用户名: 密码: 验证码:
烧结设备关键技术研究及工程实践
详细信息    本馆镜像全文|  推荐本文 |  |   获取CNKI官网全文
摘要
混合机和烧结机是烧结厂的核心设备,随着设备的大型化,高炉容积在不断扩大,大型高炉对含铁炉料的强度、粒度、化学成分,尤其是冶炼特性的要求越来越高。所以,生产优质烧结矿所需要的设备——混合设备和烧结设备的作用显得尤其重要。规模不断扩大的同时也出现很多问题:如混合机经过长时间的连续运转,机内物料粘结在其内壁,不易清除,物料混合制粒效果不好,橡胶轮胎磨损严重;烧结机漏风导致烧结矿质量下降、产量降低、返矿增多,能耗加大,直接影响到高炉的生产。
     针对上述问题,本文进行了如下研究工作:
     首先分析了混合机混合、制粒时物料的运动过程,对其内部物料运动的六种状态进行总结。找出影响圆筒混合机混匀、制粒的主要因素,对一次混合和二次混合时的最佳操作参数做了深入研究,使得工艺得到优化。
     其次对圆筒混合机筒体径向的力学性能进行分析,推导出径向受力的计算方程。研究了圆筒混合机筒体轴向受力情况,提出采用三弯矩方程,并结合轮胎受力与其径向位移之间的关系,建立方程组求解支撑轮胎的受力,这样得到的结果更符合实际。分析了筒体与轮胎之间的滑动摩擦力对轮胎磨损的影响,并给出计算实例。运用有限元软件ANSYS分析了总压力在各个支撑轮胎间的分配、轮胎的应力、应变和位移情况,得出了轮胎受力与轮胎径向位移之间的关系曲线。
     再次,分析了烧结机的系统漏风情况,描述了烧结机各个部位的密封形式及方法,首次提出对烧结机机头机尾采用风箱外高副接触头尾密封技术,风箱滑道采用磁液密封,并在国内几十家钢铁企业应用,经过长时间运行后测试密封效果,结果表明漏风率都有明显的下降,取得了良好的效果。
     最后,根据台车列辊轮轮距的交替变化,确定了星轮相隔布置的两类齿距,其中星轮的齿数为偶数。将啮合原理与星轮和辊轮啮合的具体工况相结合,建立了分段的星轮实际齿廓曲线,并将该分段曲线用统一方程表达。针对星轮在运行中出现的齿面损伤,应用赫兹接触理论对齿面接触应力进行了计算,并从多方面研究了提高星轮齿面承载能力的措施。采用非线性有限元对理想接触工况及实际接触工况进行了模拟分析,进一步揭示了齿面损伤产生的原因并证明了提高齿面承载能力所采用措施的有效性。在上述研究基础上,设计制造了新型带式烧结机的偶数齿数变齿距头尾星轮,有效解决了带式烧结机台车运行速度的波动问题,同时消除了下台车列部分起拱现象,提高其承载能力。
Mixer and sintering machine is the core equipment of sintering plant. With the large-scale of equipment and increasing of blast furnace volume, the strength, particle size and chemical composition, especially smelting characteristics of charging including iron are called for increasingly high quality. Therefore, as necessary equipments of producing high quality sinter production, mixing and sintering equipments becomes particularly important. Constantly expanding scale of blast furnace causes many problems. After a long period of continuous operation, material in mixer sticks to inner wall and is difficult to be removed. Meanwhile, the granulating effects of mixed materials are very poor and sever wear of rubber tires occurs. Air leakage of sintering machine leads to a decline of sinter quality, decreasing of production and increasing of return fines ratio and energy consumption. So, it has a direct impact on the production of blast furnace.
     Aiming at above problems, research works were carried out as follows:
     Firstly, the movement of material during mixing and granulating was analyzed and it's six motion states in mixer were summarized. Based on the influence factors analyzing for uniform mixing and granulating of drum mixer, optimal operation parameters of mixing and twice-mixing were lucubrated and the process was optimized.
