高炉出铁口炮泥加工机理及开铁口装备研究
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摘要
近年来,我国钢铁产业发展迅速,目前粗钢年产量已经达到6.3亿吨,约占全世界钢产量的45%,钢材品种和质量也不断优化,国内自给率已超过96%,技术和装备水平明显提高,大中型钢铁企业的主体设备基本实现大型化、自动化。
目前,国内各大钢铁厂大部分都对传统的电动和气动开铁口机向全液压开铁口机进行升级或改造,取得了较好的效果。高炉开铁口机是高炉炉前的关键设备之一,其钻削铁口炮泥的效果直接影响高炉的工作效率和生产安全。随着高炉向大型化发展,高炉出铁口炮泥的配方不断改进,其强度和硬度提高,导致开铁口机的钻削效果差、开口效率低,钻具使用寿命短、消耗成本高等问题一直难以解决。
本文的研究内容结合我国钢铁行业的发展要求,针对济南钢铁集团炼铁厂开铁口机对炮泥钻削以及开铁口机装备存在的问题,旨在突破目前我国高炉开铁口领域存在的技术瓶颈,提高生产效率,降低生产成本,推动相关行业的发展。
本文采取理论研究结合虚拟样机技术和有限元分析技术对高炉出铁口炮泥温度场进行分析,从高炉出铁口炮泥焙烧后的理化性能、高温焙烧矿相、显微组织结构等方面分析炮泥的结构特性和力学性能,研究铁口炮泥钻削机理,并优化设计开铁口钻头；基于运动学和动力学仿真分析,优化设计和研究全液压开铁口机的结构和关键组成部分,并进行生产现场验证。
建立高炉出铁口炮泥的有限元模型,利用ABAQUS软件对其温度场进行有限元分析,获得了高炉出铁口炮泥温度场分布,为铁口炮泥焙烧机理研究奠定了基础。基于高炉炮泥的功能要求、原料配比和理化性能等基本特性,建立了高炉炮泥的破坏准则。
对高炉炮泥的切削性能进行研究,采用YG类硬质合金刀具,系统研究了不同焙烧温度条件下获得炮泥的切削机理和刀具磨损机理。
建立了开铁口机钻具系统的虚拟样机模型,采用ADAMS对其进行了动力学仿真分析,为钻具系统的优化设计奠定了基础。
系统分析了开铁口机钻头的失效形式,设计开发了一种新型开铁口钻头,其特殊的结构具有把持和固齿作用,避免钻头在高温环境下的钻进过程中刀片脱落导致钻头失效,生产现场实际应用效果表明,该新型钻头可明显提高开铁口质量和效率。
基于二流式雾化原理,研究开发出开铁口机雾化水冷却装置,可以有效地降低钻头失效或钻杆变形,同时有利于出铁口孔道内高温炮泥的局部龟裂和微破碎,减少钻进阻力,提高开铁口效率,减少烟尘污染和粉尘排放量,降低操作工人的劳动强度,改善炉前作业环境。
建立了全液压开铁口机的虚拟样机模型,并对其进行动力学仿真分析,获得其在整个工作过程中的受力状况,确定其各主要约束处的受力峰值,为设计开发新型矮身全液压开铁口机奠定了基础。
提出并研究开发了矮身全液压开铁口机,针对高炉生产现场有限的空间,以大回转结构代替传统的折叠式结构,提高整机刚性；采用锚钩结构提高钻具系统的稳定性和工作可靠性。
Steel and iron industry of China has made great progress in the past few years. Higher requests to the blast furnace ironmaking technology and equipment were proposed to fit the rapid development in steel and iron industry and the optimization of product structures. The crude steel annual production of China is 630 million tons, which is about 45% of the world's production. The board rate increases rapidly and the quality of steel is improved continuously. The self-sufficient rate of steel and ironin in China is more than 96% at the present time. The capability of independent innovation has been enhanced continuously. The technique and equipment level has been improved obviously. Major progress has been made in the integrated innovation of ten million ton iron and steel complex. Therefore, it is necessary to improve the technique and equipment level.
Tapping machine and its drilling tool are the keys to blast furnace ironmaking, their operation effect has direct impact to the production efficiency and safety of blast furnace. Short service life, high cost and low efficiency of the drilling tool have always been the technical problems which puzzle the steel and iron industry in China. At present, domestic steel manufacturers are faced with the important task of rebuilding and upgrading tapping machine from electrical or pneumatic to entire hydraulic. This research complies with the requirements of development in the steel and iron industry, and specifically address the technical problems of drilling tool and tapping machine existing in the practical production of the Jinan Steel and Iron Group, aims to breakthrough the technical bottleneck in drilling tool and tapping machine of the blast furnace, to enhance the production efficiency, reduce production cost, and promote the development of iron and steel industry.
