布料溜槽长寿命设计及其剩余寿命研究
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摘要
布料溜槽是高炉布料系统中最核心的部分之一,所有进入高炉的炼铁原材料都要通过布料溜槽,布料溜槽极易失效。目前,提高布料溜槽的使用寿命,成为各大、小钢铁企业所亟待解决的问题。溜槽鹅头是布料溜槽的重要组成部分之一,鹅头是否可以重复利用目前是通过经验判断,如果判断失误,将难免造成事故,而太保守又会造成较大的浪费,不能充分发挥其经济效益。因此,提高溜槽使用寿命、采用科学的方法评估溜槽寿命对降低生产损失、降低高炉休风率以及充分发挥无料钟炉顶高炉的优势具有十分重要的现实意义。
布料溜槽的长度和b值(溜槽回转中心到溜槽底部的垂直距离)对溜槽的寿命有着重要影响,论文在对溜槽布料规律进行研究基础上,考虑其布料要求与使用寿命等因素,推导了设计溜槽时的长度和b值计算公式。
论文针对目前高炉布料溜槽使用寿命达不到用户要求的实际情况,对溜槽常见失效形式进行失效分析,研究了溜槽衬板、承力外壳、保护外壳和溜槽鹅头等部件的失效原因,并根据布料溜槽失效原因对溜槽整体结构、衬板和保护外壳进行了改进设计,研制出了长寿命布料溜槽。
针对目前主要靠经验判断布料溜槽鹅头是否可重复利用的缺陷,提出了用断裂力学相关理论来预测鹅头疲劳寿命的方法。首先,利用有限元分析软件ANSYS分析了布料溜槽的受力情况,再根据有限元分析结果结合断裂力学相关理论,对鹅头进行了疲劳裂纹扩展速度预测和剩余寿命预测。并通过逆运算得到了指定寿命下的容许缺陷长度,为判断溜槽鹅头是否可重复利用提供依据。
Distributor chute is the core of a blast furnace system, almost all of the iron-making materials need pass through it, so it is easy to lose efficacy. At present, how to prolong the service time of the distributor chute is the critical problem to be solved for iron and steel enterprises. The chute head is an important component of the distributor chute. Nowadays, whether the chute head can be reused is judged by experienced workers. A error judgment will inevitably cause serious accidents, otherwise, waste and low economic benefit are always happened. In a word, research on lengthening and scientific evaluating the life of a distributor chute has the important significance to low production loss, reduce the downtime percentage and make full use of the advantage of bell-less top blast furnace.
The length of distributor chute and the value b (the vertical distance from chute centre to the bottom of chute) have an important influence on the service life. Based on the research of burden distribution and take the factors such as distribution requirements and the service life into consideration, the formula of the length of chute and value b is presented in this paper.
In view of the actual condition that the service life of the distributor chute can't satisfy the consumers, failure analysis of the chute are firstly finished; then the failure reasons for the parts such as liner, maternal, protective shell, chute head and so on are secondly studied; based on the failure reasons, modification design of the global structure of chute, liner and protective shell is thirdly made; and a long life distributor chute is finally developed in this dissertation.
To solve the defect that whether the chute head can be reused is judged by experienced workers, a method of fatigue life prediction on the chute head using the relative theory of fracture mechanics is presented in this paper. Firstly, the force condition of the distributor chute is analyzed by ANSYS; then the fatigue crack growth rate and the residual life of the chute head are forecasted on the basis of FEA results and relative theory of fracture mechanics; finally the acceptable defect length in assigned life are obtained by inverse operation. In summation, the above research works provide a basis for determing whether the chute head can be reused or not.
