高炉热风炉陶瓷燃烧器的研究与应用
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摘要
高炉热风炉是高炉炼铁中高炉加热鼓风的重要设备,是现代高炉不可缺少的重要组成部分。高风温是高炉提高产量、降低能耗、提高生铁质量和降低生铁成本的有效措施之一。热风炉陶瓷燃烧器又是热风炉的关键设备,热风炉陶瓷燃烧器设计的优劣,直接关系到热风炉设计的质量和热风炉的使用效果。
本文针对太原钢铁公司3#高炉热风炉陶瓷燃烧器在生产中出现的问题,通过理论计算与分析的方法确定了陶瓷燃烧器设计参数,并在此基础上运用相似理论建立模型的试验研究的方法开发了一种带中心扰流柱的热风炉陶瓷燃烧器,这种燃烧器运用于太原钢铁公司3#、4#高炉热风炉,新余钢铁公司7#、8#高炉热风炉、武钢集团鄂城钢铁有限公司1080 m~3高炉热风炉。带中心扰流柱的热风炉陶瓷燃烧器,采用空气二次加入,煤气环道中央设置中心绕流柱,煤气入口设置煤气导流板等措施增强煤气与空气的混合效果,通过合理分配空气通道和煤气通道的阻力,使瓷燃烧器的阻力只有传统套筒式陶瓷燃烧器25%,增加陶瓷燃烧器的燃烧能力和燃烧器的负荷调节范围。
本文还针对顶燃式热风炉在运用中存在的问题,以柳钢6#高炉的球式热风炉为研究对象,采用模型试验的研究方法开发了用于顶燃式热风炉的多火孔无焰陶瓷燃烧器。多火孔无焰陶瓷燃烧器采用一对空气和煤气管道与热风炉相连,减少了拱顶开孔,结构稳定;具有独立的煤气和助燃空气环道以及多火孔结构;环道中设有导流砖,使各喷火孔喷出的气量均匀,保证燃烧在空气过剩系数较小(1.05)的情况下,使煤气能完全燃烧,从而提高燃烧温度,实现无焰燃烧,消除燃烧脉动;工作时阻损小,调节范围大,工作稳定可靠;燃烧器立式安装于热风炉顶部,有利于改善拱顶初始气流分布。生产实践证明,可提高热风温度50～150℃,节约高炉煤气约15%,经济效益显著。
本文还从理论研究的基础出发,建立了顶燃式热风炉三维模型,并通过数值计算,对冷态和热态条件下的气体流动和燃烧过程进行了模拟。分析了热风炉内部流场和燃烧器的燃烧特性。论文首先建立与原形相似比为1:6的三维模型,选择适合模拟顶燃式热风炉内气体流动的标准κ—ε湍流模型,采用SIMPLE算法对压力和速度进行耦合,在给定速度入口的边界条件下,分析了热风炉内气体的流场、燃烧室出口和燃烧器喷口出口处的气流均匀性。然后对基于概率密度的PDF燃烧模型进行了介绍,采用这一模型及P1辐射模型,对顶燃式热风炉燃烧室的燃烧情况进行了模拟。受计算机计算能力限制,选择1/7的热风炉三维模型进行计算,切割面定义为周期性边界条件。在给定空气和煤气入口速度及出口压力,计算得到了热风炉燃烧室的速度分布、温度分布、各组分的浓度分布等。模拟计算结果与实际运行经验在定性上是一致的,可以用数值模拟的方法对热风炉的燃烧情况进行定性对比。
最后,论文对课题进行了总结,并对热风炉技术的未来发展进行了展望。高风温将是热风炉技术发展不断追求的目标,但不应超过1450℃。采用耐高温的炉子下部支柱和炉箅子,提高离开热风炉的烟气温度至600～650℃,然后利用烟气采用高温热管换热器预热空气和煤气,追求尽量高的煤气预热温度应是未来的主要发展方向。顶燃式热风炉将代替内燃式和外燃式热风炉成为未来发展的方向。高炉热风炉的设计寿命以15～20年为宜。数值模拟技术是一种节约成本,参数结构调整方便的很实用的一种技术,作为试验研究的一种补充是有益的,但还有待发展,未来热风炉技术研究最可能模式是数值模拟技术开发和实验室模型验证的结合。
Hot blast stove is a key facility in blast furnace ironmaking. Higher temperature blast is an ultimate target for the blast furnace ironmaking. The Ceramic burner is yet an important key for the hot blast stove. It is determined that the quality of the stove when we design and use it.