This research combines theoretical analysis, virtual prototype technology and finite element method to complete the analysis of the blast furnace taphole clay temperature field. The structure characteristic of taphole clay and the strength theory about brittle material were studied in terms of its physical and chemical properties, high temperature phase and theoretical strength, which made a foundation for stress analysis of drilling tool in the next stage. The kinematical and dynamical analysis of the working process is taken by using ADAMS software for its structure design. Practical results have proved that the taphole drilling machine meet low energy consumption, environmental protection and efficient performance.
The finite element method analysis model of the blast furnace taphole clay is established and its temperature field is analyzed. Temperature contour of taphole clay was carried out, which made a foundation for stress analysis of drilling tool in the next stage. In addition, basic characteristics of blast furnace taphole clay, such as the function requirements, raw materials allocated proportion, the physical and chemical properties etc. were analyzed. The structure characteristic of taphole clay and the strength theory about brittle material were studied. The destruction criterion of brittle material which is similar to concrete and suitable for taphole clay has been determined.
According to the theoretical strength and failure criterion, experimental study of taphole clay's cutting property has been finished. Cemented carbide tool was used for the experiment. The cutting scrap and tool wear mechanism of different roasted clay were investigated.
Virtual prototype model of the tapping machine and drilling tool system was built, dynamic simulation analysis with ADAMS was carried out, and the dynamic characteristics of the system were obtained. The stress distribution in drill was analyzed in theory and was simulated. Different failure modes of the drill under normal temperature and high temperature were analyzed, the main reason for its failure in the process of opening taphole is that the drill edges falling off from the tank of drill body. A new tapping drill was developed according to the design criterion of rock drill on the basis of full consideration the failure reasons of dill, and the preliminary scene examination was carried. Practical results indicated that the defect which the blade fell off under high temperature would be overcome through the adoption of this new drill. Its working efficiency was distinct enhanced and its cost was obvious reduced compared with original one.
Based on the principle of two-flow atomization, a new atomized water cooling system has been developed. It can effectively reduce drill pipe deformation and drill failure, and also conducive to the high-temperature taphole clay occurs micro-cracking and crushing, result in reducing drilling resistance, improving the efficiency of opening furnace taphole, reducing emissions of soot and dust pollution.
Virtual prototype model of the entire hydraulic tapping machine was built, and its dynamic simulation analysis was carried out. Force status of the tapping machine and the maximum force in each constraint in the whole work process were obtained. The finite element analysis and the strength check of each key element of the tapping machine were finished.
Research and developed a new kind of short body hydraulic tapping machine, which is especially suitable for the limited space of blast furnace production environment. A rotary structure was designed to replace the traditional folding structure to improve the whole system rigid. An anchor structure was developed to improve the stability and work reliability of dirlling system.
目前,国内各大钢铁厂大部分都对传统的电动和气动开铁口机向全液压开铁口机进行升级或改造,取得了较好的效果。高炉开铁口机是高炉炉前的关键设备之一,其钻削铁口炮泥的效果直接影响高炉的工作效率和生产安全。随着高炉向大型化发展,高炉出铁口炮泥的配方不断改进,其强度和硬度提高,导致开铁口机的钻削效果差、开口效率低,钻具使用寿命短、消耗成本高等问题一直难以解决。
本文的研究内容结合我国钢铁行业的发展要求,针对济南钢铁集团炼铁厂开铁口机对炮泥钻削以及开铁口机装备存在的问题,旨在突破目前我国高炉开铁口领域存在的技术瓶颈,提高生产效率,降低生产成本,推动相关行业的发展。
本文采取理论研究结合虚拟样机技术和有限元分析技术对高炉出铁口炮泥温度场进行分析,从高炉出铁口炮泥焙烧后的理化性能、高温焙烧矿相、显微组织结构等方面分析炮泥的结构特性和力学性能,研究铁口炮泥钻削机理,并优化设计开铁口钻头；基于运动学和动力学仿真分析,优化设计和研究全液压开铁口机的结构和关键组成部分,并进行生产现场验证。
建立高炉出铁口炮泥的有限元模型,利用ABAQUS软件对其温度场进行有限元分析,获得了高炉出铁口炮泥温度场分布,为铁口炮泥焙烧机理研究奠定了基础。基于高炉炮泥的功能要求、原料配比和理化性能等基本特性,建立了高炉炮泥的破坏准则。
对高炉炮泥的切削性能进行研究,采用YG类硬质合金刀具,系统研究了不同焙烧温度条件下获得炮泥的切削机理和刀具磨损机理。
建立了开铁口机钻具系统的虚拟样机模型,采用ADAMS对其进行了动力学仿真分析,为钻具系统的优化设计奠定了基础。
系统分析了开铁口机钻头的失效形式,设计开发了一种新型开铁口钻头,其特殊的结构具有把持和固齿作用,避免钻头在高温环境下的钻进过程中刀片脱落导致钻头失效,生产现场实际应用效果表明,该新型钻头可明显提高开铁口质量和效率。
基于二流式雾化原理,研究开发出开铁口机雾化水冷却装置,可以有效地降低钻头失效或钻杆变形,同时有利于出铁口孔道内高温炮泥的局部龟裂和微破碎,减少钻进阻力,提高开铁口效率,减少烟尘污染和粉尘排放量,降低操作工人的劳动强度,改善炉前作业环境。
建立了全液压开铁口机的虚拟样机模型,并对其进行动力学仿真分析,获得其在整个工作过程中的受力状况,确定其各主要约束处的受力峰值,为设计开发新型矮身全液压开铁口机奠定了基础。
提出并研究开发了矮身全液压开铁口机,针对高炉生产现场有限的空间,以大回转结构代替传统的折叠式结构,提高整机刚性；采用锚钩结构提高钻具系统的稳定性和工作可靠性。
Steel and iron industry of China has made great progress in the past few years. Higher requests to the blast furnace ironmaking technology and equipment were proposed to fit the rapid development in steel and iron industry and the optimization of product structures. The crude steel annual production of China is 630 million tons, which is about 45% of the world's production. The board rate increases rapidly and the quality of steel is improved continuously. The self-sufficient rate of steel and ironin in China is more than 96% at the present time. The capability of independent innovation has been enhanced continuously. The technique and equipment level has been improved obviously. Major progress has been made in the integrated innovation of ten million ton iron and steel complex. Therefore, it is necessary to improve the technique and equipment level.
