高炉板壁结合冷却器破损原因解析
|
摘要
高炉长寿已经成为当代炼铁技术进步的重要组成部分,提高高炉冷却设备寿命是保障高炉长寿的关键环节。为分析板壁结合冷却壁破损的本质原因,从而给冷却器结构优化设计及安全生产提供有效指导,通过建立流体-热-结构多场耦合模型,基于传热理论和有限元数值模拟,解析了板壁结合冷却体系流场、温度场、应力场分布特征。结合高炉实际案例,系统分析了板壁结合冷却器破损的本质原因,指出冷却器破损的具体部位,验证了模拟分析结果的准确性。研究结果表明,高炉冷却板前端两侧部位及冷却壁水管层流底层是冷却系统的薄弱环节,在同等冷却条件下,该区域温度高于其他部位4.5℃;冷却板前端变形量最大,达到2 mm;生产高炉用焦炭质量M10、M40大幅波动从而导致渣皮频繁脱落是造成冷却板破损的主要原因。
Blast furnace longevity has become an important part of the progress of modern ironmaking technology. Improving furnace cooling equipment life is one of the key factors to ensure the longevity. To figure out the damage cause to the stave-plate compound cooling system and provide effective guidance for the optimal design of cooler structures and safe production,a fluid-thermal-structural coupling model was developed according to the actual size. Based on the heat transfer theory and the finite element numerical simulation,the distribution characteristics of flow field,temperature field and stress field were analyzed. Combined with the actual case of blast furnace,the essential reasons of the damage were systematically studied and the specific damaged parts were pointed out. The accuracy of the simulation analysis results is verified by the real-time recorded temperature data of a commercial blast furnace. The results show that the front two sides of the cooling plate and laminar sublayer in the water pipes are the weak link of the cooling system. Under the same condition,the temperature in the front two sides of the cooling plate is higher than that of other parts at 4.5 ℃. The deformation of the front end of the cooling plate is the largest,reaching 2 mm. The main reasons for the breakage of the cooling plate is the frequent falling of the slag skin caused by the large fluctuation of the coke quality M10 and M40 index in the production of the blast furnace.
Blast furnace longevity has become an important part of the progress of modern ironmaking technology. Improving furnace cooling equipment life is one of the key factors to ensure the longevity. To figure out the damage cause to the stave-plate compound cooling system and provide effective guidance for the optimal design of cooler structures and safe production,a fluid-thermal-structural coupling model was developed according to the actual size. Based on the heat transfer theory and the finite element numerical simulation,the distribution characteristics of flow field,temperature field and stress field were analyzed. Combined with the actual case of blast furnace,the essential reasons of the damage were systematically studied and the specific damaged parts were pointed out. The accuracy of the simulation analysis results is verified by the real-time recorded temperature data of a commercial blast furnace. The results show that the front two sides of the cooling plate and laminar sublayer in the water pipes are the weak link of the cooling system. Under the same condition,the temperature in the front two sides of the cooling plate is higher than that of other parts at 4.5 ℃. The deformation of the front end of the cooling plate is the largest,reaching 2 mm. The main reasons for the breakage of the cooling plate is the frequent falling of the slag skin caused by the large fluctuation of the coke quality M10 and M40 index in the production of the blast furnace.
引文
[1]焦克新,张建良,左海滨,等.长寿高炉炉缸冷却系统的深入探讨[J].中国冶金,2014,24(4):16.(JIAO Ke-xin,ZHANG Jian-liang,ZUO Hai-bin,et al.In-depth discussion of cooling system of long campaign blast furnace[J].China Metallurgy,2014,24(4):16.)
[2]李峰光,张建良.基于ANSYS“生死单元”技术的铜冷却壁挂渣能力计算模型[J].工程科学学报,2016,38(4):546.(LI Feng-guang,ZHANG Jian-liang.Calculation model of the adherent dross capacity of copper staves based on ANSYS birthdeath element technology[J].International Journal of Minerals,Metallurgy and Materials,2016,38(4):546.)
[3]程树森,杨天钧,左海滨,等.高炉炉身下部及炉缸、炉底冷却系统的传热学计算[J].钢铁研究学报,2004,16(5):10.(CHENG Shu-sen,YANG Tian-jun,ZUO Hai-bin,et al.Design of lower shaft and hearth bottom for long campaign blast furnace[J].Journal of Iron and Steel Research,2004,16(5):10.)
