基于响应曲面法的铁水预熔脱磷渣组成优化
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摘要
铁水预脱磷的处理普遍采用石灰渣系,主要由CaO, FemOn和CaF_2等组成,含CaF_2高,炉衬侵蚀严重,且生成的含氟脱磷产物对环境危害大,不利于脱磷渣的综合利用。针对以上问题对脱磷渣系进行优化设计,采用FactSage软件考察单因素(FeO,Na_2CO_3和MnO含量、碱度和脱磷温度)对铁水脱磷效果的影响,采用响应曲面法(RSM)确定主要影响因素和水平,对铁水预熔脱磷渣配比进行优化。结合模拟结果,在CaO-SiO2-FeO渣系中添加助熔剂(Na_2CO_3与MnO)进行脱磷预处理实验。建立预测铁水脱磷率的多元回归模型,通过方差分析和响应曲面分析对各因素的交互作用进行优选,得到脱磷渣(CaO-SiO2-FeO-Na_2CO_3-MnO)的最佳配比。结果表明,脱磷率随碱度、FeO含量和助熔剂含量提高而增大,脱磷剂的最佳配比为37.79%FeO,6.24%Na_2CO_3,9.89%MnO,碱度4.50,温度1387℃。将预测结果用于实验,最终脱磷率为97.30%,相对误差为2.70%。响应曲面法可较好地预测和指导实验,按优化成分进行脱磷实验可获得较高的铁水脱磷率,此方法能为铁水脱磷提供理论指导。
The lime-based slag system is generally applied to the treatment of pre-dephosphorization of molten iron, which mainly composed of CaO, FemO n, CaF_2, etc. However, the CaF_2 contained in the slagalways results in the serious lining erosion and the environmental hazard caused by fluorine-containing dephosphorization by-product, which is not conducive to the comprehensive utilization of dephosphorization slag. The optimization design of dephosphorization slag system was carried out in the present study for the above problems.The effect of single factor(FeO, Na_2CO_3 and MnO content and basicity) on the dephosphorization of molten iron was investigated by Equilib modle in the FactSage calculation software. The main influencing factors such as FeO content,MnO content, Na_2CO_3 content, basicity and reaction temperature and the optimization design for the pre-melting dephosphorization slag composition were investigated by Box-Behnken modle in response surface methodology. A pre-mixing fluxing agent(Na_2CO_3 and MnO) was added to the CaO-SiO2-FeO slag system for dephosphorization pretreatment based on the single factor influence calculation. A multiple regression model to predict the dephosphorization rate of molten iron was established, the interaction of each factor and optimal composition of dephosphorization slag(CaO-SiO2-FeO-Na_2CO_3-MnO) were studied and optimized by variance analysis and response surface method, furthermore. The results showed that the calculated dephosphorization rate of molten iron was increased with the increasement of alkalinity, FeO content and flux content. The optimum dephosphorization conditions were 37.79% FeO, 6.24% Na_2CO_3, 9.89% MnO, with basicity of 4.50 and reaction temperature of 1387 ℃,the dephosphorization rate was 97.30% with relative error of 2.70%. The response surface methodology calculated result was in well accordance with experimental results of higher dephosphorization rate and can provide theoretical guidance for the industrial application of molten iron dephosphorization.
The lime-based slag system is generally applied to the treatment of pre-dephosphorization of molten iron, which mainly composed of CaO, FemO n, CaF_2, etc. However, the CaF_2 contained in the slagalways results in the serious lining erosion and the environmental hazard caused by fluorine-containing dephosphorization by-product, which is not conducive to the comprehensive utilization of dephosphorization slag. The optimization design of dephosphorization slag system was carried out in the present study for the above problems.The effect of single factor(FeO, Na_2CO_3 and MnO content and basicity) on the dephosphorization of molten iron was investigated by Equilib modle in the FactSage calculation software. The main influencing factors such as FeO content,MnO content, Na_2CO_3 content, basicity and reaction temperature and the optimization design for the pre-melting dephosphorization slag composition were investigated by Box-Behnken modle in response surface methodology. A pre-mixing fluxing agent(Na_2CO_3 and MnO) was added to the CaO-SiO2-FeO slag system for dephosphorization pretreatment based on the single factor influence calculation. A multiple regression model to predict the dephosphorization rate of molten iron was established, the interaction of each factor and optimal composition of dephosphorization slag(CaO-SiO2-FeO-Na_2CO_3-MnO) were studied and optimized by variance analysis and response surface method, furthermore. The results showed that the calculated dephosphorization rate of molten iron was increased with the increasement of alkalinity, FeO content and flux content. The optimum dephosphorization conditions were 37.79% FeO, 6.24% Na_2CO_3, 9.89% MnO, with basicity of 4.50 and reaction temperature of 1387 ℃,the dephosphorization rate was 97.30% with relative error of 2.70%. The response surface methodology calculated result was in well accordance with experimental results of higher dephosphorization rate and can provide theoretical guidance for the industrial application of molten iron dephosphorization.