     Secondly,the author analyzed the radial mechanical properties of mixing drum cylinder and derived from calculating method of radial force. Under analyzing axial force of cylinder of drum mixer, three-moment equation was proposed. Combined with the force of tire and its radial displacement, these equations used to solve the force of support tire were established. The results obtained by the method seem more tally to actual operation. Furthermore, the effects of sliding frictional force between cylinder and tire on wear also were analyzed and calculation example was given. Pressure distribution between all support tires, stress, strain, and displacement of tires were simulated with ANSYS. And the relation curve between force of tire and radial displacement was educed.
     Thirdly, by analyzing air leakage and seal forms of sinter machine, author presented the sealing technique of head and tail of sinter machine for the first time and magnetism-fluid sealing was utilized on the bellows chute. All the measures and technologies have been applied in tens of steel enterprises. After a long period of testing of sealing, air leakage rate has a obvious decreasing and a good effect was achieved.
     Finally, two kinds of teeth space arranged alternately and the even number of teeth are determined for the sprocket wheel according to the interval changed wheelbases of the rolling wheels in the pallet cars. By combining the meshing principle with the actual working condition between the sprocket wheel and the pallet cars, the practical tooth profile curve is established and expressed by universal equation. Aiming at the tooth surface damage of the sprocket wheel while working, the contact stress of the tooth surface is calculated by using the Hertz theory, and various measures to improve the load capacity of the sprocket wheel tooth surface are studied. The distributions of the contact stress simulated with nonlinear FEM in the ideal working condition and the actual working condition show further that the damage reasons of the tooth surface and prove the availability of the methods for improving the load capacity. Based on the study results mentioned above, the front and back sprocket wheels with even number of teeth, varying teeth space and high load capacity for new type sintering machine are designed and manufactured. The speed fluctuation of pallet cars of belt-type sinter machine was effectively solved. It is more important that the arch problem of lower pallet cars was also eliminated and bearing capacity was also increased.
引文
1 Ian Christmas.世界钢铁工业的现状与发展前景. 2001中国钢铁年会论文集(上集).北京:冶金工业出版社, 2001: 4-5
    2张寿荣.关于21世纪我国钢铁工业的若干思考. 2001中国钢铁年会论文集(上集).北京:冶金工业出版社, 2001: 61-69
    3李世俊.中国钢铁企业的机遇与挑战. 2001中国钢铁年会论文集(上集) .北京:冶金工业出版社, 2001: 48-50
    4 K. Yamada, K. Imada, T. Lida. Modification of Tobata No.3 Sintering Machine and the Operation After Modification. Australian Refrigeration, Air Conditioning and Heating, 1991, 45(1): 127
    5 M. Yu. Pazyuk; V. I. Grankovskii, A. A. Poleshchuk. Operation of Sintering Machine Surge Hoppers. Steel in the USSR, 1984, 14(4): 167-169