[4]左海滨,洪军,张建良,等.不同工况下各种材质高炉冷却壁温度场数值模拟[J].武汉科技大学学报,2014,37(2):102.(ZUO Hai-bin,HONG Jun,ZHANG Jian-liang,et al.Numerical simulation of temperature field of BF cooling staves of different materials under different conditions[J].Journal of Wuhan University of Science and Technology,2014,37(2):102.)
[5]Huan Y W,Lei L P,Fang G,et al.Thermo-mechanical coupling finite element analysis of blast furnace copper stave[J].Metallurgical Equipment,2009,3:45.
[6]邓凯,程惠尔,吴俐俊,等.结构参数对高炉冷却壁温度场及热应力分布的影响[J].钢铁研究学报,2006,18(2):1.(DENG Kai,CHENG Hue-er,WU Li-jun,et al.Influence of structural parameters on temperature field and thermal stress of BF cooling stave[J].Journal of Iron and Steel Research,2006,18(2):1.)
[7]Manmohan S,Sankalp V.Thermal analysis of blast furnace cooling stave using CFD[J].International Journal of Innovative Technology and Exploring Engineering,2014(2):10.
[8]Anil K,Shiv N B,Rituraj C.Computational modeling of blast furnace cooling stave based on heat transfer analysis[J].Materials Physics and Mechanics,2012,15:46.
[9]刘增勋.高炉冷却壁热力耦合分析[D].沈阳:东北大学,2009.(LIU Zeng-xun.Coupled Thermo-Mechanical Analysis About Blast Furnace Staves[D].Shenyang:Northeastern University,2009.)
[10]刘奇,程树森,牛建平.高炉铜冷却壁水管热应力分析[J].重庆大学学报,2015,38(2):17.(LIU Qi,CHENG Shu-sen,NIU Jian-ping.Analysis of thermal stress in a water pipe of blast furnace copper stave[J].Journal of Chongqing University,2015,38(2):17.)
[11]焦克新,张建良,左海滨,等.高炉冷却壁非稳态传热热态实验分析[J].钢铁,2014,49(12):13.(JIAO Ke-xin,ZHANG Jian-liang,ZUO Hai-bin.Thermal trial analysis on unsteady heat transfer for blast furnace cooling stave[J].Iron and Steel,2014,49(12):13.)
[12]Adity Ganguly,Srinivas Reddy A,Ashok Kumar.Process visualization and diagnostic models using real time data of blast furnaces at tata steel[J].ISIJ International,2010(50):1010.
[13]Choi S W,Yoo J L,Choi T H,et al.Measuring thickness of the copper stave in blast furnace using ultrasonic technique in cooling line[J].International Conference on Control,Automation and Systems,2010,10:330.
[14]Choi S W,Kim D.On-line ultrasonic system for measuring thickness of the copper stave in the blast furnace[C]//AIP Conference Proceeding.[S.l.]:American Institute of Physics,2012:1715.
[15]CHENG Peng,CHUNG Ken.Conjugate heat transfer analysis of copper staves and sensor bars in a blast furnace for various refractory lining thickness[J].International Communications in Heat and Mass Transfer,2011,39(1):58.
[16]张少杰.浅谈高炉用冲压焊接冷却板的损坏原因及改进[J].中国冶金,2016,26(3):39.(ZHANG Shao-jie.Damage reason and improvement of stamping and welding cooling plate for blast furnace[J].China Metallurgy,2016,26(3):39.)
[17]康磊,车玉满,王宝海,等.高炉铜冷却壁取样研究及破损原因分析[J].钢铁,2014,49(12):28.(KANG Lei,CHE Yuman,WANG Bao-hai,et al.Damage reason analysis of BF copper stave[J].Iron and Steel,2014,49(12):28.)
[2]李峰光,张建良.基于ANSYS“生死单元”技术的铜冷却壁挂渣能力计算模型[J].工程科学学报,2016,38(4):546.(LI Feng-guang,ZHANG Jian-liang.Calculation model of the adherent dross capacity of copper staves based on ANSYS birthdeath element technology[J].International Journal of Minerals,Metallurgy and Materials,2016,38(4):546.)