引文
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[13]徐颖,李明利,赵选民,等.响应曲面回归分析法-一种新的回归分析法在材料研究中的应用[J].稀有金属材料与工程,2001,30(6):428-432.Xu Y,Li M L,Zhao X M,et al.The response curved surface regression analysis technique-the application of a new regression analysis technique in materials research[J].Rare Metal Materials and Engineering,2001,30(6):428-432.
[14]徐冉,宋波,毛璟红.CaO-SiO2-Al2O3-MgO-TiO2钢渣体系熔化性能[J].北京科技大学学报,2010,32(11):1422-1427.Xu R,Song B,Mao J H.Melting performance of CaO-SiO2-Al2O3-MgO-TiO2 slag system[J].Journal of University of Science and Technology Beijing,2010,32(11):1422-1427.
[15]毛红,宋波,赵保东,等.CaO-MgO-SiO2-Al2O3-Fet O-MnO-P2O5渣系中FetO和MnO活度的测定和研究[J].钢铁研究学报,1999,11(5):6-10.Mao H,Song B,Zhao B D,et al.Measurement and study on activities of Fet O and MnO in CaO-MgO-SiO2-Al2O3-Fet O-MnO-P2O5 slag system[J].Journal of Iron and Steel Research,1999,11(5):6-10.
[16]左君,严丽君,杨秀琴,等.响应曲面法优化超细氧化亚铜光催化降解对硝基苯酚[J].北京科技大学学报,2010,32(8):1045-1052.Zuo J,Yan L J,Yang X Q,et al.Photocatalytic degradation optimization of p-nitrophenol liquid by using ultrafine cuprous oxide with response surface methodology[J].Journal of University of Science and Technology Beijing,2010,32(8):1045-1052.
[17]周越,张利波,彭金辉,等.微波干燥锰碳合金球的响应曲面法优化[J].化学工程,2012,40(1):26-29.Zhou Y,Zhang L B,Peng J H,et al.Optimization of microwave drying of manganese-carbon alloy ball by using response surface methodology[J].Chemical Engineering,2012,40(1):26-29.
[2]杨福,毕学工,周进东.助熔剂种类与配比对高磷铁水脱磷渣高温性能的影响[J].武汉科技大学学报,2010,33(5):482-485.Yang F,Bi X G,Zhou J D.Influence of type and blending ratio of fluxing accelerating agent on high-temperature properties of dephosphorization slag in high phosphorus hot metal[J].Journal of Wuhan University of Science and Technology,2010,33(5):482-485.
[3]Mizukami H,Ishikawa M,Hirata T,et al.Dissolution mechanism of fluorine in aqueous solution from fluorine containing synthetic slag[J].ISIJ International,2004,44(3):623-629.
[4]周进东,毕学工,吴杰,等.高磷铁水预脱磷合理工艺的实验研究[J].过程工程学报,2011,11(1):50-55.Zhou J D,Bi X G,Wu J,et al.Experimental study on rational technology of dephosphorization pretreatment for high phosphorus content hot iron[J].The Chinese Journal of Process Engineering,2011,11(1):50-55.
[5]李杰,乐可襄.用CaO-Fe2O3-CaF2-Al2O3-Na2CO3熔剂进行铁水预处理脱磷的实验研究[J].安徽工业大学学报(自然科学版),2003,20(3):177-180.Li J,Yue K X.Study on dephosphorizing flux containing CaO-Fe2O3-CaF2-Al2O3-Na2CO3 for hot metal pretreatment[J].Journal of Anhui University of Technology(Natural Science Edition),2003,20(3):177-180.