    6 V. V. Grekov, A. K. Semenov, G. E.Isaenko, et al. Improvement in Productivity of the Sintering Machines. Stal', 1995, (12): 6-8
    7 G. I. Shepelev, L. I. Murashko. New Sintering Machines for Sintering Plant Reconstruction. Stal', 1991, (4): 6-8
    8 A. Avdeeno, V. I. Klejn, N. M. Logvinov, et al. Utilization of Heat of Hot Sinter at the Sintering Machine. Stal', 2003, (1): 13-14
    9 R. B. Yusupov, V. P. Lekin, M. E. Polushkin, et al. Influence of Parameters of the Sintering Process on Machine Productivity and Sinter Quality. Metallurg, 2003, (12): 28-29
    10 S. M. Kulakov, N. F. Bondar, V. B. Trofimov. Optimizing Automatic-regulator Settings in Sintering Machines. Steel in Translation, 2007, 37(6): 501-504
    11 B. S. Tleugabulov, Loading Units for Sintering Machines. Steel in Translation, 2007, 37(3): 256-260
    12 E. L. Kharanu, Zh. A. N. Vidal, Da Silva, et al. Modernization of Sinter Shop at CST with Extending of Sinter Machine Pallet. Stal', 1999, (4): 3-6
    13汪用澎,张信.大型烧结设备.北京:机械工业出版社, 1997: 11-195
    14 Brone D, Muzzio F J. Enhanced mixing in double-cone blenders. Power Technol, 2000,110(2):169-179
    15王凯,冯连芳.混合设备设计.北京:机械工业出版社, 2000: 1-66
    16白明华,何云华.大型橡胶轮胎传动圆筒混合机力学性能及传动形式研究.中国机械工程, 2002,13(2): 108-110
    17 V. P. Movchan. Development of Technology of Sinter-pellets Sintering on Conveyor Burning Machine. Metallurgicheskaya i Gornorudnaya Promyshlennost, 2002, (3): 6-9
    18 D. Uchitel', V. T. Kiyashko, S. I. Shul'ga, et al. About Opportunity for Final Pelletizing of the Sinter Charge Materials on the Loading Tray of the Sintering Machine. Metallurgicheskaya i Gornorudnaya Promyshlennost, 2004, (1), 100-102
    19宋国良,傅志华,张全.烧结机增产节能的途径.钢铁研究学报, 2000, 12(6): 61-64
    20冶金工业部长沙黑色冶金矿山设计研究院.烧结设计手册.北京:冶金工业出版社, 1990: 91-157, 309-315, 430-435
    21白明华,孟令忠,阎瑞河.冶金与重型锻压设备.北京:机械工业出版社, 2001: 19-31
    22 V. I. Klejn, A. A. Avdeeno. Modernization of the Sintering Machines. Stal', 2003, (1): 11-12
    23西安重型机械研究所.国外烧结设备.北京:机械工业出版社, 1975: 3-5
    24傅菊英,姜涛,朱得庆.烧结球团学.长沙:中南工业大学出版社, 1996: 1-26
    25 D. Kolar, S. Pejovnik, M. M. Ristic. Sintering-theory and practice. Proceedings of the 5th International Round Table Conference on Sintering. Portoroz, Yugoslavia, 1981: 7-10
    26宁天星,潘朝英,张景智.宝钢烧结生产设备.北京:冶金工业出版社, 1997: 1-35
    27钱植仪,张景智,夏辛明.宝钢烧结生产工艺.北京:冶金工业出版社, 1995: 1-17
    28 R. B. Yusupov, V. P. Lekin, M.E. Polushkin, et al. Effect of the Parameters of the Sintering Operation on the Productivity of Sintering Machines and the Quality of the Sinter. Metallurgist, 2003, 47(11-12): 487-490
    29 Kim Yong Ho, Kwon Wook Hyun. An Application of Min-max Generalized Predictive Control to Sintering Processes. Control Engineering Practice, 1998, 6(8): 999-1007
    30 Shigaki Ichiro, Narazaki Hiroshi. Machine-learning Approach for a Sintering Process Using a Neural Network. Production Planning and Control, 1999, 10(8): 727-734
    31 Yu. A. Frolov, Analysis of Gas Dynamic Operation of the Sintering Machines. Stal', 2005, (6): 42-51
    32姜宏洲.烧结机尾烧结质量智能检测仪的研制. [东北大学工学博士学位论文]. 2000: 1-16
    33孙文东.烧结生产系统的优化与控制研究. [华中科技大学工学博士学位论文]. 2004:1-11
