重钢转炉复吹的模拟研究
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摘要
以重钢不同炉役期的转炉尺寸为依据,根据相似理论,设计制作1:8的复吹转炉模型、顶(底)喷枪的等温模拟模型。首次在模拟时考虑了转炉内气体喷出后温度升高而膨胀的非等温流动问题,并设计制作了顶(底)喷枪的非等温矫型模化模型。
通过冷态模型实验,研究了底吹供气强度对熔池搅拌混匀时间的影响、底吹喷枪堵塞问题对熔池搅拌混匀时间的影响,探讨了“钢-渣-气”乳化时的搅拌混匀问题、各因素对熔池喷溅量的影响、对熔池冲击深度的影响、熔体对砌体的冲刷作用。实验结果表明:
(1)采用完全几何相似的等温模拟方法实验,得出重钢转炉在整个炉役期内,合理的底吹供气强度在0.06～0.11m3/min.t范围内变化;而矫形模化方法实验,得出的底吹供气强度比完全几何相似模拟所需的底吹供气强度小,为0.04m3/min.t左右,且受枪位的变化和冶炼过程中不同时期(“钢液”和“钢+渣”)的影响较小。
(2)各种有底吹搅拌(全开和有部分堵塞)时的顶底复吹均比全堵(即只有纯顶吹)的混匀时间短,说明顶底复合吹炼的搅拌及冶金效果比纯粹的顶吹要好。顶底复吹时,当底吹喷枪有部分堵塞的偏心底吹搅拌效果比对称底吹搅拌的效果好,单一底吹搅拌作用效果最好。
(3)顶底复吹时,基本枪位下操作对熔池的搅拌混匀效果最好,混匀时间最短。在基本枪位以上一定范围内,混匀时间有所增加但增加不大。操作枪位过低,所需的混匀时间较长。
(4)在冶炼过程进入氧化脱碳期,“钢+渣+气”三者形成乳化熔体时,底吹供气强度或顶枪枪位等对熔池的搅拌混匀作用的影响比冶炼初期(“钢液”或“钢+渣”)弱,主要是因为在此阶段顶吹气流的搅拌作用和反应所形成的气体等的搅拌效果更强而占主导地位,搅拌混匀时间明显缩短。
(5)在基本枪位下,复吹转炉的底吹供气强度对喷溅量的影响不大,但过强的底吹供气强度会使复吹转炉的喷溅量增加。喷溅量随枪位的提高而增加,但当枪位提到一定程度继续提高枪位,顶吹气流对熔池的冲击能量下降,喷溅量降低。
(6)“钢+渣”乳化的情况下,流体对炉壁的冲刷作用明显高于相同位置处“钢液”的情况,而形成“钢+渣+气”乳化液后,顶吹气流引起的搅动对炉底的冲刷作用减弱,对炉壁(液位附近)的冲刷最严重。
建立了转炉复吹的数值模拟计算模型,利用PHOENICS V3.3软件对转炉熔
池内的流体流动进行了数值模拟,结果指出:
(1)在本模拟条件下,转炉熔池底部中心是底吹搅拌的死区,在“死区”中钢液流动迟缓,动力学条件差,将成为影响底吹搅拌混匀条件的限制性环节。
(2)当转炉生产进入中后期,在转炉炉底周边存在流动迟缓的“死区”,如果部分底吹喷枪被堵塞,底吹气流在转炉熔池内会引起非对称(扰动)流动。
(3)在转炉顶吹熔池底部中心,特别是熔池中上部距转炉轴中心0.5～0.7倍半径的区域相对于其它区域,形成了速度小流动迟缓的旋涡区、其动力学条件差,是顶吹搅拌的“死区”,在实际生产中应设法减少或消除该流动死区。
(4)复吹熔池内各截面上流动速度的总体分布与顶吹熔池的情况相近,但复吹熔池内的流动速度比顶吹时大,搅拌更强,对炉墙的冲刷作用也强得多。数学模拟说明,虽然底吹流股的流量、速度等参数相对于顶吹流股的对应参数小得多,但在熔池中所起的作用非常明显。
重钢炼钢厂采用转炉复吹工艺进行试生产研究,已取得初步效果,可创直接经济效益2.17元/吨。本文的研究结果对转炉不同炉役期复吹工艺的制定具有一定的指导意义,还可根据底吹喷枪的工作状况调整和优化复吹工艺,以期取得更好的经济效益。
Based on the converter dimension of different service lives in the Chongqing Iron and Steel Co. Ltd, according to the similarity theory, a combined blowing converter model and top (bottom) lance isothermal analog model are designed as the scale of 1:8. the non-isothermal flow caused by temperature lifting induced expansion after the aero blowing off in the converter is considered in the analog firstly, and the non-isothermal rectification analog models are built.
