全氢罩式炉退火工艺设备的仿真与优化
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摘要
全氢炉是一种使用很广泛的用于带钢冷轧后退火处理的工业炉，自从我国从二十世纪五十年代引进制造第一台冷轧钢卷罩式炉以来，罩式炉在国内经历了由引进消化国外产品，变成现在的自主设计制造生产。但是全氢炉在国内的设计应用以及自行改造等方面仍然存在一些制约性的难题：带钢退火质量不好，容易出现钢卷的粘结和氧化色现象，钢卷的全氢炉退火工艺曲线目前大部分只能依靠生产经验来制定，没有一个科学合理的制定与评价方法。针对这些问题，本文以全氢炉为对象，对全氢炉退火工艺的仿真与优化进行了研究。
本文首先对国内外全氢炉的发展过程进行了综述，并对国内外全氢炉在退火工艺曲线的制定方法、退火过程中出现的问题等各方面的研究工作进行了分析和评价，为本文的后续研究工作奠定了基础，本文从以下方面进行了研究：
首先对全氢炉的结构进行了介绍，并分析了全氢炉的工作流程，以及全氢炉的使用中经常出现的内罩破损等现象，然后使用计算机数值模拟的方法对全氢炉内加热过程的燃烧空间进行了数值仿真，数值仿真的结果显示，常见全氢炉加热罩中，燃烧器分两层均匀布置在加热罩下部，这使全氢炉燃烧空间下部对应高度位置出现局部高温区，这使得内罩温度分布不均匀，下部高温区对应的位置容易损坏，如果将燃烧器分为多排，均匀分散布置在加热罩上，则可以减小加热空间内不同高度位置的温差，使温度分布更加均匀，有利于内罩向钢卷的传热。
本文接着对全氢炉工作过程进行了能量耦合分析，然后根据其工作过程的特点分别建立了全氢炉炉气传热模型、全氢炉加热罩传热模型、全氢炉内罩传热模型、全氢炉保护性氢气传热模型与流动模型、全氢炉冷却罩传热模型和全氢炉钢卷温度计算模型。接着本文根据建立的全氢炉退火过程中的各个数学模型，设计了全氢炉数字化仿真平台，该仿真平台可根据已有的钢卷退火过程各阶段的时间计算得到钢卷在退火过程中的温度场变化，或者根据钢卷退火的温度需求计算得到钢卷退火过程各阶段的时长。本文用现场试验数据对程序计算的结果进行了检验，结果表明，该全氢炉数字化仿真平台计算得到的结果是可靠合理的。
针对目前在冷轧厂广泛存在的全氢炉退火后钢卷粘结与氧化色缺陷，本文对其产生的原因分别进行了分析和总结，并结合在某冷轧厂的现场插片试验数据进行了分析，结果表明，钢卷退火工艺曲线设置不合理，钢卷退火过程中热应力过大是造成钢卷粘结的主要原因，钢卷出炉过早是引起氧化色的主要原因。
在本文最后，将蓄热式燃烧技术应用到全氢炉上，设计了一种新型的全氢炉加热罩。将全氢炉上原有的燃烧器系统、热管式换热器系统更改为蓄热式燃烧器，分散布置在加热罩上。该新型全氢炉加热罩的优点是节省燃料，燃烧室温度均匀，钢卷退火质量好，内罩寿命长。
The full-hydrogen annealer furnace is a widely used industrial furnace for steel stripannealing after cold rolling. Since the first rolled scroll bell furnace was introduced andmanufactured in the1950s, bell furnace in our country has changed from introducing andassimilate foreign products to independent design and manufacture. But some restrictiveproblem still exists in design and application as well as improvement of full-hydrogenannealer furnace: pool annealing quality, prone to appear bonding and oxidation colorphenomenon of the steel coil, the full-hydrogen annealer furnace annealing curve of thesteel coil can only rely on production experience to formulate at present, without a scientificand reasonable formulation and evaluation method. To solve these problems, studies areconducted on simulation and optimization of annealing process of full-hydrogen bellfurnace.