    34白明华.带式烧结机新结构原理与设计计算.北京:机械工业出版社, 1996: 1-242
    35西安重型机械研究所.重型机械.北京:机械工业出版社, 1995: 1-52
    36 S. F. Koloda. Analytical Determination of Gaps Between Elements of Side Seals of Strand Sintering Machines Communication 2. Steel in the USSR, 1980, 10(8): 448-450
    37 Zhang. Yanling, Gao. Junshan. Application of Optimal Sinter Burden Design. Mineral Metallurgy Materials, 2002, 9(1): 20-24
    38 N. I. Vorob'ev, V. A. Andreev, E. A. Kazantsev, et al. Growth of Sinter Production at the Chelyabinsk Metallurgical Combine. Metallurgist, 2002, 46(1-2): 47-48
    39 M. F. Vitushchenko, L. K. Gerasimov, V. N. Vzdorov, et al. Improving the Longitudinal Seals and the Gas-outlet Channel of AKM-312 Sintering Machines. Metallurgist, 1985, 29(3-4): 83-85
    40金永龙,徐南平,邬士英,等.烧结机分区段漏风测试技术研究及应用.钢铁, 2003, 38(3): 1-3
    41宋国良,傅志华,张全.烧结机增产节能的途径.钢铁研究学报, 2000, 12(6): 61-64
    42高彦,么占坤,孙长征,等.烧结机漏风治理技术方案.烧结球团, 2004, 29(1): 38-42
    43 Higuchi Kenichi, Kawaguchi Takuya; Kobayashi Masanori, et al. Improvement of Productivity by Stand-support Sintering in Commercial Sintering Machines. Revue de Metallurgie, 2002, 99(3): 241-248
    44金永龙,徐南平,邬士英,等.烧结机漏风测定新技术的研究和应用.钢铁研究学报, 1999, 11(3): 67-70
    45韩绿林,姚桐,程国彪,等.烧结技术改造的生产实践.钢铁, 2005, 40(11): 13-15
    46 Takashima Nobuhiro, Takahashi Hiroyasu, Sugawara Minoru, et al. Countermeasures for Prevention of Air Leakage at Sintering Machine and Their Effects. Kawasaki Steel Technical Report, 1986, (15): 9-15
    47 Hauck Thorsten, Klima Rolf; Kofler Arnd, et al. Verbesserte uberwachung und regelung an sinteranlagen (Improved Process Control of a Sinter Plant). Stahl und Eisen, 2003, 123(4): 69-73
    48 Okuda Kosuke, Imada Kunihiro, Mochizuki Michiharu, et al. Improvement of Sintering Operation at the Low Productivity Level. Transactions of the Iron and Steel Institute of Japan, 1984, 25(3):75-84
    49 P. R. Dawson. Recent Developments in Iron Ore Sintering, Part 4, The Sintering Process. Ironmaking and Steelmaking, 1993, 20(2): 150-159
    50修建生.带式烧结机运动模拟及磁液密封研究. [燕山大学工学硕士学位论文]. 2000: 54-68, 29-41
    51董书岐,李传收,谷华,等.带式烧结机台车起拱及其改进.烧结球团, 2005, 30(2): 39-41
    52 N. V. Panishev, A. G. Neyasov, O. N. Podbornykh, et al. Control of Operating Parameters on Lengthened Sintering Machine. Steel in the USSR, 1988, 18(5): 193-194
    53 Higuchi Masaaki, Iizuka Motohiko, Takasaki Yasuto. On the Facilities and Operational Control of No.5 Sinter Machine at Fukuyama Works, Nippon Kokan K. K. Ironmaking Proceedings, Metallurgical Society of AIME, Iron and Steel Division, 1976, 36: 525-538
    54 V. I. Klejn, A. A. Avdeeno, G. M. Majzel'. Modernization of the Sintering Machines. Stal', 2003, (1): 11-12
    55 M. I. Kotlyar, Research of the Rational Shape of the Loading Tray of a Sintering Machine. Metallurgicheskaya i Gornorudnaya Promyshlennost, 2004, (2): 105-106
    56刘建钢.湘钢90m2烧结机消除台车起拱的实践.烧结球团, 1997, 22(6):58-60
    57伏庆旦.烧结机密封装置的使用与改进.宝钢技术, 1997, (4): 8-13
    58刘相佩,烧结机回程道上台车起拱问题的探讨.烧结球团, 2003, 28(1): 36-37
    59邱坤.偶数齿形烧结机及参数研究. [燕山大学工学硕士学位论文]. 1992: 1-32
    60白明华,胡国清,邱坤,等.无起拱烧结机新理论的研究.机械工程学报, 1995, 31(6): 68-72.