Through the cold model experiment, the bottom aero supplied strength and the bottom lance blocked influences on the stirring uniform time of the molten bath are studied. The stirring uniform time, all factors’ influence on the amount of splash , and the influence on the attacked depth, the molten bath erosion effect on the bricking-up are discussed. And the experiments’ results show that:
(1) Adoptting the completed geometric similarity isothermal analog method, the experiments are carried out. And the conclusions are obtained as below: the reasonable bottom aero supplied strength for the Chongqing Iron and Steel Co. Ltd’s converter whole service lives is between the 0.06 m3/min.t and 0.11 m3/min.t. and through the experiment applying the rectification analog method, the conclusion of the bottom aero supplied strength less than the completed geometric similarity, the value is about 0.04m3/min.t and effected by the lance position’s change and the phase of different smelting process slightly.
(2)The stirring uniform time under the entirely open or partial blocked combined blowing stirring needed time shorter than under the conditions of the only top blown, namely the bottom supplied aero blocked completed. The results show that the stirring and metallurgy effectiveness under the condition of combined blown are better than that of the only top blown; and under the combined blown conditions, the stirring effectiveness when the decentration bottom lance blocked partial are better than that under the condition of the symmetry bottom, and the bottom blown without the top blown has the best stirring effectiveness.
(3)Under the condition of combined blown, the stirring effectiveness under the fundamental position is the best and the stirring uniform needed time is the least. Above the basic lance position of given range, the stirring uniform time increase slowly. And the stirring uniform needed time is longer under the condition of the
over-low lance position.
(4)When the smelting process enter into the oxygenizing decarbonization stage, the steel, slag, and aero form emulsifying molten bath, the bottom aero supplied strength or the lance position’s influence on the stirring uniform is weaker than that at the time of early smelt stage. the main reasons are that the top blown aero flow has stronger stirring effect and position the dominant place, so that stirring uniform needed time cut down obviously.
(5)Under the basic lance position, the bottom blowing aero supplied strength has trivial effect, but the extreme strong supplied aero can increase the converter’s splash. And the amount of splash rising as the lance position lifting, but when the lance position raised to given degree, the top blown’s impact energy on the molten bath fall down, and the amount of splash reduce.
(6) The fluid erosion effect on the converter wall is higher than that of the molten steel at the same position under the condition of steel and slag emulsifying. After forming the steel, slag, aero emulsification, the erosion effect on the bottom of the converter caused by the top blown weaken, and the erosion on the converter is the most serious.
The simulation computing models are established, and the fluid-flow simulation are carried out applying the PHOENICS software. The results are listed as following.
(1)Under the simulation condition, the center of the converter bottom is the bottom blown stirring dead zone, and the dead zone ,in which the molten steel flow slowly and the dynamics conditions are bad, become the restrictive segment of the condition for the bott
通过冷态模型实验,研究了底吹供气强度对熔池搅拌混匀时间的影响、底吹喷枪堵塞问题对熔池搅拌混匀时间的影响,探讨了“钢-渣-气”乳化时的搅拌混匀问题、各因素对熔池喷溅量的影响、对熔池冲击深度的影响、熔体对砌体的冲刷作用。实验结果表明:
(1)采用完全几何相似的等温模拟方法实验,得出重钢转炉在整个炉役期内,合理的底吹供气强度在0.06～0.11m3/min.t范围内变化;而矫形模化方法实验,得出的底吹供气强度比完全几何相似模拟所需的底吹供气强度小,为0.04m3/min.t左右,且受枪位的变化和冶炼过程中不同时期(“钢液”和“钢+渣”)的影响较小。
(2)各种有底吹搅拌(全开和有部分堵塞)时的顶底复吹均比全堵(即只有纯顶吹)的混匀时间短,说明顶底复合吹炼的搅拌及冶金效果比纯粹的顶吹要好。顶底复吹时,当底吹喷枪有部分堵塞的偏心底吹搅拌效果比对称底吹搅拌的效果好,单一底吹搅拌作用效果最好。
(3)顶底复吹时,基本枪位下操作对熔池的搅拌混匀效果最好,混匀时间最短。在基本枪位以上一定范围内,混匀时间有所增加但增加不大。操作枪位过低,所需的混匀时间较长。
(4)在冶炼过程进入氧化脱碳期,“钢+渣+气”三者形成乳化熔体时,底吹供气强度或顶枪枪位等对熔池的搅拌混匀作用的影响比冶炼初期(“钢液”或“钢+渣”)弱,主要是因为在此阶段顶吹气流的搅拌作用和反应所形成的气体等的搅拌效果更强而占主导地位,搅拌混匀时间明显缩短。
(5)在基本枪位下,复吹转炉的底吹供气强度对喷溅量的影响不大,但过强的底吹供气强度会使复吹转炉的喷溅量增加。喷溅量随枪位的提高而增加,但当枪位提到一定程度继续提高枪位,顶吹气流对熔池的冲击能量下降,喷溅量降低。