布料溜槽的长度和b值(溜槽回转中心到溜槽底部的垂直距离)对溜槽的寿命有着重要影响,论文在对溜槽布料规律进行研究基础上,考虑其布料要求与使用寿命等因素,推导了设计溜槽时的长度和b值计算公式。
论文针对目前高炉布料溜槽使用寿命达不到用户要求的实际情况,对溜槽常见失效形式进行失效分析,研究了溜槽衬板、承力外壳、保护外壳和溜槽鹅头等部件的失效原因,并根据布料溜槽失效原因对溜槽整体结构、衬板和保护外壳进行了改进设计,研制出了长寿命布料溜槽。
针对目前主要靠经验判断布料溜槽鹅头是否可重复利用的缺陷,提出了用断裂力学相关理论来预测鹅头疲劳寿命的方法。首先,利用有限元分析软件ANSYS分析了布料溜槽的受力情况,再根据有限元分析结果结合断裂力学相关理论,对鹅头进行了疲劳裂纹扩展速度预测和剩余寿命预测。并通过逆运算得到了指定寿命下的容许缺陷长度,为判断溜槽鹅头是否可重复利用提供依据。
Distributor chute is the core of a blast furnace system, almost all of the iron-making materials need pass through it, so it is easy to lose efficacy. At present, how to prolong the service time of the distributor chute is the critical problem to be solved for iron and steel enterprises. The chute head is an important component of the distributor chute. Nowadays, whether the chute head can be reused is judged by experienced workers. A error judgment will inevitably cause serious accidents, otherwise, waste and low economic benefit are always happened. In a word, research on lengthening and scientific evaluating the life of a distributor chute has the important significance to low production loss, reduce the downtime percentage and make full use of the advantage of bell-less top blast furnace.
The length of distributor chute and the value b (the vertical distance from chute centre to the bottom of chute) have an important influence on the service life. Based on the research of burden distribution and take the factors such as distribution requirements and the service life into consideration, the formula of the length of chute and value b is presented in this paper.
In view of the actual condition that the service life of the distributor chute can't satisfy the consumers, failure analysis of the chute are firstly finished; then the failure reasons for the parts such as liner, maternal, protective shell, chute head and so on are secondly studied; based on the failure reasons, modification design of the global structure of chute, liner and protective shell is thirdly made; and a long life distributor chute is finally developed in this dissertation.
To solve the defect that whether the chute head can be reused is judged by experienced workers, a method of fatigue life prediction on the chute head using the relative theory of fracture mechanics is presented in this paper. Firstly, the force condition of the distributor chute is analyzed by ANSYS; then the fatigue crack growth rate and the residual life of the chute head are forecasted on the basis of FEA results and relative theory of fracture mechanics; finally the acceptable defect length in assigned life are obtained by inverse operation. In summation, the above research works provide a basis for determing whether the chute head can be reused or not.
引文
[1] Hiroshi KAGECHIKA. Production and technology of iron and steel in Japan during 2006[J]. ISIJ international, 2007, 47(6):773-794.
[2] The technical society, the iron and steel institute of Japan. Production and Technology of Iron and steel in Japan during 2007[J]. ISIJ international, 2008, 48(6):707-728.
[3]沙永志.我国中小高炉的未来和挑战[J].炼铁交流, 2008, 01(01):49-52.
[4]王维兴.中国高炉炼铁技术发展评述[J].钢铁, 2007, 42(3):1-4.
[5]杨天钧.中国高炉炼铁技术的进展[J].中国冶金, 2004, (6):1-7.
[6]张寿荣. 21世纪前期钢铁工业的发展趋势及我国面临的挑战[J].中国钢铁年会论文集, 2007.
[7] G.Heynert. Development in Ironmaking Practice[J]. London, 1973:109-130.
[8]陈达士.现代高炉炼铁综合计算与工艺参数计算实用手册[M].北京:当代中国音像出版社, 2005
[9]严允进.炼铁机械[M].北京:冶金工业山版社, 1995.
[10]任廷志,盛义平.高炉溜槽布料器的布料规律[J].钢铁, 1995(5):5-8.
[11]戴敏孝,邬妙玲.高炉无料钟炉顶溜槽的修复[J].机械工程材料, 1996(6):50-51.
[12]华成.无料钟炉顶布料溜槽的综合分析[J].冶金设备, 2010(6):67-70.
[13]张建民.无料钟炉顶布料溜槽使用寿命研究[J].华东冶金学院学, 1999(l):84-86.