Tapping machine and its drilling tool are the keys to blast furnace ironmaking, their operation effect has direct impact to the production efficiency and safety of blast furnace. Short service life, high cost and low efficiency of the drilling tool have always been the technical problems which puzzle the steel and iron industry in China. At present, domestic steel manufacturers are faced with the important task of rebuilding and upgrading tapping machine from electrical or pneumatic to entire hydraulic. This research complies with the requirements of development in the steel and iron industry, and specifically address the technical problems of drilling tool and tapping machine existing in the practical production of the Jinan Steel and Iron Group, aims to breakthrough the technical bottleneck in drilling tool and tapping machine of the blast furnace, to enhance the production efficiency, reduce production cost, and promote the development of iron and steel industry.
This research combines theoretical analysis, virtual prototype technology and finite element method to complete the analysis of the blast furnace taphole clay temperature field. The structure characteristic of taphole clay and the strength theory about brittle material were studied in terms of its physical and chemical properties, high temperature phase and theoretical strength, which made a foundation for stress analysis of drilling tool in the next stage. The kinematical and dynamical analysis of the working process is taken by using ADAMS software for its structure design. Practical results have proved that the taphole drilling machine meet low energy consumption, environmental protection and efficient performance.
The finite element method analysis model of the blast furnace taphole clay is established and its temperature field is analyzed. Temperature contour of taphole clay was carried out, which made a foundation for stress analysis of drilling tool in the next stage. In addition, basic characteristics of blast furnace taphole clay, such as the function requirements, raw materials allocated proportion, the physical and chemical properties etc. were analyzed. The structure characteristic of taphole clay and the strength theory about brittle material were studied. The destruction criterion of brittle material which is similar to concrete and suitable for taphole clay has been determined.
According to the theoretical strength and failure criterion, experimental study of taphole clay's cutting property has been finished. Cemented carbide tool was used for the experiment. The cutting scrap and tool wear mechanism of different roasted clay were investigated.
Virtual prototype model of the tapping machine and drilling tool system was built, dynamic simulation analysis with ADAMS was carried out, and the dynamic characteristics of the system were obtained. The stress distribution in drill was analyzed in theory and was simulated. Different failure modes of the drill under normal temperature and high temperature were analyzed, the main reason for its failure in the process of opening taphole is that the drill edges falling off from the tank of drill body. A new tapping drill was developed according to the design criterion of rock drill on the basis of full consideration the failure reasons of dill, and the preliminary scene examination was carried. Practical results indicated that the defect which the blade fell off under high temperature would be overcome through the adoption of this new drill. Its working efficiency was distinct enhanced and its cost was obvious reduced compared with original one.
Based on the principle of two-flow atomization, a new atomized water cooling system has been developed. It can effectively reduce drill pipe deformation and drill failure, and also conducive to the high-temperature taphole clay occurs micro-cracking and crushing, result in reducing drilling resistance, improving the efficiency of opening furnace taphole, reducing emissions of soot and dust pollution.
Virtual prototype model of the entire hydraulic tapping machine was built, and its dynamic simulation analysis was carried out. Force status of the tapping machine and the maximum force in each constraint in the whole work process were obtained. The finite element analysis and the strength check of each key element of the tapping machine were finished.
Research and developed a new kind of short body hydraulic tapping machine, which is especially suitable for the limited space of blast furnace production environment. A rotary structure was designed to replace the traditional folding structure to improve the whole system rigid. An anchor structure was developed to improve the stability and work reliability of dirlling system.
引文
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