莱钢3#连铸机传热数学模型的研究及二冷的优化
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摘要
随着中国加入世界贸易组织步伐的迈进，世界经济全球化趋势使得钢铁企业的国际、国内竞争将会更加激烈。我国钢铁企业将会受到国外优质低价进口产品的挑战。以质量求生存也就提到越来越高的地位。国内许多钢铁厂纷纷对现有设备和生产工艺进行改造，以提高铸坯的内、外部质量。在这种形式下，我们和山东莱芜炼钢厂技术科针对其炼钢厂3#小方坯连铸机45#钢铸坯由于生产工艺条件原因造成的铸坯内部质量缺陷问题和二冷优化进行了研究。
本课题根据莱钢炼钢厂生产现场的实际情况，从理论上分析了铸坯内部中心疏松和偏析产生的机理、其影响因素和改善预防它的相应连铸技术。在实践中，我们一方面以3#连铸机的45#钢种为研究对象，运用用二维传热数学模型对150×150mm~2小方坯冷却凝固温度场进行了模拟，这为以后的二冷段动态配水的研究打下基础。另一方面，我们根据现场实际情况，在对二冷水水质，冷却水水量进行检测后，对水质进行了改善，调整了二冷区的喷淋设备和水量。与此同时，我们对铸坯取样进行低倍分析，并对获得的低倍图片和分析结果进行了分析，得到了如下主要结论：
1．本课题中运用数学模型模拟的铸坯矫直前温度，在误差范围内，基本能反映现场的实际测量的铸坯温度情况，但是总体来说还是很粗糙。由于现场的实验条件有限，经费不充裕的情况下，运用现场的实际条件，仅能对铸坯矫直前表面温度进行测量。要想使得本模型能更好的指导现场生产，从而提高铸坯质量，还必需在经费允许的情况下，尽量在二冷室多设置几个代表性的测温点，并能获得相应的大量铸坯表面温度数据，然后再结合线性回归分析方法计算出二冷区各个冷却段的水量和拉速的关系式的系数，进而运用参数控制法对二冷水进行控制。这部分工作为后期的铸机二冷段动态配水的研究打下了基础。
2．至于铸坯的低倍试验，根据对它的分析结果大致能反映铸机的一些基本状况，对连铸生产实践有一定的指导作用。因为在铸坯取样时有点影响炼钢厂的生产节奏，所以取得的样本点数量不大，虽然能大概地反映铸坯内部质量的一部分状况，但是不能很全面的说明问题。所以，要是想进一步调整冷却水配置参数，优化二冷效果和改善铸坯质量，还需要在连铸机的设备、连铸工艺和铸坯内部质量的检验方面做进一步深入的系统工作。
3．在连铸生产过程中尽量在钢水流动性不影响生产的情况下，采用低过热度保护浇铸，这有利于铸坯内部缩小柱状晶区，扩大等轴晶区，这有利于提高铸坯的内部质量。莱钢在这一方向的工艺控制做得比较好，铸坯内部质量也比以前有了比较好的改善。
4．连铸机结晶器采用电磁搅拌后，有利于结晶器内部夹杂物的上浮，提高了铸坯的清洁度；另外结晶器电磁搅拌有利于结晶器内部均匀形核，改善铸坯外表面和内部的质量。这一点我们从实际生产中可得到了验证。
5．由于3#连铸机软水循环系统及浊水循环系统都存在一定漏水，而在生产中测试所得的实际冷却水流量冷却水量远小于设计水量。由于二冷水流量小，不仅影响铸坯质量，也容易引起漏钢。在清洗了二冷系统过滤器，并调整了二冷区
冷却设备如：喷淋水条和喷嘴的情况下，二冷效果得到了明显改善。在生产过程
中发生漏钢的机率明显降低了，铸坯的内部质量也得到了良好的改善。
With the advancing steps of China entering the World Trade Organization, the global economic trend makes that the competition between iron & steel enterprises home and abroad becomes more and more violently . The iron & steel enterprises at home are facing the challenge from abroad, of the import products which is produced in high quality and with low cost. In order to exist, the demand on product quality is getting higher and higher. Many factories begin to innovate the present equipments and produce procedure ,in order to improve the inner & outer quality of billets. In such situation, we are asked to cooperate with the technical department in Shandong LaiWu Steelmaking Factory( LWSF) on the study of the improving of billet inner quality problems and the optimizing of secondary cooling zones.