A ceramic burner with a pole for the hot blast stove was studied in this article. The characters of pressure drop, homogeneousness of flows at burner ports, the distribution of flows in the chambers were studied through cold model experiments based on Similarity Theory. This new type of ceramic burner enhanced mixture of gas and air through two stages mixture of gas and air, placing a pole in the center of the gas channel and placing a ban in the inlet of gas and reduced the pressure drop of the burner through distributing the pressure drop in gas channel and air channel. It just has 1/4 times pressure drop and more combustion capability when compared with the tube-in-tube ceramic burner. This ceramic burner was applied successfully in the hot blast stove of No.3 and No.4 Blast furnace in Taiyuan Iron & Steel Corp. Ltd., the hot blast stove of No.7 and No.8 Blast furnace in Xinyu Iron & Steel Corp. Ltd. and the hot blast stove of 1080 Blast furnace in E'cheng Iron & Steel Corp. Ltd.
A Multi-burner-port Annular Flameless Ceramic Burner (MAFCB) of shaftless stove was yet studied in this article. The characters of pressure drop, homogeneousness of flows at burner ports, the distribution of flows in the chambers and joint were studied by cold model experiments based on Similarity Theory. This new type ceramic burner just has one inlet of gas and air respectively when jointed with the body of shaftless stove and there are not flames when it burns. These will make the doom of the shaftless stove steadily and protect the regenerative burned out. This type of ceramic burner was successfully applied in the shaftless stove filled with refractory balls of 6th blast furnace at Liuzhou Iron & Steel Corporation Ltd. and it get a higher and steadiness of hot blast temperature at 1200℃when just combusted BFG and the thermal efficiency of shaftless stove was up to 78.95%.
Mathematic simulation is another method used to develop the combustions and furnaces. This was used to develop the mult-burner-port annular flameless ceramic burner of shaft stove. In this paper, a three-dimensional model of shaftless stove which the geometric similarity ratio is one sixth to the prototype is presented. Based on the governing equation and k-εturbulence model which suits to the gas flow in the shaftless stove, the three-dimensional model is solved by FLUENT commercial software with SIMPLE algorithm. The flow fields of hot-blast stove are obtained. The numerical results also show the homogeneous characters of the combustion chamber outlet and the nozzle outlet, and the drift current is under control in the regenerator when flow control bricks are used in the gas loop. In addition, the current simulation methods of combustion are analyzed. Based on the probability density function combustion model and P1 radiation model which suit to the gas combustion in the ceramic burner, the combustion process is simulated. The velocity distribution, temperature distribution and component distribution of the gas are obtained. By adjusting some parameters of the model, the numerical results can reflect the reality combustion process rightly.
At last, the paper summarizes the subject, and some ideas are given for the coming investigation of the hot blast stove. Higher temperature blast is an ultimate target for the blast furnace ironmaking and it will be researched, but it will not exceed 1450℃. The gas and air will be preheated to about 500℃through improve the exhaust temperature to about 550℃, based on using high temperature stand and grid. Shaftless stove is a trend when designed the hot blast stove. Mathematic simulation will be used to develop the ceramic burner and the hot blast stove.
本文针对太原钢铁公司3#高炉热风炉陶瓷燃烧器在生产中出现的问题,通过理论计算与分析的方法确定了陶瓷燃烧器设计参数,并在此基础上运用相似理论建立模型的试验研究的方法开发了一种带中心扰流柱的热风炉陶瓷燃烧器,这种燃烧器运用于太原钢铁公司3#、4#高炉热风炉,新余钢铁公司7#、8#高炉热风炉、武钢集团鄂城钢铁有限公司1080 m~3高炉热风炉。带中心扰流柱的热风炉陶瓷燃烧器,采用空气二次加入,煤气环道中央设置中心绕流柱,煤气入口设置煤气导流板等措施增强煤气与空气的混合效果,通过合理分配空气通道和煤气通道的阻力,使瓷燃烧器的阻力只有传统套筒式陶瓷燃烧器25%,增加陶瓷燃烧器的燃烧能力和燃烧器的负荷调节范围。
本文还针对顶燃式热风炉在运用中存在的问题,以柳钢6#高炉的球式热风炉为研究对象,采用模型试验的研究方法开发了用于顶燃式热风炉的多火孔无焰陶瓷燃烧器。多火孔无焰陶瓷燃烧器采用一对空气和煤气管道与热风炉相连,减少了拱顶开孔,结构稳定;具有独立的煤气和助燃空气环道以及多火孔结构;环道中设有导流砖,使各喷火孔喷出的气量均匀,保证燃烧在空气过剩系数较小(1.05)的情况下,使煤气能完全燃烧,从而提高燃烧温度,实现无焰燃烧,消除燃烧脉动;工作时阻损小,调节范围大,工作稳定可靠;燃烧器立式安装于热风炉顶部,有利于改善拱顶初始气流分布。生产实践证明,可提高热风温度50～150℃,节约高炉煤气约15%,经济效益显著。
本文还从理论研究的基础出发,建立了顶燃式热风炉三维模型,并通过数值计算,对冷态和热态条件下的气体流动和燃烧过程进行了模拟。分析了热风炉内部流场和燃烧器的燃烧特性。论文首先建立与原形相似比为1:6的三维模型,选择适合模拟顶燃式热风炉内气体流动的标准κ—ε湍流模型,采用SIMPLE算法对压力和速度进行耦合,在给定速度入口的边界条件下,分析了热风炉内气体的流场、燃烧室出口和燃烧器喷口出口处的气流均匀性。然后对基于概率密度的PDF燃烧模型进行了介绍,采用这一模型及P1辐射模型,对顶燃式热风炉燃烧室的燃烧情况进行了模拟。受计算机计算能力限制,选择1/7的热风炉三维模型进行计算,切割面定义为周期性边界条件。在给定空气和煤气入口速度及出口压力,计算得到了热风炉燃烧室的速度分布、温度分布、各组分的浓度分布等。模拟计算结果与实际运行经验在定性上是一致的,可以用数值模拟的方法对热风炉的燃烧情况进行定性对比。
