键件的温度场、应力场进行应力分
析，并按JB4732一95《钢制压力容器分析设计标准》进行应力评定，
从而更深入的洞察材料在塑性成形过程中发生的变形、微观组织的变
化，为探索新的塑性成形工艺打下基础。
用于制取城市煤气和化工合成气的鲁齐加压气化炉是国际上公认
的成熟而先进的煤制气设备。但从目前情况看，我国煤炭加压气化的
理论研究，气化炉制造技术研究等方面和鲁齐公司相比仍有较大差距。
因此，开展鲁齐加压气化炉关键件技术攻关工作是十分必要的。
In our country, the main energy depends on the coal fuel, the coal resource is very rich, the geologic reserves of the coal proved up at present has reached to the amount of 7700 hundred millions of tons, the reserves of the coal is the third in the world. But it is lower capacity to converse solid coal into the gas fuel and chemical combination synthetical material, so, it is very important that solve the key technology of Lurgi pressure gasifier for Yima coal gas project in Henan province, to exploit, design and fabricate independently in stead of importation of the whole and spare parts, so as to save a large amount of foreign exchange
Yima coal gas project in Henan province adopt the technology of Lurgi, introduce the technology software of MARK-IV/4 type of Lurgi corporation,
Into our country, the manufacture is being in charge of by Harbin Boiler Works co. , Ltd. this product both are large ( the weight of more than 120 tons) and double sleeve shells, designed .manufactured and accepted ace. to the engineering specifications of lurgi in Germany and GB150, the new technology such as : the cold bending and cold press sizing of the shells, the whole machining of the surface for deep depth lumen and the larger valve sealing surface depositing, are very difficulty.
Primary research items are as follows :
1.By means of computer simulate of ANSYS program, using its powerful treatment function, simulate the process of the bending
of the larger and thin-walled shells, adopt the process of the cold bending and cold press sizing of the shells, and the clearance between the 2 sleeves of the shell circle for fit up ensured
2. After the whole PWHT , the product has to be machined to the requirements of the perpendicularity 90°±1' of the 2 drive axes sleeves to supporting surface, and the perpendicularity 90
°±5' of the upper and lower flanges sealing surface to the axes of shell, due to being heavy product (the weight of 120 tons) ,and structure complex, machining study and non touch 3 coordinate measure,lay the foundation of machining of petroleum and chemical combination equipments and nuclear products.
3. The sealing surface of the upper & lower valves of the coal lock hopper, required to deposit horniness alloy metal, the depositing area larger , the depositing metal high hardness, and the most strict requirements in quality. The technology test performed, the first process of automatic plasma arc welding used, and deposit quality meets the requirements of the drawing & the specification.
4.Stress analyzed on the temperature & the Stress distributing for the key pieces of the gasifier by using ANSYS program, and Stress qualified according to the specification of
JB4732-955 《specification for Stress analyzing design of steel pressure vessel》 , the shape distortion, microcosmic organism change of the materials can be observed deeply, and the foundation of exploring new forming technology can he laid.
The Lurgi pressure gasifier for coal gas & synthetical gas
are the recognized, mature & advanced equipments. But, in our country, compared with Lurgi company , a great difference existed on the theory study of the coal pressure gasified & its manufacture technology study at present .So it is necessary to tackle key technical problem for the Lurgi pressure gasifier.