In this article ,according to the fact of produce spot in LWSF, it theoretically analyzes the engendering mechanism of central loosening and segregation in billets, concerning affecting factors and concasting techniques. In practice, we study the producing Grade 45# steel on No.3 continuous casting machine ,on one hand, and apply two dimension heat transfer mathematical model to simulating the cooling temperature field of 150X 150mm2 billet. All this founds the basis for dynamic distributing of cooling water in secondary zones. On the other hand, after having some check-up of the cooling water volume, we improve the quality of cooling water , adjust the spraying devices and water volume in secondary cooling zones. In the mean time, we take some samples of the billets to have macrophotographical examination, and the concerning analysis results come to the following primary conclusions:
1. In the thesis, the simulation result of the surface temperature before straightening, approximately explains the fact within the permitting error range, but the model is very coarse, generally speaking. Because of the limited condition and insufficient capitals, we can only measure the superficial billet temperature before the straightening machine. In order to make the model more fit for the billet production, we should firstly set more temperature detecting point in the secondary cooling zones to get plenty of data of surface temperature, and then use the linearr regression method to figure out the coefficient in the equation of drawing speed and water volume in different section of the secondary zones, and make use of parameter controlling method to control the distribution of secondary cooling water. The work done in this article, contributes to the latter research of dynamic distribution of secondary cooling water.
2.1n the macrophotographical test of billet, the analysis results probably explain the condition of the equipments ,it has a certain role in conducting practical production. Because the operation of getting billet samples disturbs the fluency of operating process ,the amount of samples is limited. Although we have get same effect in the research, to get more advancement ,we should do further and systematic work in
equipments, procedure and sample examinations.
3. Considering of not decreasing the fluidity of steel in production, we can apply low superheat technique to cast steel under protection. This helps to reduce the column crystal area, enlarge the ,that to say, it improves the inner billet quality. LWSF have done a good job at this aspect in the procedure, thus their efforts get a better return.
4. After adapting electric magnetic stirring( EMS) in the mould, it helps the inclusions to float in the mould ,and improves the cleanness of casting steel; what is more, EMS also contributes to the uniform forming of nucleus in the mould and does good to the improvement of inner& outer quality. All these can be proved in practice.
5. Because the phenomena of water leakage in cooling water circuit system, the factual water volume inspected is far less than the designed water volume. For this kind of reason , it has some disadvantageous effect on the billet quality, and it leads to the leakage easily. After
本课题根据莱钢炼钢厂生产现场的实际情况，从理论上分析了铸坯内部中心疏松和偏析产生的机理、其影响因素和改善预防它的相应连铸技术。在实践中，我们一方面以3#连铸机的45#钢种为研究对象，运用用二维传热数学模型对150×150mm~2小方坯冷却凝固温度场进行了模拟，这为以后的二冷段动态配水的研究打下基础。另一方面，我们根据现场实际情况，在对二冷水水质，冷却水水量进行检测后，对水质进行了改善，调整了二冷区的喷淋设备和水量。与此同时，我们对铸坯取样进行低倍分析，并对获得的低倍图片和分析结果进行了分析，得到了如下主要结论：
1．本课题中运用数学模型模拟的铸坯矫直前温度，在误差范围内，基本能反映现场的实际测量的铸坯温度情况，但是总体来说还是很粗糙。由于现场的实验条件有限，经费不充裕的情况下，运用现场的实际条件，仅能对铸坯矫直前表面温度进行测量。要想使得本模型能更好的指导现场生产，从而提高铸坯质量，还必需在经费允许的情况下，尽量在二冷室多设置几个代表性的测温点，并能获得相应的大量铸坯表面温度数据，然后再结合线性回归分析方法计算出二冷区各个冷却段的水量和拉速的关系式的系数，进而运用参数控制法对二冷水进行控制。这部分工作为后期的铸机二冷段动态配水的研究打下了基础。
2．至于铸坯的低倍试验，根据对它的分析结果大致能反映铸机的一些基本状况，对连铸生产实践有一定的指导作用。因为在铸坯取样时有点影响炼钢厂的生产节奏，所以取得的样本点数量不大，虽然能大概地反映铸坯内部质量的一部分状况，但是不能很全面的说明问题。所以，要是想进一步调整冷却水配置参数，优化二冷效果和改善铸坯质量，还需要在连铸机的设备、连铸工艺和铸坯内部质量的检验方面做进一步深入的系统工作。
3．在连铸生产过程中尽量在钢水流动性不影响生产的情况下，采用低过热度保护浇铸，这有利于铸坯内部缩小柱状晶区，扩大等轴晶区，这有利于提高铸坯的内部质量。莱钢在这一方向的工艺控制做得比较好，铸坯内部质量也比以前有了比较好的改善。
4．连铸机结晶器采用电磁搅拌后，有利于结晶器内部夹杂物的上浮，提高了铸坯的清洁度；另外结晶器电磁搅拌有利于结晶器内部均匀形核，改善铸坯外表面和内部的质量。这一点我们从实际生产中可得到了验证。
