HIsmelt熔融還原技術(shù)剖析課件

1、HIsmelt熔融還原技術(shù)Smelt Reduction Technology - HIsmelt 匯報(bào)人：賈利軍Presentor: Jia Lijun匯報(bào)內(nèi)容Content1 HIsmelt技術(shù)簡介HIsmelt introduction2 HIsmelt工藝技術(shù)優(yōu)勢(shì)Technical advantage of HIsmelt3 生產(chǎn)情況介紹Plant operation experience4 工藝流程的優(yōu)化Optimization of process5 結(jié)論 Conclusion1.1 引言 Background HIsmelt煉鐵工藝是已實(shí)現(xiàn)工業(yè)化生產(chǎn)的熔融還原煉鐵技術(shù)之一，屬于當(dāng)

2、今冶金領(lǐng)域前沿技術(shù)，經(jīng)過三十多年的研究開發(fā)和生產(chǎn)實(shí)踐，工藝技術(shù)逐漸成熟。 As one of the commercialized smelt reduction iron-making technology, HIsmelt has evolved to a mature solution after thirty years of research and development. HIsmelt煉鐵工藝技術(shù)是利用非焦煤及鐵礦粉采取噴射方式生產(chǎn)液態(tài)鐵，是解決我國焦煤資源貧乏和環(huán)保問題的先進(jìn)煉鐵技術(shù)。 HIsmelt uses non-coking coal and iron ore fin

3、es, which offers a solution to the coking coal scarcity and environmental problem in China. HIsmelt煉鐵工藝在澳大利亞奎那那工廠從2005年至2008年已有3年的生產(chǎn)實(shí)踐。由于HIsmelt技術(shù)上的優(yōu)勢(shì)，吸引了全球鋼鐵行業(yè)的目光，受世界金融危機(jī)影響，HIsmelt奎那那示范廠2008年年底停產(chǎn)，且不再復(fù)產(chǎn)。HIsmelt Kwinana plant in Australia had run fours years from 2005 to 2008 and it successfully demo

4、nstrated the advantage of this technology . It was forced to shut down due to global economic crisis. 國內(nèi)某公司自2004年以來一直致力于新煉鐵工藝、技術(shù)、裝備的研究，在2012年決定利用部分HIsmelt奎那那工廠設(shè)備，并通過進(jìn)一步優(yōu)化工藝流程，建設(shè)新的HIsmelt熔融還原煉鐵生產(chǎn)廠。 A Chinese company , who has been focusing on the research of innovative iron-making technology, process

5、 and equipment, decided to build a HIsmelt plant in China. This plant uses some of the Kwinana equipment, but also makes some modification by optimizing the existing process.1.2 HIsmelt工藝描述 HIsmelt Process Description煤氣室煙道上部燃燒區(qū)渣口水冷板噴泉及渣層殘鐵口熱風(fēng)噴槍水冷板天然氣噴槍（或煤槍）固體噴槍帶內(nèi)襯前置爐帶內(nèi)襯的前置爐通道帶內(nèi)襯的爐底鐵水熔池渣區(qū)冷卻器 煤中碳素溶于鐵水

6、, 礦石溶于渣中 carbon in the coal dissolve in the bath, 含鐵原料被還原成液態(tài)鐵水； Iron-bearing material is reduced to liquid iron 脈石和灰份被從礦石和煤中分離形成爐渣； gang and ash from ore and coal form slag工藝反應(yīng)產(chǎn)生的煤氣與熱風(fēng)進(jìn)行二次燃燒產(chǎn)生熱能； process gas combust with hot blast to produce energy渣與鐵水液體把能量帶入熔池以維持反應(yīng)。 metal and slag droplet bring par

7、t of the energy back to the bath to sustain the reaction SRV 熔融還原爐中發(fā)生的反應(yīng)為：Reaction in the SRV: 1.3 HIsmelt工藝流程 HIsmelt process flowIron oredolomitedryerPre-reduction kilnCycloneBag houseDust injectionCoal millCoal limeGranulated slagCoal millOre injectioncoal injectionlimel injectionIron recoverySla

8、g granulationLadle carSteel millPig casterKnock out vesselConvective coolerWaste gasFGDCyclone de-dustingStovesboilerFGDSuck fanOxygen plantElectrical blowerscrubberHot gas generator for the coal millGeneratorHIsmelt工藝技術(shù)優(yōu)勢(shì) Advantages of HIsmelt 投資成本低：與傳統(tǒng)的煉鐵技術(shù)相比，Lower capital cost compared with tradi

9、tional blast furnace due to: HIsmelt不需要焦?fàn)t和燒結(jié)廠或球團(tuán)廠，因此建設(shè)成本降低； HIsmelt eliminates coke oven, sinter plant and pellet plant HIsmelt 工藝中的許多設(shè)備和設(shè)施，如熱風(fēng)爐、噴煤系統(tǒng)、發(fā)電等都是高爐煉鐵工藝常用的設(shè)施，因此工廠建設(shè)相對(duì)比較簡單， HIsmelt shares many common equipment used in blast furnace, such as hot blast stoves, generator etc. HIsmelt技術(shù)所使用的原料比較靈