    61白明华,胡国清,刘洪彬,等.偶数齿带式烧结机的研究.中国机械工程, 1996, 7(1): 71-72
    62白明华,胡国清,邱坤,等.烧结机尾部星轮阻力矩装置的研究.重型机械, 1995 (5): 18-20
    63岳晓丽.偶数齿匀速带式烧结机运动计算机模拟. [燕山大学工学硕士学位论文]. 1996: 1-62
    64白明华,何云华.匀速、变速中新齿形的研究.机械工程学报, 2001, 37(12): 83-85
    65余梅生,周为娟.新型带式烧结机三维运动仿真的研究与实现.计算机仿真, 2001, 19(5): 90-91
    66余梅生,新型烧结机的仿真及其建模中的图形转换问题.中国机械工程, 2001, 13(10): 871-873
    67郝春雨.新型带式烧结机设计理论研究及其参数化. [燕山大学工学硕士学位论文]. 2004: 1-62
    68 Lioya K. Powder Technology Handbook. New York. Marcel Dekker,1990:1-139
    69 German. Powder Metallurgy Science. New York. Chemical Publishing Co. inc, 1995:1-50
    70 D.R.Van Puyvelde, B.R.Young, M.A,Wilson,etc. Experimental determination of transverse mixing kinetics in a rolling drum by image analysis. Powder Technology, 1999,106:183-191
    71欧阳洪武,刘咏,陈海林,等.粉体混合过程的实验和数值模拟研究.材料导报,2003,17(8):5-7
    72孙其诚,王光谦,杨宁.水平圆筒型混合机中颗粒混合的离散模拟.中国粉体技术, 2002,8(1): 6-9
    73白明华,关毅民.圆筒混合机内物料运动分析.东北重型机械学院学报, 1992,16(2): 110-116
    74傅永华.有限元分析基础.武汉:武汉大学出版社, 2003: 1-100
    75张国瑞.有限元法.北京:机械工业出版社, 1991: 1-100
    76应隆安.有限元方法讲义.北京:北京大学出版社, 1988: 1-50
    77李开泰.有限元方法及其讲义.西安:西安交通大学出版社, 2001: 1-10
    78嘉禾工作室. ANSYS 5.7有限元实例分析教程.北京.机械工业出版社, 2002: 120-122
    79 J .T. Tielking. A Finite Element Tire Model. Tire Science and Technology, 1984,11(1): 50-63
    80 J. R. Luchini, J. M. Peters, R. H. Arhtur. Tire Rolling Loss Computation with the Finite Element Method. Tire Science and Technology, 1994,22,(4): 206-222
    81 J.P.Chang, K.Satyamurthy. An Efficient Approach for the Three-Dimensional Finite Element Analysis of Tires. Tire Science and Technology, 1993,16(1): 60-261
    82安相壁,李树珉,马效.车轮定位与轮胎磨损关系分析.汽车设计与研究, 2001(2): 30-32
    83 Nien-Tsu Tseng. Finite Element Analysis of Freely Rotating Tires Tire Science and Technology, 1987,15(2): 135-149
    84 J .T. Tielking. A Finite Element Tire Model Tire Science and Technology, 1984,11(1): 50-63
    85 Milner, J. Christopher. Measurement of tire-Road friction using a bouncing wheel. Australian Road Research, 1990,20(3): 62-71
    86方庆红,路金林,赵力群.轮胎磨损分析中接地能量的有限元计算模型研究.沈阳化工学院学报, 2002,16(3): 228-231
    87 J. J. Kalker. Contact Mechanics Algorithms. Communications of Applied Numerical Methods, 1988,(4): 25-32
    88 Milner, J. Christopher. Measurement of tire-Road friction using a bouncing wheel. Australian Road Research, 1990,20(3): 62-71
    89 Johnson, K. L. Contact mechanics. Cambridge University Press, 1985: 29-47
    90美国ANSYS公司北京办事处. ANSYS非线性分析指南, 2000: 1-36
    91张建春.烧结机头尾及中间密封装置的改进.冶金设备, 2006, 156: 73-75