[14]王志宁,宋国法等.低噪音抗冲击耐磨溜槽的研制[J].哈尔滨理工大学学报, 1998, 3(6):30-32.
[15]郭雄文.长寿命高炉布料溜槽设计及其CAD系统开发[D].长沙:中南大学, 2008.
[16] J.E.Reher. The origin of the blast furnace[M]. Ironmakong&Steekmakong Engineer, 1999:23-25.
[17] Joan Cantrell. Developments in the North American Iron and Steel Industry[J]. Iorn&Steel Technology, 2004, Vol.1, No.3:23.
[18] AngeleA.M anenti From Blast Funrace to EAF. The technology for the conversion from Integrated producer to high-quality Electric minimill. Iron&Steel Technology. 2004, Vol.7, No.:122-128
[19] K.Yoshimasa, T.Jimbo, T.Sakai. Development of simulation model for burden distribution at blast furnace top, Trans. ISIJ.23 (1045) 1983.
[20] Y. Okumo, Development of a mathematical model for burden distribution in a blast furnace, in: 44th Iron Making Conference, Detroit, Proc. 1985, pp. 543-552.
[21] V.R. Radhakrishnan,K. Maruthy Ram. Mathematical model for predictive control of the bell-less top charging system of a blast furnace. Journal of Proccss Control,2001, Vol.11,No.:565-586.
[22]刘云彩.高炉布料规律Ⅱ-溜槽布料器的布料规律[J].钢铁, 1982, 17(6):20-23.
[23]于成忠,金昕.无钟高炉布料器布料规律研究[J].冶金设备, 2007(4):15-18.
[24]任廷志,盛义平.无钟布料溜槽结构尺寸的研究[J].重型机械, 1995(3):13-17.
[25]王平.无料钟料流运动轨迹数学模拟[J].钢铁研究学报, 2006, 18(5):5-9.
[26]袁嫔,孙一峰,肖涵.高炉气密箱布料溜槽的有限元与工况分析[J].冶金设备, 2010(4):31-33.
[27]李永清,刘竹林.湘钢2号高炉布料溜槽磨穿分析及处理措施[J].炼铁, 2003, 22(3):31-32.
[28]刘元意,王子金.布料溜槽磨断事故的判断和处理[J].炼铁, 2001, 20(5):41-42.
[29]王强.新钢1号高炉布料溜槽坠落事故分析[J].炼铁, 2005, 24(5):47-49.
[30]曾静,熊焰,张友登.高炉布料溜槽边部开裂分析[J].物理测试, 2008, 26(4):54-56.
[31] Fernández I,Belzunce F J. Wear and oxidation behaviour of highchromium white cast irons[J]. Mater Charact, 2007:1-6.
[32]张建明.无料钟炉顶布料溜槽使用寿命研究[J],华东冶金学院学报, 1999, 16(1):84-86.
[33]高晓松,高晓柏.长寿命布料溜槽的研制[J].中国设备工程, 2005(4):31-32.
[34]王利传,周佳梅,位连增等.高炉受料斗、布料器衬板堆焊镶块技术[J].山东冶金, 2003, 25(4):65-66.
[35]杨勇勤,陈启超.消失模铸造高炉溜槽衬板[J].特种铸造及有色合金, 2007, 27(12):952-954.
[36]孙建勇.硬质合金耐磨衬板在炼铁高炉中的应用[J].冶金设备, 2010(3):77-80.
[37] A.W.Roberts. Chute Performane eand design for rapid flow conditions. Chemieal Engineering and Teehnology, 26(2003)163-170
[38] A.W.Roberts, S.Wiche. Prediction of lining wear life of bins and chutes in bulk solids hand- ling operations. Tribology International 26(1993)345-351.
[39]聂松辉,刘宏昭,邱爱红等.高炉布料溜槽抗磨损技术研究[J].钢铁, 2007, 42(7):10-14.
[40]江晓瑜. 450m3高炉无料钟布料器和有限元分析[D].河北:燕山大学, 2007.
[41] A.I.Voloshin, A.A.Ivanov, N.A.Mikhailov, N.N.Rudenko. Improving the design of blast furnace charging apparatuses [J]. Metallurgist, 2004, 48(7-8):317-319.