10、活，因此無需大型原料混勻場，極大降低了HIsmelt工廠的占地面積。 HIsmelt is flexible in raw materials selection and no blending facility is needed.2 HIsmelt工藝技術(shù)優(yōu)勢(shì) Advantages of HIsmelt操作成本低：Lower operational cost直接使用礦粉和煤粉作為原燃料煉鐵，不用焦炭、球團(tuán)和燒結(jié)。HIsmelt uses iron ore fines and coal directly; no coke, sinter or pellet will be needed.更大

11、的原料靈活性Great flexibility in raw material：HIsmelt技術(shù)可直接噴吹傳統(tǒng)高爐燒結(jié)廠不宜使用的低品位鐵礦粉。 HIsmelt can use low grade iron ore fines which otherwise can not be used by the blast furnace sinter plant.鐵水質(zhì)量穩(wěn)定，磷含量很低，基本不含硅，因此可進(jìn)行少渣煉鋼，降低煉鋼成本。 Stable hot metal quality, low P content, almost no silicon; so less slag is needed

12、 in the steel mill and thus reducing steel mill cost鐵水成分 ChemistryHIsmeltBFC4.00.15%4.5%Si0.01%0.50.3%Mn0.02%0.40.2%P0.020.01%0.090.02%S0.10.05%0.040.02%溫度 Temperature /1430-145014501500Himselt工藝與高爐生產(chǎn)鐵水成分對(duì)比HIsmelt Hot Metal vs. BF Hot Metal鐵水質(zhì)量好 Superior hot metal quality降低環(huán)境影響，通過變革性的工藝創(chuàng)新，取消焦?fàn)t、燒結(jié)，HI

13、smelt極大的降低了SO2和NOx、基本遏制二惡英、焦油和酚的排放。Almost no emission of dioxins, phenols or tars due to the revolutionary process and elimination of coking oven and sintering process. 更綠色環(huán)保的煉鐵技術(shù) Less Environmental Impact3 生產(chǎn)情況介紹 Production Experience3.1 奎納納情況概覽 Kwinana summary 從2005年11月開始了為期3年的達(dá)產(chǎn)運(yùn)行：2006年底實(shí)現(xiàn)50%，200

14、7年實(shí)現(xiàn)80%，2008年實(shí)現(xiàn)85%three year ramp-up period beginning in November 2005: 50% by 2006, 80% by 2007, 85% by 2008期間主要問題大多由外圍設(shè)備引起，在這些問題得以解決后生產(chǎn)率逐步上升。Major problems caused by ancillary equipment and production rate continued to rise as bottlenecks removed 2008年12月，由于經(jīng)濟(jì)危機(jī)影響，生鐵市場低迷，工廠因此關(guān)閉。Plant put under car

15、e and maintenance and then closed due to sluggish market demand caused by global economic crisis from end of 20083.2 HIsmelt的生產(chǎn)情況 Production Data of HIsmelt由上圖中可知，2008年12月日產(chǎn)最大達(dá)到1834t。Daily production reaches a maximum of 1834t in December of 2008.3.2 HIsmelt的煤耗 Coal Rate of HIsmelt4 工藝流程的優(yōu)化 Process

16、Modification 基于奎納納工廠的經(jīng)驗(yàn)，山東省冶金設(shè)計(jì)院、力拓公司和業(yè)主決定對(duì)部分工藝流程和設(shè)備進(jìn)行改進(jìn)，以降低成本和浪費(fèi)。 Based on the Kwinana experience, SDM, Rio Tinto and the end user decided to modify some of the process and equipment to reduce cost and waste.4.1 新礦粉預(yù)熱系統(tǒng) Modification of the Iron Ore Preheating 為降低工程投資，礦粉預(yù)熱采用了技術(shù)可靠的雙回轉(zhuǎn)窯工藝 A double kil

17、n system is used which help reduce capital cost特點(diǎn) Advantage:改進(jìn)后的工藝既能實(shí)現(xiàn)礦粉的加熱、預(yù)還原的目的，且技術(shù)成熟、設(shè)備運(yùn)行穩(wěn)定、作業(yè)率高。The kiln system is capable of preheating and pre-reducing the iron ore. It is a mature, stable and efficient solution. 同時(shí)，改進(jìn)后的預(yù)熱還原系統(tǒng)既可以采用煤粉也可以采用SRV煤氣作為燃料，設(shè)計(jì)獨(dú)立的煤粉供應(yīng)系統(tǒng)，有助于提高HIsmelt工藝整體的作業(yè)率。At the same