    92李特文.齿轮啮合原理.卢贤占,高业田,王树人译.第二版.上海:上海科学技术出版社, 1994: 1-67
    93张启先,张玉茹.我国机械学研究的新进展与展望.机械工程学报, 1996, 32 (4): 1-4
    94雷光,许洪基.齿轮设计、制造的发展与展望.齿轮, 1987, 11(4): 54-56
    95 F. L. Litvin. Applied Theory of Gearing: State of the Art. Transactions of the ASME, 1995, 117: 128-134
    96 M. H. French, Gear Conformity and Load Capacity. Proceedings of the Institute of Mechanical Engineers, 1965-1966, 180(43): 1013-1024
    97 A. O. Lebeck, E. I. Radzimovsky. The Synthesis of Tooth Profile Shapes and Spur Gears of High Load Capacity. ASME Journal of Engineering for Industry, 1970, 92(4): 543-553
    98 N. E. Anderson, S. H. Loewenthal. Design of Spur Gears for Improved Efficiency. ASME Journal of Mechanical Design, 1982, 104(4): 767-774
    99 H. Iyoi, S. Ishimura. x-Theory in Gear Geometry. ASME Journal of Mechanisms, Transmissions, and Automation in Design, 1983, 105(3): 286-290
    100 G. W. Eggeman. Design of a Synthesized Helical Gear Set. ASME Journal of Mechanisms, Transmissions, and Automation in Design, 1987, 109(3): 419-423
    101吴序堂.齿轮啮合原理.北京:机械工业出版社, 1982: 1-92
    102朱孝录,鄂中凯.齿轮承载能力分析.北京:高等教育出版社, 1992: 1-7
    103林菁.基于啮合角函数的平面圆齿轮共轭齿廓啮合理论研究. [东北大学工学博士学位论文]. 1998: 20-34
    104林菁.共轭曲线啮合角函数理论及其应用.北京:科学出版社, 2005: 21-34, 119-126
    105复旦大学数学系.曲线与曲面.北京:科学出版社, 1977: 34-66, 160-254
    106 Imre Juhász. Cubic parametric curves of given tangent and curvature. Computer-Aided Design, 1998, 30(1): 1-9
    107徐良宏,孟勇,陈铁.给定两端点及端点处切方向和曲率的空间Bezier曲线的插值问题.数值计算与计算机应用, 2001, (2): 81-86
    108孙恒,傅则绍.机械原理(第四版).北京;高等教育出版社, 1995: 51-59, 338-355
    109范扬波.销齿传动的重合度计算.福州大学学报(自然科学版), 1999, 27(1): 52-55
    110曾向阳,谢国明,王学平. UGNX基础及应用教程.北京:电子工业出版社, 2003: 3-9
    111朱孝录,齿轮传动设计手册.北京:化学工业出版社, 2005: 93-172
    112黄炎.局部应力及其应用.北京:机械工业出版社, 1996: 134-173, 567-615
    113 K. L. Johnson.接触力学.徐秉业,罗学富,刘信声,等译.北京:高等教育出版社, 1992: 96-122
    114周宁. ANSYS机械工程应用实例.北京:中国水利水电出版社, 2006: 1-7
    115关天民. FA型摆线针轮行星传动齿形优化方法与相关理论的研究, [大连交通大学工学博士学位论文]. 2005: 39-41
    116臧新良.张力减径过程组元模型理论及其虚拟仿真系统研究. [燕山大学工学博士学位论文]. 2001: 23-26
    117宋乐民.齿形与齿轮强度.北京:国防工业出版社,. 1987: 105-140
    118 C. P. Bhateja, W. L. Bowen. The hollow roller bearing. Journal of Lubrication Technology. Transactions of ASME, 1980, 102(4): 222-234
    119吕彭民,丁智.架桥机滚柱轮结构最佳空心度研究.中国公路学报, 2005, 18(2): 123-126
    120 R. L. Huston, Multibody Dynamics-Model and Analysis Methods, Appl. Mech. Rev, 1991, 44 (3): 109-117

© 2004-2018 中国地质图书馆版权所有 京ICP备05064691号 京公网安备11010802017129号

地址:北京市海淀区学院路29号 邮编:100083

电话:办公室:(+86 10)66554848;文献借阅、咨询服务、科技查新:66554700