[6]彭军,王世俊,刘丽霞,等.铁水预处理脱磷渣低氟化研究[J].特殊钢,2009,30(1):54-57.Peng J,Wang S J,Liu L X,et al.A study on dephosphorization of hot metal pretreatment by low fluoride slag[J].Special Steel,2009,30(1):54-57.
[7]Inoue R,Suito H.Mechanism of dephosphorization with CaO-SiO2-FetO slags containing mesoscopic scale 2CaO?SiO2particles[J].ISIJ International,2006,46(2):188-194.
[8]郭上型,董元篪,陈二保,等.向CaO基熔剂中添加Li2O,Na2O,K2O和BaO对钢水回磷控制效果的影响[J].钢铁研究学报,2001,13(4):6-9.Guo S X,Dong Y C,Chen E B,et al.Effect of adding Li2O,Na2O,K2O and BaO into lime-based fluxes on dephosphorization controlling of liquid steel[J].Journal of Iron and Steel Research,2001,13(4):6-9.
[9]曹战民,宋晓艳,乔芝郁.热力学模拟计算软件FactSage及其应用[J].稀有金属,2008,32(2):216-219.Cao Z M,Song X Y,Qiao Z Y.Thermodynamic modeling software FactSage and its application[J].Chinese Journal of Rare Metals,2008,32(2):216-219.
[10]张洪彪,董凌燕,陈登福,等.高磷铁水脱磷的热力学分析及实验研究[J].过程工程学报,2009,9(增刊1):137-141.Zhang H B,Dong L Y,Chen D F,et al.Thermodynamic analysis of dephosphorization for high phosphorus hot metal and experimental study[J].The Chinese Journal of Process Engineering,2009,9(S1):137-141.
[11]王永菲,王成国.响应面法的理论与应用[J].中央民族大学学报(自然科学版),2005,14(3):236-240.Wang Y F,Wang C G.The application of response surface methodology[J].Journal of the Central University for Nationalities(Natural Sciences Edition),2005,14(3):236-240.
[12]乐可襄,董元篪,王世俊.CaO-Fe2O3-CaF2铁水预处理脱磷熔剂的研究[J].炼钢,2001,17(1):48-50.Yue K X,Dong Y C,Wang S J.Study on dephosphorizing flux containing CaO-Fe2O3-CaF2 for hot metal pretreatment[J].Steelmaking,2001,17(1):48-50.
[13]徐颖,李明利,赵选民,等.响应曲面回归分析法-一种新的回归分析法在材料研究中的应用[J].稀有金属材料与工程,2001,30(6):428-432.Xu Y,Li M L,Zhao X M,et al.The response curved surface regression analysis technique-the application of a new regression analysis technique in materials research[J].Rare Metal Materials and Engineering,2001,30(6):428-432.
[14]徐冉,宋波,毛璟红.CaO-SiO2-Al2O3-MgO-TiO2钢渣体系熔化性能[J].北京科技大学学报,2010,32(11):1422-1427.Xu R,Song B,Mao J H.Melting performance of CaO-SiO2-Al2O3-MgO-TiO2 slag system[J].Journal of University of Science and Technology Beijing,2010,32(11):1422-1427.
[15]毛红,宋波,赵保东,等.CaO-MgO-SiO2-Al2O3-Fet O-MnO-P2O5渣系中FetO和MnO活度的测定和研究[J].钢铁研究学报,1999,11(5):6-10.Mao H,Song B,Zhao B D,et al.Measurement and study on activities of Fet O and MnO in CaO-MgO-SiO2-Al2O3-Fet O-MnO-P2O5 slag system[J].Journal of Iron and Steel Research,1999,11(5):6-10.
[16]左君,严丽君,杨秀琴,等.响应曲面法优化超细氧化亚铜光催化降解对硝基苯酚[J].北京科技大学学报,2010,32(8):1045-1052.Zuo J,Yan L J,Yang X Q,et al.Photocatalytic degradation optimization of p-nitrophenol liquid by using ultrafine cuprous oxide with response surface methodology[J].Journal of University of Science and Technology Beijing,2010,32(8):1045-1052.
[17]周越,张利波,彭金辉,等.微波干燥锰碳合金球的响应曲面法优化[J].化学工程,2012,40(1):26-29.Zhou Y,Zhang L B,Peng J H,et al.Optimization of microwave drying of manganese-carbon alloy ball by using response surface methodology[J].Chemical Engineering,2012,40(1):26-29.