LF泡沫精炼渣研究及钢包精炼炉数理模拟
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摘要
本文通过LF泡沫精炼渣的实验研究以及对具体精炼炉原型主要冶金过程的数学物理模拟,对某冶金企业的钢包精炼炉进行了有针对性的分析讨论,以期对设备的顺行以及潜力的发挥提供理论指导。
钢包精炼炉的泡沫渣精炼工艺是提高热效率、降低生产成本的有效手段。本研究中对LF精炼渣的泡沫化性能与其成分组成之间的关系以及精炼炉发泡剂的发泡性能等内容进行了实验室研究和分析,并在此基础上对得到的精炼渣的脱硫及脱氧等精炼性能进行了考察。分析表明,CaO-Al2O3-SiO2系精炼渣的脱硫性能和泡沫化性能存在一定的冲突,需要根据实际生产的要求加以综合考虑。实验中得到了适合精炼炉特点的兼顾泡沫化性能和精炼性能的渣成分组成范围,w(CaO) 45～60%,w(Al2O3) 30～40%,w(SiO2) 10～15%,w(MgO) 5～10%,w(CaF2)<5%。
由于钢包精炼炉内的还原气氛,泡沫渣工艺中发泡剂的使用是必要的,课题研究中对常用的发泡剂进行了实验考察。作为发泡剂,碳酸盐与碳化物相比优点明显,碳酸盐与其它物质组成复合发泡剂后发泡作用有所改善,但过分增加复合发泡剂中碳化物的含量作用不大。实验中对精炼炉发泡剂的机理进行了分析,其发泡作用应该从提供气源以及其反应产物改变熔渣的性质等多方面考虑。
钢包精炼炉的熔池搅拌混合行为与普通底吹钢包的主要区别是其加热用的交流电弧和相对较厚的精炼渣。课题实施中对具体尺寸的钢包精炼炉进行了物理模拟,重点考察了加热电弧和泡沫渣对熔池搅拌混合行为的影响并分析了原因,电弧的影响作用主要表现在对熔体循环流动的阻碍,中心底吹时电弧现象对均混时间的影响程度比偏心底吹时大的多,并随底吹气量的增大而增大。精炼炉中泡沫化的顶渣比普通钢包要厚得多,搅拌气体造成的卷渣现象也更明显,易于得到较大的渣钢反应面积。在该实验条件下模型的临界卷渣气量大约为0.3m3/h。对于具体钢包的底吹方式,总的来说偏心喷吹的效果好于中心喷吹,这与传统的研究结果是一致的。在偏心双点喷吹时,近壁点采用小气量的方式比平均分配气量要好得多,但在实验中并未发现这种方式比单点偏心喷吹更有效。
课题研究中针对具体的钢包精炼炉进行了数学模拟,得到其主要生产过程的数学模型(LF温度预报模型、非金属夹杂物去除模型、精炼渣脱硫预报模型)。模型计算结果与生产数据的比较显示,得到的数学模型与实际生产是符合的。
LF的温度模型计算结果说明,生产过程中提供给该精炼炉的电弧加热时间并不很充裕,要在有限的时间内达到要求的钢水温度,需要使用较高的电弧输入功率,并要采用理想的埋弧精炼工艺才能达到生产的要求。处理过程中温降梯度最大的时段是精炼渣料的加入阶段,如果为了其它目的而过分增大精炼渣的用量,在处理时间内达到要求的精炼终点温度将有一定的困难。
Based on the experimental study on LF foaming slag for steel refining and physical mathematical simulation to the main metallurgy processes of ladle furnace, analysis was accomplished in detail to certain ladle furnace in a domestic steel company.
The technology of foaming slag refining is a effective method to improve heating efficiency and reduce the cost. Because of the characteristic of ladle furnace, its slag foaming technology is different form other metallurgy equipments. Relationship between slag foaming capability with ingredients of slag was researched in experiments, so did the refining capability of foaming slag. According to the results, there is some conflict between slag foaming and desulphurizing capabilities. The composition extension of foaming slag for steel refining was obtained: w(CaO)45～60%, w(Al2O3)30～40%, w(SiO2)10～15%, w(MgO)5～10%, w(CaF2)<5%.
Foaming agent was necessary in ladle furnace because its reducing condition. As foaming agent, carbonates were superior to carbide. And better result would be acquired if composite agent was used. Additionally, action mechanism of foaming agent should be understood on aspects both supplying of gas and changing to the physical property of molten slag.
Compared with ordinary bottom stirring ladle, heating arc and much more slag are main differences of ladle furnace. Water model study to the specific dimension LF was completed in research according to similarity principle for physical simulation, emphasis laid on the influence of arc phenomenon and foaming slag. Arc phenomenon is a obstacle to ladle bottom stirring, especially in case of centre blowing. Foaming slag is liable to generate slag drop when bottom stirring, so slag entrapment is much easier to be observed in LF. Under such experimental conditions, the critical gas-blowing rate for slag entrapment is about 0.3m3h-1.As to blowing mode, the manner with less gas rate in wall-nearer nozzle is better when double nozzles blowing, but it was not much effective than off-center blowing with single nozzle.
The mathematical models of main LF metallurgical processes were obtained (temperature prediction model, removal model of non-metal inclusion, LF desulphurization prediction model). The comparison between calculated results and actual data shows that the obtained models were corresponded with the actuality. So the models were reliable for theoretical analysis of certain LF process.