引文
[1] 孙家广，杨长贵．计算机图形学．北京：清华大学出版社，1995
[2] 邱万川．压力容器制造中的卷板工艺．化工炼油机械．1979，4(1)
[3] R.W. Nichols 《Pressure Vessel Engineering Technology》1971, 308～313P
[4] 《Welding & Metal Fabrication》 1963, No. 6, 242P
[5] ISO Recommendation R831, Rules for Construction of Stationary Boilers, lst Edition, September, 1968
[6] 余同希，章亮炽．塑性弯曲理论及应用．第一版．北京：科学出版社，1987：11-16页
[7] 石振东，刘国庆．实验数据处理与曲线拟合技术．第一版．哈尔滨：哈尔滨船舶工程学院出版社，1991
[8] Interpretive Report of pressure Vesearch Section 3—Fabrication and Environmental Considerations—A.P. Bank, WRC Bulletin No. 158, Juauary, 1971
[9] ASME Boiler and Pressure Vessel Code, Section Ⅲ, Rules for Construction of Nuclear Power Plant Components, 1971
[10] JB马丁著，余同希，赵学仁，王礼立等译．塑性力学——基础及其一般结果。北京理工大学出版社，1990：8—10页
[11] 钦明浩，吴焱明，蒋守仁，徐业宜．轴类零件校直的有限元解法．合肥工业大学学报(自然科学版)．1996，19(2)
[12] 童秉枢，李学志，吴志军，张春风．机械CAD技术基础．北京：清华大学出版社，1996
[13] 莫西宁．弯卷机和矫正机．北京：机械工业出版社，1958
[14] 余俊，周济．机械CAD基本教程．武汉：华中理工大学，1987
[15] 严蔚敏，吴伟民．数据结构．北京：清华大学出版社，1989
[16] 杜平安，王豪才．产品CAD中的参数化建模方法．计算机辅助设计与制造，1996．6
[17] ASME Boiler and Pressure Vessel, Section Ⅷ—1, 1996 edition
[18] ASME Boiler and Pressure Vessel, Section Ⅷ—2, 1996 edition
[19] 徐德安．运用正交试验法优化切削参数．机械工人．2000，9
[20] 李尚健．金属塑性成形过程模拟．第一版．北京．机械工业出版社，1999
[21] 霍同如，徐秉业．板材成形的计算机辅助工程系统．力学进展．1996，26(4)：548—557页
[22] 梁柄文，胡世光编，弹塑性稳定性理论．北京：国防工业出版社，1983
[23] 王选．软件设计方法．北京：清华大学出版社，1992
[24] 崔俊芝，梁俊著。现代有限元软件方法．北京：国防工业出版社，1995
[25] 董湘怀，李尚健，肖景容．三维板料成形过程的有限元模拟．机械工程学报．1995，31(1)：53—59页
[26] BeauoinA Jet al..Incorplastic Crystallographic Texture in Finite Element Simulation of Sheet Forming. Proceedings of NUMISHEET' 96.1996
[27] Makamachi A et al. (Eds.) Proceedings of NUMISHEET 93.1993
[28] 陈如欣，胡忠民．塑性有限元法及其在金属塑性成形中的应用．重庆：重庆大学出版社，1989
[29] 刘相华．刚塑性有限元法及其在轧制中的应用．北京：冶金工
业出版社，1994
[30] 单德彬，吕炎，王真．金属体积成形过程三维刚塑性有限元模拟技术的研究．塑性工程学报．1997，4(3)：98—102页
[31] 肖景容，李尚健主编．塑性成形模拟理论．武汉；华中理工大学出版社，1994
[32] 汪大年主编．金属塑性成形原理(修订本)．北京：机械工业出版社，1986
[33] 朱伯驭．弹塑性力学．第一版．北京：科学出版社，1990
[34] 刘鸿文．材料力学．第二版．北京：高等教育出版社，1982
[35] 蔡春源主编．机电液设计手册(中)．北京：机械工业出版社，1997
[36] 束德林．金属力学性能．第一版．北京：机械工业出版社，1987
[37] 谭伟．校直工艺的现状调查．渝州大学学报．1997，14(14)
[38] 罗仁如．基础标准手册．第一版．南昌：江西科学技术出版社，1987
[39] 林治平编著．上限元在塑性加工工艺中的应用．北京：中国铁道出版社，1991