[42]HENRIK SAXEN, JANHINNELA. Model for burden distribution tracking in the blast furnace[J]. Mineral Processing&Extractive Metall, 2004(25):1-27
[43]刘起.高炉溜槽:中国, CN2795222Y[P]. 2007-07-12.
[44]陈传尧.疲劳与断裂[M].武汉:华中科技大学出版社, 2001.
[45] J.A.Banantine, J.J.Corner and J.L Handrock. Fundamentals of Metal Fatigue Analysis [M]. Englewood Cliffs, N, J:Prentice-Hall, Inc, 1990.
[46] H.O.Fuchs and R.I.Stephens. Metal Fatigue in Engineering [M]. JOHN WILEY&SONS, 1980.
[47]赵少汴.抗疲劳设计[M].北京:机械工业出版社, 1994.
[48]叶绍松.烧结混料机的有限元分析与剩余寿命研究[D].武汉:武汉理工大学, 2006.
[49]权秀敏.基于有限元和断裂力学的桥式起重机结构疲劳寿命研究[D].武汉:武汉科技大学, 2006.
[50] http://www.hnzdgm.com.
[51]李美栓.金属的高温腐蚀[M].北京:冶金工业出版社, 2001.
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[56]周益春.材料固体力学(上册)[M].北京:科学出版社, 2005.
[2] The technical society, the iron and steel institute of Japan. Production and Technology of Iron and steel in Japan during 2007[J]. ISIJ international, 2008, 48(6):707-728.
[3]沙永志.我国中小高炉的未来和挑战[J].炼铁交流, 2008, 01(01):49-52.
[4]王维兴.中国高炉炼铁技术发展评述[J].钢铁, 2007, 42(3):1-4.
[5]杨天钧.中国高炉炼铁技术的进展[J].中国冶金, 2004, (6):1-7.
[6]张寿荣. 21世纪前期钢铁工业的发展趋势及我国面临的挑战[J].中国钢铁年会论文集, 2007.
[7] G.Heynert. Development in Ironmaking Practice[J]. London, 1973:109-130.
[8]陈达士.现代高炉炼铁综合计算与工艺参数计算实用手册[M].北京:当代中国音像出版社, 2005
[9]严允进.炼铁机械[M].北京:冶金工业山版社, 1995.
[10]任廷志,盛义平.高炉溜槽布料器的布料规律[J].钢铁, 1995(5):5-8.
[11]戴敏孝,邬妙玲.高炉无料钟炉顶溜槽的修复[J].机械工程材料, 1996(6):50-51.
[12]华成.无料钟炉顶布料溜槽的综合分析[J].冶金设备, 2010(6):67-70.
[13]张建民.无料钟炉顶布料溜槽使用寿命研究[J].华东冶金学院学, 1999(l):84-86.
[14]王志宁,宋国法等.低噪音抗冲击耐磨溜槽的研制[J].哈尔滨理工大学学报, 1998, 3(6):30-32.
[15]郭雄文.长寿命高炉布料溜槽设计及其CAD系统开发[D].长沙:中南大学, 2008.
[16] J.E.Reher. The origin of the blast furnace[M]. Ironmakong&Steekmakong Engineer, 1999:23-25.
[17] Joan Cantrell. Developments in the North American Iron and Steel Industry[J]. Iorn&Steel Technology, 2004, Vol.1, No.3:23.
[18] AngeleA.M anenti From Blast Funrace to EAF. The technology for the conversion from Integrated producer to high-quality Electric minimill. Iron&Steel Technology. 2004, Vol.7, No.:122-128
[19] K.Yoshimasa, T.Jimbo, T.Sakai. Development of simulation model for burden distribution at blast furnace top, Trans. ISIJ.23 (1045) 1983.
[20] Y. Okumo, Development of a mathematical model for burden distribution in a blast furnace, in: 44th Iron Making Conference, Detroit, Proc. 1985, pp. 543-552.