(6)“钢+渣”乳化的情况下,流体对炉壁的冲刷作用明显高于相同位置处“钢液”的情况,而形成“钢+渣+气”乳化液后,顶吹气流引起的搅动对炉底的冲刷作用减弱,对炉壁(液位附近)的冲刷最严重。
建立了转炉复吹的数值模拟计算模型,利用PHOENICS V3.3软件对转炉熔
池内的流体流动进行了数值模拟,结果指出:
(1)在本模拟条件下,转炉熔池底部中心是底吹搅拌的死区,在“死区”中钢液流动迟缓,动力学条件差,将成为影响底吹搅拌混匀条件的限制性环节。
(2)当转炉生产进入中后期,在转炉炉底周边存在流动迟缓的“死区”,如果部分底吹喷枪被堵塞,底吹气流在转炉熔池内会引起非对称(扰动)流动。
(3)在转炉顶吹熔池底部中心,特别是熔池中上部距转炉轴中心0.5～0.7倍半径的区域相对于其它区域,形成了速度小流动迟缓的旋涡区、其动力学条件差,是顶吹搅拌的“死区”,在实际生产中应设法减少或消除该流动死区。
(4)复吹熔池内各截面上流动速度的总体分布与顶吹熔池的情况相近,但复吹熔池内的流动速度比顶吹时大,搅拌更强,对炉墙的冲刷作用也强得多。数学模拟说明,虽然底吹流股的流量、速度等参数相对于顶吹流股的对应参数小得多,但在熔池中所起的作用非常明显。
重钢炼钢厂采用转炉复吹工艺进行试生产研究,已取得初步效果,可创直接经济效益2.17元/吨。本文的研究结果对转炉不同炉役期复吹工艺的制定具有一定的指导意义,还可根据底吹喷枪的工作状况调整和优化复吹工艺,以期取得更好的经济效益。
Based on the converter dimension of different service lives in the Chongqing Iron and Steel Co. Ltd, according to the similarity theory, a combined blowing converter model and top (bottom) lance isothermal analog model are designed as the scale of 1:8. the non-isothermal flow caused by temperature lifting induced expansion after the aero blowing off in the converter is considered in the analog firstly, and the non-isothermal rectification analog models are built.
Through the cold model experiment, the bottom aero supplied strength and the bottom lance blocked influences on the stirring uniform time of the molten bath are studied. The stirring uniform time, all factors’ influence on the amount of splash , and the influence on the attacked depth, the molten bath erosion effect on the bricking-up are discussed. And the experiments’ results show that:
(1) Adoptting the completed geometric similarity isothermal analog method, the experiments are carried out. And the conclusions are obtained as below: the reasonable bottom aero supplied strength for the Chongqing Iron and Steel Co. Ltd’s converter whole service lives is between the 0.06 m3/min.t and 0.11 m3/min.t. and through the experiment applying the rectification analog method, the conclusion of the bottom aero supplied strength less than the completed geometric similarity, the value is about 0.04m3/min.t and effected by the lance position’s change and the phase of different smelting process slightly.
(2)The stirring uniform time under the entirely open or partial blocked combined blowing stirring needed time shorter than under the conditions of the only top blown, namely the bottom supplied aero blocked completed. The results show that the stirring and metallurgy effectiveness under the condition of combined blown are better than that of the only top blown; and under the combined blown conditions, the stirring effectiveness when the decentration bottom lance blocked partial are better than that under the condition of the symmetry bottom, and the bottom blown without the top blown has the best stirring effectiveness.
(3)Under the condition of combined blown, the stirring effectiveness under the fundamental position is the best and the stirring uniform needed time is the least. Above the basic lance position of given range, the stirring uniform time increase slowly. And the stirring uniform needed time is longer under the condition of the
over-low lance position.
(4)When the smelting process enter into the oxygenizing decarbonization stage, the steel, slag, and aero form emulsifying molten bath, the bottom aero supplied strength or the lance position’s influence on the stirring uniform is weaker than that at the time of early smelt stage. the main reasons are that the top blown aero flow has stronger stirring effect and position the dominant place, so that stirring uniform needed time cut down obviously.
(5)Under the basic lance position, the bottom blowing aero supplied strength has trivial effect, but the extreme strong supplied aero can increase the converter’s splash. And the amount of splash rising as the lance position lifting, but when the lance position raised to given degree, the top blown’s impact energy on the molten bath fall down, and the amount of splash reduce.
(6) The fluid erosion effect on the converter wall is higher than that of the molten steel at the same position under the condition of steel and slag emulsifying. After forming the steel, slag, aero emulsification, the erosion effect on the bottom of the converter caused by the top blown weaken, and the erosion on the converter is the most serious.