最后,论文对课题进行了总结,并对热风炉技术的未来发展进行了展望。高风温将是热风炉技术发展不断追求的目标,但不应超过1450℃。采用耐高温的炉子下部支柱和炉箅子,提高离开热风炉的烟气温度至600～650℃,然后利用烟气采用高温热管换热器预热空气和煤气,追求尽量高的煤气预热温度应是未来的主要发展方向。顶燃式热风炉将代替内燃式和外燃式热风炉成为未来发展的方向。高炉热风炉的设计寿命以15～20年为宜。数值模拟技术是一种节约成本,参数结构调整方便的很实用的一种技术,作为试验研究的一种补充是有益的,但还有待发展,未来热风炉技术研究最可能模式是数值模拟技术开发和实验室模型验证的结合。
Hot blast stove is a key facility in blast furnace ironmaking. Higher temperature blast is an ultimate target for the blast furnace ironmaking. The Ceramic burner is yet an important key for the hot blast stove. It is determined that the quality of the stove when we design and use it.
A ceramic burner with a pole for the hot blast stove was studied in this article. The characters of pressure drop, homogeneousness of flows at burner ports, the distribution of flows in the chambers were studied through cold model experiments based on Similarity Theory. This new type of ceramic burner enhanced mixture of gas and air through two stages mixture of gas and air, placing a pole in the center of the gas channel and placing a ban in the inlet of gas and reduced the pressure drop of the burner through distributing the pressure drop in gas channel and air channel. It just has 1/4 times pressure drop and more combustion capability when compared with the tube-in-tube ceramic burner. This ceramic burner was applied successfully in the hot blast stove of No.3 and No.4 Blast furnace in Taiyuan Iron & Steel Corp. Ltd., the hot blast stove of No.7 and No.8 Blast furnace in Xinyu Iron & Steel Corp. Ltd. and the hot blast stove of 1080 Blast furnace in E'cheng Iron & Steel Corp. Ltd.
A Multi-burner-port Annular Flameless Ceramic Burner (MAFCB) of shaftless stove was yet studied in this article. The characters of pressure drop, homogeneousness of flows at burner ports, the distribution of flows in the chambers and joint were studied by cold model experiments based on Similarity Theory. This new type ceramic burner just has one inlet of gas and air respectively when jointed with the body of shaftless stove and there are not flames when it burns. These will make the doom of the shaftless stove steadily and protect the regenerative burned out. This type of ceramic burner was successfully applied in the shaftless stove filled with refractory balls of 6th blast furnace at Liuzhou Iron & Steel Corporation Ltd. and it get a higher and steadiness of hot blast temperature at 1200℃when just combusted BFG and the thermal efficiency of shaftless stove was up to 78.95%.
Mathematic simulation is another method used to develop the combustions and furnaces. This was used to develop the mult-burner-port annular flameless ceramic burner of shaft stove. In this paper, a three-dimensional model of shaftless stove which the geometric similarity ratio is one sixth to the prototype is presented. Based on the governing equation and k-εturbulence model which suits to the gas flow in the shaftless stove, the three-dimensional model is solved by FLUENT commercial software with SIMPLE algorithm. The flow fields of hot-blast stove are obtained. The numerical results also show the homogeneous characters of the combustion chamber outlet and the nozzle outlet, and the drift current is under control in the regenerator when flow control bricks are used in the gas loop. In addition, the current simulation methods of combustion are analyzed. Based on the probability density function combustion model and P1 radiation model which suit to the gas combustion in the ceramic burner, the combustion process is simulated. The velocity distribution, temperature distribution and component distribution of the gas are obtained. By adjusting some parameters of the model, the numerical results can reflect the reality combustion process rightly.
At last, the paper summarizes the subject, and some ideas are given for the coming investigation of the hot blast stove. Higher temperature blast is an ultimate target for the blast furnace ironmaking and it will be researched, but it will not exceed 1450℃. The gas and air will be preheated to about 500℃through improve the exhaust temperature to about 550℃, based on using high temperature stand and grid. Shaftless stove is a trend when designed the hot blast stove. Mathematic simulation will be used to develop the ceramic burner and the hot blast stove.
引文
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