[3]程树森,杨天钧,左海滨,等.高炉炉身下部及炉缸、炉底冷却系统的传热学计算[J].钢铁研究学报,2004,16(5):10.(CHENG Shu-sen,YANG Tian-jun,ZUO Hai-bin,et al.Design of lower shaft and hearth bottom for long campaign blast furnace[J].Journal of Iron and Steel Research,2004,16(5):10.)
[4]左海滨,洪军,张建良,等.不同工况下各种材质高炉冷却壁温度场数值模拟[J].武汉科技大学学报,2014,37(2):102.(ZUO Hai-bin,HONG Jun,ZHANG Jian-liang,et al.Numerical simulation of temperature field of BF cooling staves of different materials under different conditions[J].Journal of Wuhan University of Science and Technology,2014,37(2):102.)
[5]Huan Y W,Lei L P,Fang G,et al.Thermo-mechanical coupling finite element analysis of blast furnace copper stave[J].Metallurgical Equipment,2009,3:45.
[6]邓凯,程惠尔,吴俐俊,等.结构参数对高炉冷却壁温度场及热应力分布的影响[J].钢铁研究学报,2006,18(2):1.(DENG Kai,CHENG Hue-er,WU Li-jun,et al.Influence of structural parameters on temperature field and thermal stress of BF cooling stave[J].Journal of Iron and Steel Research,2006,18(2):1.)
[7]Manmohan S,Sankalp V.Thermal analysis of blast furnace cooling stave using CFD[J].International Journal of Innovative Technology and Exploring Engineering,2014(2):10.
[8]Anil K,Shiv N B,Rituraj C.Computational modeling of blast furnace cooling stave based on heat transfer analysis[J].Materials Physics and Mechanics,2012,15:46.
[9]刘增勋.高炉冷却壁热力耦合分析[D].沈阳:东北大学,2009.(LIU Zeng-xun.Coupled Thermo-Mechanical Analysis About Blast Furnace Staves[D].Shenyang:Northeastern University,2009.)
[10]刘奇,程树森,牛建平.高炉铜冷却壁水管热应力分析[J].重庆大学学报,2015,38(2):17.(LIU Qi,CHENG Shu-sen,NIU Jian-ping.Analysis of thermal stress in a water pipe of blast furnace copper stave[J].Journal of Chongqing University,2015,38(2):17.)
[11]焦克新,张建良,左海滨,等.高炉冷却壁非稳态传热热态实验分析[J].钢铁,2014,49(12):13.(JIAO Ke-xin,ZHANG Jian-liang,ZUO Hai-bin.Thermal trial analysis on unsteady heat transfer for blast furnace cooling stave[J].Iron and Steel,2014,49(12):13.)
[12]Adity Ganguly,Srinivas Reddy A,Ashok Kumar.Process visualization and diagnostic models using real time data of blast furnaces at tata steel[J].ISIJ International,2010(50):1010.
[13]Choi S W,Yoo J L,Choi T H,et al.Measuring thickness of the copper stave in blast furnace using ultrasonic technique in cooling line[J].International Conference on Control,Automation and Systems,2010,10:330.
[14]Choi S W,Kim D.On-line ultrasonic system for measuring thickness of the copper stave in the blast furnace[C]//AIP Conference Proceeding.[S.l.]:American Institute of Physics,2012:1715.
[15]CHENG Peng,CHUNG Ken.Conjugate heat transfer analysis of copper staves and sensor bars in a blast furnace for various refractory lining thickness[J].International Communications in Heat and Mass Transfer,2011,39(1):58.
[16]张少杰.浅谈高炉用冲压焊接冷却板的损坏原因及改进[J].中国冶金,2016,26(3):39.(ZHANG Shao-jie.Damage reason and improvement of stamping and welding cooling plate for blast furnace[J].China Metallurgy,2016,26(3):39.)
[17]康磊,车玉满,王宝海,等.高炉铜冷却壁取样研究及破损原因分析[J].钢铁,2014,49(12):28.(KANG Lei,CHE Yuman,WANG Bao-hai,et al.Damage reason analysis of BF copper stave[J].Iron and Steel,2014,49(12):28.)