The development of the full-hydrogen bell furnace domestic and overseas was reviewed inthis paper, and various aspects of the research work are analyzed and assessed, such asannealing process curve formulation method, problems occur in the annealing process andso on, which laid the foundation for the subsequent research. Then, studies are conductedfrom the following aspects:
First the structure of the full-hydrogen annealer furnace is introduced and the workingprocess of the full-hydrogen annealer furnace and phenomenons often appear during usagesuch as inner cover breakage is analysised. Then the computer numerical calculationmethod was used to simulate the combustion space of the heating process of thefull-hydrogen annealer furnace. Numerical simulation results show that the existingcommon full-hydrogen annealer furnace burner is divided into two layer uniformarrangement in the burner lower, this causes full-hydrogen annealer furnace combustionspace corresponding lower appear local high temperature region, which makes the innercover uneven distribution of temperature, easy to cause damage. If the burner is divided intomultiple rows of evenly dispersed layout in heating hood, then can reduce the temperaturedifference in different height position of the furnace, make temperature distribution moreuniform, which is good for the inner cover to transfer heat to steel coil.
Then the energy coupling analysis has been made on the working process of thefull-hydrogen annealer furnace, and temperature calculation model, heating covertemperature calculation model, cover temperature calculation model, protective hydrogen temperature calculation model, cooling cover temperature calculation model and steel rolltemperature calculation model of the full-hydrogen annealer furnace are establishedaccording to the characteristics of its working process. Then according to all kinds of theestablished full-hydrogen annealer furnace mathematical model of annealing process,designed annealing curve formulate program, this program can be realized on the basis ofthe existing steel coil annealing process each phase time calculation for steel coil in theprocess of annealing temperature, or according to the steel coil annealing temperaturecalculated demand of steel coils annealing process of each stage duration. This article testedthe result of the computation program with the field test data, and the results indicate that,this full-hydrogen annealer furnace annealing curve formulate program for the calculationof the result is reliable and reasonable.
For the steel roll bonding and oxidation color defect that is now widely existing in thefull-hydrogen annealer furnace, the reasons were analyzed and summarized in this paper,and analyzed with the test data got in a insert experiment, indicate that, steel coil annealingprocess curve set is not reasonable, and steel coil annealing process of thermal stress is themain reason cause steel roll bonding. And steel roll are premature is the main reason causeoxidation color.
In the end of this article, regenerative cross combustion technology is applied tofull-hydrogen annealer furnace, a new type of full-hydrogen annealer furnace heating coveris designed. The original burner system, heat pipe heat exchanger system of thefull-hydrogen annealer furnace is changed to regenerative burner, scattered layout in heatinghood. The advantages of the new full-hydrogen annealer furnace heating cover are save fuel,combustion chamber temperature uniformity, steel coil annealing are of good quality andinner covers have long life.
本文首先对国内外全氢炉的发展过程进行了综述，并对国内外全氢炉在退火工艺曲线的制定方法、退火过程中出现的问题等各方面的研究工作进行了分析和评价，为本文的后续研究工作奠定了基础，本文从以下方面进行了研究：
首先对全氢炉的结构进行了介绍，并分析了全氢炉的工作流程，以及全氢炉的使用中经常出现的内罩破损等现象，然后使用计算机数值模拟的方法对全氢炉内加热过程的燃烧空间进行了数值仿真，数值仿真的结果显示，常见全氢炉加热罩中，燃烧器分两层均匀布置在加热罩下部，这使全氢炉燃烧空间下部对应高度位置出现局部高温区，这使得内罩温度分布不均匀，下部高温区对应的位置容易损坏，如果将燃烧器分为多排，均匀分散布置在加热罩上，则可以减小加热空间内不同高度位置的温差，使温度分布更加均匀，有利于内罩向钢卷的传热。
本文接着对全氢炉工作过程进行了能量耦合分析，然后根据其工作过程的特点分别建立了全氢炉炉气传热模型、全氢炉加热罩传热模型、全氢炉内罩传热模型、全氢炉保护性氢气传热模型与流动模型、全氢炉冷却罩传热模型和全氢炉钢卷温度计算模型。接着本文根据建立的全氢炉退火过程中的各个数学模型，设计了全氢炉数字化仿真平台，该仿真平台可根据已有的钢卷退火过程各阶段的时间计算得到钢卷在退火过程中的温度场变化，或者根据钢卷退火的温度需求计算得到钢卷退火过程各阶段的时长。本文用现场试验数据对程序计算的结果进行了检验，结果表明，该全氢炉数字化仿真平台计算得到的结果是可靠合理的。
针对目前在冷轧厂广泛存在的全氢炉退火后钢卷粘结与氧化色缺陷，本文对其产生的原因分别进行了分析和总结，并结合在某冷轧厂的现场插片试验数据进行了分析，结果表明，钢卷退火工艺曲线设置不合理，钢卷退火过程中热应力过大是造成钢卷粘结的主要原因，钢卷出炉过早是引起氧化色的主要原因。
在本文最后，将蓄热式燃烧技术应用到全氢炉上，设计了一种新型的全氢炉加热罩。将全氢炉上原有的燃烧器系统、热管式换热器系统更改为蓄热式燃烧器，分散布置在加热罩上。该新型全氢炉加热罩的优点是节省燃料，燃烧室温度均匀，钢卷退火质量好，内罩寿命长。