18、time, this system can run on both coal and SRV offgas, which help increase the utilization rate.4.2 礦粉噴吹系統(tǒng)Modification of Iron Ore Injection System考慮新的礦粉預(yù)熱系統(tǒng)的收塵系統(tǒng)收集的粉塵中含有大量的含鐵氧化物及少量未然碳粉，為提高資源的利用率，新的HIsmelt工藝設(shè)計(jì)中增加一套細(xì)粉噴吹系統(tǒng)，其主要作用：將工廠產(chǎn)生的含鐵、含碳粉塵噴入SRV內(nèi)，完成含鐵廢棄物的合理利用，提高鐵水產(chǎn)量，同時(shí)噴入SRV內(nèi)的含碳粉塵可以為鐵礦石的融化還原提供熱源和還原劑，

19、有利于降低噸鐵工序能耗。The new HIsmelt plant added a dust injection system to recover the iron bearing dust and carbon bearing dust, which will help reduce waste and improve raw material utilization rate.4.3 鐵、渣系統(tǒng)的改進(jìn)Modification of the slag and metal handling system殘鐵回收：當(dāng)SRV事故狀態(tài)時(shí)，一次殘鐵量約300t鐵水需從SRV爐內(nèi)排出，因此新設(shè)計(jì)中通過

20、增加殘鐵回收跨，殘鐵回收跨內(nèi)設(shè)置有殘鐵受鐵設(shè)施，設(shè)置有通向鑄鐵廠房的80t鐵水罐電動(dòng)平車，使SRV爐殘鐵能至鑄鐵機(jī)鑄鐵，有利于殘鐵的再利用。End tapped metal recovery: about 300t hot metal will be discharged to the pit if there is an emergency. A end tap metal recovery facility is designed and 80t ladle cars are used to transfer the end tap metal to the pig caster. 熔渣處

21、理及渣中鐵的回收技術(shù) Slag handling and iron recovery 該流程能有效回收HIsmelt熔融還原技術(shù)生產(chǎn)熔渣中攜帶的鐵，能提高HIsmelt工藝鐵水收得率，降低HIsmelt工藝的工序成本。This process helps recover the iron trapped in the slag during slag tapping, thus reducing the production cost.圖中：1熔渣溝；2渣罐；2渣罐；3專用起重機(jī)；4渣罐運(yùn)輸車；5渣罐傾翻裝置；6熔渣溝；7熔渣處理設(shè)施；8鐵水罐運(yùn)輸車；9鐵水罐； HIsmelt熔融還原工藝熔渣

22、中鐵的回收流程如下圖The following is the process of recovering the iron trapped in the slag:4.4 煤氣余熱回收系統(tǒng) Modification of offgas waste heat recovery system去除煤氣中攜帶的較大顆粒煙塵，防止后續(xù)煤氣管道積灰堵塞。Remove the large particles in the dust and avoid blocking the offgas pipes降低氣體的含塵量，提高氣體的對(duì)流換熱系數(shù)。Reduce dust content and increase

23、heat exchange efficiency回收余熱，產(chǎn)生蒸汽用于發(fā)電；Waste heat is recovered to generate electricity當(dāng)余熱鍋爐故障時(shí)，高溫氣體可以直接進(jìn)入濕法洗滌系統(tǒng)，不影響SRV正常生產(chǎn)。When the boils stops, hot offgas will goes to scrubber.4.5 鍋爐及動(dòng)力系統(tǒng) Modification of the Boiler and Power system原鼓風(fēng)發(fā)電機(jī)組利舊 Old TAB will be re-used新增一臺(tái)中溫中壓抽汽凝汽式汽輪發(fā)電機(jī)組。 Add a new medi

24、um pressure turbine generator增設(shè)一臺(tái)電動(dòng)鼓風(fēng)機(jī)備用。 Add a back up electrical blower制氧驅(qū)動(dòng)方式改為電動(dòng)。 Oxygen plant is driven by electricity燃?xì)忮仩t采用自然循環(huán)，在爐膛下部采用強(qiáng)化傳熱傳質(zhì)的SRV煤氣鍋爐爐內(nèi)蓄熱穩(wěn)燃裝置，保證了難以燃燒的SRV煤氣的充分燃燒。 The boiler uses natural circulation. There is a thermal storage device in the lower chamber of the boiler which help stabilize combustion.特點(diǎn)：各系統(tǒng)相互獨(dú)立，互不影響。 Characteristic: the function of each equipment is not solely reliant on the upstream equipment, which provides redundancy.5 總 結(jié) ConclusionHlsmelt熔融還原煉鐵技術(shù)是實(shí)現(xiàn)工業(yè)化生產(chǎn)的非高爐煉鐵技術(shù)之一，其工藝可看作是冶金行業(yè)中各種成熟技術(shù)的新組合，和當(dāng)前的耐火材料技術(shù)、噴吹技術(shù)、煙氣余熱回收和凈化