5．由于3#连铸机软水循环系统及浊水循环系统都存在一定漏水，而在生产中测试所得的实际冷却水流量冷却水量远小于设计水量。由于二冷水流量小，不仅影响铸坯质量，也容易引起漏钢。在清洗了二冷系统过滤器，并调整了二冷区
冷却设备如：喷淋水条和喷嘴的情况下，二冷效果得到了明显改善。在生产过程
中发生漏钢的机率明显降低了，铸坯的内部质量也得到了良好的改善。
With the advancing steps of China entering the World Trade Organization, the global economic trend makes that the competition between iron & steel enterprises home and abroad becomes more and more violently . The iron & steel enterprises at home are facing the challenge from abroad, of the import products which is produced in high quality and with low cost. In order to exist, the demand on product quality is getting higher and higher. Many factories begin to innovate the present equipments and produce procedure ,in order to improve the inner & outer quality of billets. In such situation, we are asked to cooperate with the technical department in Shandong LaiWu Steelmaking Factory( LWSF) on the study of the improving of billet inner quality problems and the optimizing of secondary cooling zones.
In this article ,according to the fact of produce spot in LWSF, it theoretically analyzes the engendering mechanism of central loosening and segregation in billets, concerning affecting factors and concasting techniques. In practice, we study the producing Grade 45# steel on No.3 continuous casting machine ,on one hand, and apply two dimension heat transfer mathematical model to simulating the cooling temperature field of 150X 150mm2 billet. All this founds the basis for dynamic distributing of cooling water in secondary zones. On the other hand, after having some check-up of the cooling water volume, we improve the quality of cooling water , adjust the spraying devices and water volume in secondary cooling zones. In the mean time, we take some samples of the billets to have macrophotographical examination, and the concerning analysis results come to the following primary conclusions:
1. In the thesis, the simulation result of the surface temperature before straightening, approximately explains the fact within the permitting error range, but the model is very coarse, generally speaking. Because of the limited condition and insufficient capitals, we can only measure the superficial billet temperature before the straightening machine. In order to make the model more fit for the billet production, we should firstly set more temperature detecting point in the secondary cooling zones to get plenty of data of surface temperature, and then use the linearr regression method to figure out the coefficient in the equation of drawing speed and water volume in different section of the secondary zones, and make use of parameter controlling method to control the distribution of secondary cooling water. The work done in this article, contributes to the latter research of dynamic distribution of secondary cooling water.
2.1n the macrophotographical test of billet, the analysis results probably explain the condition of the equipments ,it has a certain role in conducting practical production. Because the operation of getting billet samples disturbs the fluency of operating process ,the amount of samples is limited. Although we have get same effect in the research, to get more advancement ,we should do further and systematic work in
equipments, procedure and sample examinations.
3. Considering of not decreasing the fluidity of steel in production, we can apply low superheat technique to cast steel under protection. This helps to reduce the column crystal area, enlarge the ,that to say, it improves the inner billet quality. LWSF have done a good job at this aspect in the procedure, thus their efforts get a better return.
4. After adapting electric magnetic stirring( EMS) in the mould, it helps the inclusions to float in the mould ,and improves the cleanness of casting steel; what is more, EMS also contributes to the uniform forming of nucleus in the mould and does good to the improvement of inner& outer quality. All these can be proved in practice.
5. Because the phenomena of water leakage in cooling water circuit system, the factual water volume inspected is far less than the designed water volume. For this kind of reason , it has some disadvantageous effect on the billet quality, and it leads to the leakage easily. After
引文
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