[21] V.R. Radhakrishnan,K. Maruthy Ram. Mathematical model for predictive control of the bell-less top charging system of a blast furnace. Journal of Proccss Control,2001, Vol.11,No.:565-586.
[22]刘云彩.高炉布料规律Ⅱ-溜槽布料器的布料规律[J].钢铁, 1982, 17(6):20-23.
[23]于成忠,金昕.无钟高炉布料器布料规律研究[J].冶金设备, 2007(4):15-18.
[24]任廷志,盛义平.无钟布料溜槽结构尺寸的研究[J].重型机械, 1995(3):13-17.
[25]王平.无料钟料流运动轨迹数学模拟[J].钢铁研究学报, 2006, 18(5):5-9.
[26]袁嫔,孙一峰,肖涵.高炉气密箱布料溜槽的有限元与工况分析[J].冶金设备, 2010(4):31-33.
[27]李永清,刘竹林.湘钢2号高炉布料溜槽磨穿分析及处理措施[J].炼铁, 2003, 22(3):31-32.
[28]刘元意,王子金.布料溜槽磨断事故的判断和处理[J].炼铁, 2001, 20(5):41-42.
[29]王强.新钢1号高炉布料溜槽坠落事故分析[J].炼铁, 2005, 24(5):47-49.
[30]曾静,熊焰,张友登.高炉布料溜槽边部开裂分析[J].物理测试, 2008, 26(4):54-56.
[31] Fernández I,Belzunce F J. Wear and oxidation behaviour of highchromium white cast irons[J]. Mater Charact, 2007:1-6.
[32]张建明.无料钟炉顶布料溜槽使用寿命研究[J],华东冶金学院学报, 1999, 16(1):84-86.
[33]高晓松,高晓柏.长寿命布料溜槽的研制[J].中国设备工程, 2005(4):31-32.
[34]王利传,周佳梅,位连增等.高炉受料斗、布料器衬板堆焊镶块技术[J].山东冶金, 2003, 25(4):65-66.
[35]杨勇勤,陈启超.消失模铸造高炉溜槽衬板[J].特种铸造及有色合金, 2007, 27(12):952-954.
[36]孙建勇.硬质合金耐磨衬板在炼铁高炉中的应用[J].冶金设备, 2010(3):77-80.
[37] A.W.Roberts. Chute Performane eand design for rapid flow conditions. Chemieal Engineering and Teehnology, 26(2003)163-170
[38] A.W.Roberts, S.Wiche. Prediction of lining wear life of bins and chutes in bulk solids hand- ling operations. Tribology International 26(1993)345-351.
[39]聂松辉,刘宏昭,邱爱红等.高炉布料溜槽抗磨损技术研究[J].钢铁, 2007, 42(7):10-14.
[40]江晓瑜. 450m3高炉无料钟布料器和有限元分析[D].河北:燕山大学, 2007.
[41] A.I.Voloshin, A.A.Ivanov, N.A.Mikhailov, N.N.Rudenko. Improving the design of blast furnace charging apparatuses [J]. Metallurgist, 2004, 48(7-8):317-319.
[42]HENRIK SAXEN, JANHINNELA. Model for burden distribution tracking in the blast furnace[J]. Mineral Processing&Extractive Metall, 2004(25):1-27
[43]刘起.高炉溜槽:中国, CN2795222Y[P]. 2007-07-12.
[44]陈传尧.疲劳与断裂[M].武汉:华中科技大学出版社, 2001.
[45] J.A.Banantine, J.J.Corner and J.L Handrock. Fundamentals of Metal Fatigue Analysis [M]. Englewood Cliffs, N, J:Prentice-Hall, Inc, 1990.
[46] H.O.Fuchs and R.I.Stephens. Metal Fatigue in Engineering [M]. JOHN WILEY&SONS, 1980.
[47]赵少汴.抗疲劳设计[M].北京:机械工业出版社, 1994.
[48]叶绍松.烧结混料机的有限元分析与剩余寿命研究[D].武汉:武汉理工大学, 2006.
[49]权秀敏.基于有限元和断裂力学的桥式起重机结构疲劳寿命研究[D].武汉:武汉科技大学, 2006.
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