[2] 邱万川．压力容器制造中的卷板工艺．化工炼油机械．1979，4(1)
[3] R.W. Nichols 《Pressure Vessel Engineering Technology》1971, 308～313P
[4] 《Welding & Metal Fabrication》 1963, No. 6, 242P
[5] ISO Recommendation R831, Rules for Construction of Stationary Boilers, lst Edition, September, 1968
[6] 余同希，章亮炽．塑性弯曲理论及应用．第一版．北京：科学出版社，1987：11-16页
[7] 石振东，刘国庆．实验数据处理与曲线拟合技术．第一版．哈尔滨：哈尔滨船舶工程学院出版社，1991
[8] Interpretive Report of pressure Vesearch Section 3—Fabrication and Environmental Considerations—A.P. Bank, WRC Bulletin No. 158, Juauary, 1971
[9] ASME Boiler and Pressure Vessel Code, Section Ⅲ, Rules for Construction of Nuclear Power Plant Components, 1971
[10] JB马丁著，余同希，赵学仁，王礼立等译．塑性力学——基础及其一般结果。北京理工大学出版社，1990：8—10页
[11] 钦明浩，吴焱明，蒋守仁，徐业宜．轴类零件校直的有限元解法．合肥工业大学学报(自然科学版)．1996，19(2)
[12] 童秉枢，李学志，吴志军，张春风．机械CAD技术基础．北京：清华大学出版社，1996
[13] 莫西宁．弯卷机和矫正机．北京：机械工业出版社，1958
[14] 余俊，周济．机械CAD基本教程．武汉：华中理工大学，1987
[15] 严蔚敏，吴伟民．数据结构．北京：清华大学出版社，1989
[16] 杜平安，王豪才．产品CAD中的参数化建模方法．计算机辅助设计与制造，1996．6
[17] ASME Boiler and Pressure Vessel, Section Ⅷ—1, 1996 edition
[18] ASME Boiler and Pressure Vessel, Section Ⅷ—2, 1996 edition
[19] 徐德安．运用正交试验法优化切削参数．机械工人．2000，9
[20] 李尚健．金属塑性成形过程模拟．第一版．北京．机械工业出版社，1999
[21] 霍同如，徐秉业．板材成形的计算机辅助工程系统．力学进展．1996，26(4)：548—557页
[22] 梁柄文，胡世光编，弹塑性稳定性理论．北京：国防工业出版社，1983
[23] 王选．软件设计方法．北京：清华大学出版社，1992
[24] 崔俊芝，梁俊著。现代有限元软件方法．北京：国防工业出版社，1995
[25] 董湘怀，李尚健，肖景容．三维板料成形过程的有限元模拟．机械工程学报．1995，31(1)：53—59页
[26] BeauoinA Jet al..Incorplastic Crystallographic Texture in Finite Element Simulation of Sheet Forming. Proceedings of NUMISHEET' 96.1996
[27] Makamachi A et al. (Eds.) Proceedings of NUMISHEET 93.1993
[28] 陈如欣，胡忠民．塑性有限元法及其在金属塑性成形中的应用．重庆：重庆大学出版社，1989
[29] 刘相华．刚塑性有限元法及其在轧制中的应用．北京：冶金工
业出版社，1994
[30] 单德彬，吕炎，王真．金属体积成形过程三维刚塑性有限元模拟技术的研究．塑性工程学报．1997，4(3)：98—102页
[31] 肖景容，李尚健主编．塑性成形模拟理论．武汉；华中理工大学出版社，1994
[32] 汪大年主编．金属塑性成形原理(修订本)．北京：机械工业出版社，1986
[33] 朱伯驭．弹塑性力学．第一版．北京：科学出版社，1990
[34] 刘鸿文．材料力学．第二版．北京：高等教育出版社，1982
[35] 蔡春源主编．机电液设计手册(中)．北京：机械工业出版社，1997
[36] 束德林．金属力学性能．第一版．北京：机械工业出版社，1987
[37] 谭伟．校直工艺的现状调查．渝州大学学报．1997，14(14)
[38] 罗仁如．基础标准手册．第一版．南昌：江西科学技术出版社，1987
[39] 林治平编著．上限元在塑性加工工艺中的应用．北京：中国铁道出版社，1991