Calculated results of temperature prediction model showed, much higher input power and foaming refining technology should be used to achieve the production requirement. In treat process, slot of the most temperature gradient is the time adding refining slag. If excessive slag were added into ladle, there would be some difficulty to achieve end-point temperature. Therefore, utilization of
钢包精炼炉的泡沫渣精炼工艺是提高热效率、降低生产成本的有效手段。本研究中对LF精炼渣的泡沫化性能与其成分组成之间的关系以及精炼炉发泡剂的发泡性能等内容进行了实验室研究和分析,并在此基础上对得到的精炼渣的脱硫及脱氧等精炼性能进行了考察。分析表明,CaO-Al2O3-SiO2系精炼渣的脱硫性能和泡沫化性能存在一定的冲突,需要根据实际生产的要求加以综合考虑。实验中得到了适合精炼炉特点的兼顾泡沫化性能和精炼性能的渣成分组成范围,w(CaO) 45～60%,w(Al2O3) 30～40%,w(SiO2) 10～15%,w(MgO) 5～10%,w(CaF2)<5%。
由于钢包精炼炉内的还原气氛,泡沫渣工艺中发泡剂的使用是必要的,课题研究中对常用的发泡剂进行了实验考察。作为发泡剂,碳酸盐与碳化物相比优点明显,碳酸盐与其它物质组成复合发泡剂后发泡作用有所改善,但过分增加复合发泡剂中碳化物的含量作用不大。实验中对精炼炉发泡剂的机理进行了分析,其发泡作用应该从提供气源以及其反应产物改变熔渣的性质等多方面考虑。
钢包精炼炉的熔池搅拌混合行为与普通底吹钢包的主要区别是其加热用的交流电弧和相对较厚的精炼渣。课题实施中对具体尺寸的钢包精炼炉进行了物理模拟,重点考察了加热电弧和泡沫渣对熔池搅拌混合行为的影响并分析了原因,电弧的影响作用主要表现在对熔体循环流动的阻碍,中心底吹时电弧现象对均混时间的影响程度比偏心底吹时大的多,并随底吹气量的增大而增大。精炼炉中泡沫化的顶渣比普通钢包要厚得多,搅拌气体造成的卷渣现象也更明显,易于得到较大的渣钢反应面积。在该实验条件下模型的临界卷渣气量大约为0.3m3/h。对于具体钢包的底吹方式,总的来说偏心喷吹的效果好于中心喷吹,这与传统的研究结果是一致的。在偏心双点喷吹时,近壁点采用小气量的方式比平均分配气量要好得多,但在实验中并未发现这种方式比单点偏心喷吹更有效。
课题研究中针对具体的钢包精炼炉进行了数学模拟,得到其主要生产过程的数学模型(LF温度预报模型、非金属夹杂物去除模型、精炼渣脱硫预报模型)。模型计算结果与生产数据的比较显示,得到的数学模型与实际生产是符合的。
LF的温度模型计算结果说明,生产过程中提供给该精炼炉的电弧加热时间并不很充裕,要在有限的时间内达到要求的钢水温度,需要使用较高的电弧输入功率,并要采用理想的埋弧精炼工艺才能达到生产的要求。处理过程中温降梯度最大的时段是精炼渣料的加入阶段,如果为了其它目的而过分增大精炼渣的用量,在处理时间内达到要求的精炼终点温度将有一定的困难。
Based on the experimental study on LF foaming slag for steel refining and physical mathematical simulation to the main metallurgy processes of ladle furnace, analysis was accomplished in detail to certain ladle furnace in a domestic steel company.
The technology of foaming slag refining is a effective method to improve heating efficiency and reduce the cost. Because of the characteristic of ladle furnace, its slag foaming technology is different form other metallurgy equipments. Relationship between slag foaming capability with ingredients of slag was researched in experiments, so did the refining capability of foaming slag. According to the results, there is some conflict between slag foaming and desulphurizing capabilities. The composition extension of foaming slag for steel refining was obtained: w(CaO)45～60%, w(Al2O3)30～40%, w(SiO2)10～15%, w(MgO)5～10%, w(CaF2)<5%.
Foaming agent was necessary in ladle furnace because its reducing condition. As foaming agent, carbonates were superior to carbide. And better result would be acquired if composite agent was used. Additionally, action mechanism of foaming agent should be understood on aspects both supplying of gas and changing to the physical property of molten slag.
Compared with ordinary bottom stirring ladle, heating arc and much more slag are main differences of ladle furnace. Water model study to the specific dimension LF was completed in research according to similarity principle for physical simulation, emphasis laid on the influence of arc phenomenon and foaming slag. Arc phenomenon is a obstacle to ladle bottom stirring, especially in case of centre blowing. Foaming slag is liable to generate slag drop when bottom stirring, so slag entrapment is much easier to be observed in LF. Under such experimental conditions, the critical gas-blowing rate for slag entrapment is about 0.3m3h-1.As to blowing mode, the manner with less gas rate in wall-nearer nozzle is better when double nozzles blowing, but it was not much effective than off-center blowing with single nozzle.
The mathematical models of main LF metallurgical processes were obtained (temperature prediction model, removal model of non-metal inclusion, LF desulphurization prediction model). The comparison between calculated results and actual data shows that the obtained models were corresponded with the actuality. So the models were reliable for theoretical analysis of certain LF process.
Calculated results of temperature prediction model showed, much higher input power and foaming refining technology should be used to achieve the production requirement. In treat process, slot of the most temperature gradient is the time adding refining slag. If excessive slag were added into ladle, there would be some difficulty to achieve end-point temperature. Therefore, utilization of
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