The simulation computing models are established, and the fluid-flow simulation are carried out applying the PHOENICS software. The results are listed as following.
(1)Under the simulation condition, the center of the converter bottom is the bottom blown stirring dead zone, and the dead zone ,in which the molten steel flow slowly and the dynamics conditions are bad, become the restrictive segment of the condition for the bott
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Luomala Matti J., Fabritius Timo M.J., Virtanen Esa O.. Physical model study of selective slag splashing in the BOF. ISIJ International, 2002, 42(11): 1219-1224.
倪红卫, 喻淑仁, 颜建新. 90t复吹转炉溅渣护炉水模试验研究. 武汉科技大学学报(自然科学版), 2002, 25(2): 120-123.
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V. B. Okhotskii. Models for local wear of the lining of a converter. Refractories and industrial ceramics, 2001, 42(11-12):411-416.
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C. Blanco, M. Diaz. Model of Mixed Control for Carbon and Silicon in a Steel Converter. ISIJ International, 1993, 33 (7): 757-763.
Taqo Yukari, Hiquchi Yoshihiko. Fluid flow analysis of jets from nozzles in top blown process. ISIJ International, 2003, 43(2): 209-215.
Gruner H., Wiemer H.E., Fix W.. New metallurgical insight into BOF steelmaking and improved process control using sublance techniques and bottom gas stirring. Iron & Steelmaker, 1985, 12(3): 31-36.
魏伟胜, 蔡志鹏, 肖忠敏. 喷射精炼过程炉衬侵蚀模拟研究(Ⅳ). 化工冶金, 1994, 15(4): 289-294.
何平, 张莱平, 梅洪生. 底吹电弧炉水力学模型实验研究. 化工冶金, 1994, 15(2): 110-114.
朱红波, 和秋昆, 谢蕴国. 复吹转炉底部耐火材料浸蚀情况的冷态模拟研究. 昆明理工大学学报, 1996, 21(6): 118-122.
潘玉华, 马萍. 复吹转炉底吹气流数学模型研究. 钢铁, 1994, 29(5): 17-21.
李保卫, 贺友多, Y. Sahai. 顶吹转炉内二次燃烧初期的一个数学模型. 金属学报, 1996, 32(2): 169-174.
李保卫, 贺友多, Y. Sahai. 顶吹转炉内金属液滴的产生、运动及传热的数学模型. 金属学报, 1995, 31(4): B146-B152.
李保卫, 贺友多. 氧气顶吹转炉二次燃烧过程中的传热. 北京科技大学学报, 1995, 17(增刊): 57-60.
张捷宇, 贺友多, Y.Sahai. 氧气顶吹转炉中的两相流流动. 燃烧科学与技术, 2000, 6(2): 115-119.
张雪峰, 李保卫, 徐楚韶. 氧气顶吹转炉中泡沫渣内部2次燃烧的数学模型. 燃烧科学与技术, 1998, 4(2): 137-143.
王庆祥. 转炉吹氧炼钢去碳过程模型的研究. 炼钢, 1996, (4): 40-44.
李伟, 贺友多. 转炉底吹气体过程中的三维数学模型. 包头钢铁学院学报, 1994, 13(1): 45-48.
章博, 邹家祥, 陈军. 溅渣护炉状态下转炉温度场的模拟分析. 重型机械, 1999, (2): 27-31.
任学平, 关丽坤, 邹家祥. 转炉炉壳的蠕变变形模型. 特殊钢, 2002, 23(6): 21-23.
任学平, 郭志强, 邹家祥. 转炉炉壳热应力分析. 炼钢, 2001, 17(6): 47-49.
崔宏伟, 吴懋林. 转炉炉体温度场分析. 矿冶, 1999, 8(4): 41-45.
程向明, 何平, 张荣生. 转炉型反应器内熔池传热的研究. 钢铁研究学报, 1994, 6(增刊): 53-57.
郑颖, 李春雷, 佟溥翘. 包钢80t复吹转炉溅渣护炉工艺实践. 钢铁, 2001, 36(8): 12-15.
郑颖, 杨富强. 包钢80t复吹转炉的冶金效果分析. 包钢科技, 2000, 26(1): 14-18.
蒋晓放. 宝钢300t转炉复吹现状与发展. 宝钢技术, 2002, (3): 1-5.
刘浏, 佟溥翘, 喻承欢. 长寿复吹转炉工艺技术开发. 钢铁, 2002, 37(10): 13-15.
徐静波, 佟溥翘. 复吹转炉在溅渣下的长寿复吹效果. 炼钢, 2002, 18(3): 6-10.
郑颖, 蒋宏, 李解. 溅渣护炉工艺条件下转炉复吹浅析. 包钢科技, 2000, 26(4): 20-22.