The full-hydrogen annealer furnace is a widely used industrial furnace for steel stripannealing after cold rolling. Since the first rolled scroll bell furnace was introduced andmanufactured in the1950s, bell furnace in our country has changed from introducing andassimilate foreign products to independent design and manufacture. But some restrictiveproblem still exists in design and application as well as improvement of full-hydrogenannealer furnace: pool annealing quality, prone to appear bonding and oxidation colorphenomenon of the steel coil, the full-hydrogen annealer furnace annealing curve of thesteel coil can only rely on production experience to formulate at present, without a scientificand reasonable formulation and evaluation method. To solve these problems, studies areconducted on simulation and optimization of annealing process of full-hydrogen bellfurnace.
The development of the full-hydrogen bell furnace domestic and overseas was reviewed inthis paper, and various aspects of the research work are analyzed and assessed, such asannealing process curve formulation method, problems occur in the annealing process andso on, which laid the foundation for the subsequent research. Then, studies are conductedfrom the following aspects:
First the structure of the full-hydrogen annealer furnace is introduced and the workingprocess of the full-hydrogen annealer furnace and phenomenons often appear during usagesuch as inner cover breakage is analysised. Then the computer numerical calculationmethod was used to simulate the combustion space of the heating process of thefull-hydrogen annealer furnace. Numerical simulation results show that the existingcommon full-hydrogen annealer furnace burner is divided into two layer uniformarrangement in the burner lower, this causes full-hydrogen annealer furnace combustionspace corresponding lower appear local high temperature region, which makes the innercover uneven distribution of temperature, easy to cause damage. If the burner is divided intomultiple rows of evenly dispersed layout in heating hood, then can reduce the temperaturedifference in different height position of the furnace, make temperature distribution moreuniform, which is good for the inner cover to transfer heat to steel coil.
Then the energy coupling analysis has been made on the working process of thefull-hydrogen annealer furnace, and temperature calculation model, heating covertemperature calculation model, cover temperature calculation model, protective hydrogen temperature calculation model, cooling cover temperature calculation model and steel rolltemperature calculation model of the full-hydrogen annealer furnace are establishedaccording to the characteristics of its working process. Then according to all kinds of theestablished full-hydrogen annealer furnace mathematical model of annealing process,designed annealing curve formulate program, this program can be realized on the basis ofthe existing steel coil annealing process each phase time calculation for steel coil in theprocess of annealing temperature, or according to the steel coil annealing temperaturecalculated demand of steel coils annealing process of each stage duration. This article testedthe result of the computation program with the field test data, and the results indicate that,this full-hydrogen annealer furnace annealing curve formulate program for the calculationof the result is reliable and reasonable.
For the steel roll bonding and oxidation color defect that is now widely existing in thefull-hydrogen annealer furnace, the reasons were analyzed and summarized in this paper,and analyzed with the test data got in a insert experiment, indicate that, steel coil annealingprocess curve set is not reasonable, and steel coil annealing process of thermal stress is themain reason cause steel roll bonding. And steel roll are premature is the main reason causeoxidation color.
In the end of this article, regenerative cross combustion technology is applied tofull-hydrogen annealer furnace, a new type of full-hydrogen annealer furnace heating coveris designed. The original burner system, heat pipe heat exchanger system of thefull-hydrogen annealer furnace is changed to regenerative burner, scattered layout in heatinghood. The advantages of the new full-hydrogen annealer furnace heating cover are save fuel,combustion chamber temperature uniformity, steel coil annealing are of good quality andinner covers have long life.
引文
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