转炉炼钢成本控制优化.ppt

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,转炉炼钢成本控制优化,炼钢成本主要三部分：可变成本、固定成本和综合回收利用。,可变成本,是指随产量的变化升降的项目，包括：钢铁料消耗、合金料、辅料、动力等。,Key Point,钢铁料,原辅料,合金,脱氧剂,能源,燃料动力,一、炼钢降本构成,2,一、炼钢降本构成,（,1,）,铁水,(,自产,),（,2,）镍铁,（,3,）,铁块（自产）,（,5,）,废钢,（,6,）次坯,（,7,）渣盆,（,8,）,自循环,（,1,）石灰石,（,2,）外购石灰,（,3,）,自产石灰,（,4,）萤石,（,5,）轻烧镁球,（,6,）颗粒增碳剂,（,7,）白云石,(8),金属球,(9),烧结矿,(10),耐火材料其它,（,1,）,氧气,（,2,）氮气,（,3,）压缩空气,（,4,）,电,（,5,）水,（,6,）煤气,（,7,）氩气,（,8,）霞普气,（,1,）硅铁,（,2,）,硅锰,（,3,）,高锰,（,4,）铬铁,（,5,）,铝铁,（,6,）,硅铝钙钡,（,7,）电石,（,8,）其它,钢铁料,原辅料,合金,脱氧剂,能源,燃料动力,3,二、降低钢铁料消耗,钢铁料消耗,，每吨合格钢消耗的钢铁料量，主要包括铁水、铁块、废钢等。,钢铁料消耗是炼钢企业生产的一项重要综合性技术经济指标，也是,炼钢成本构成的主体,，占总炼钢成本的,75%,左右，在一定程度上反映了炼钢企业的技术操作和生产组织水平，也直接体现了企业的现代化程度和科学管理水平。,4,二、降低钢铁料消耗,公司考核,折算钢铁料消耗公式：当月实际钢铁料,+,（当月全铁,-,口径全铁）*,10+,（当月自循环,-,口径自循环）*,59%+,（当月烧结矿,-,口径烧结矿）*,33%+,（当月金属球,-,口径金属球）*,40%,；其中铁水,TFe 94.412%,，自循环,16Kg/t,、烧结矿及金属球各,27.5Kg/t,。,钢种,理论消耗,Q235B,1.0480,Q235A,1.0450,A36Cr,1.0520,Q235C,1.0520,Q235BM,1.0560,Q195,1.056,Q215B,1.052,Q345B,1.045,Q390B2,1.048,Q420B,1.045,CCSA,1.056,A36,1.044,Q345B(B),1.044,510L,1.059,考核标准：,一档,:1.5,，二档,:0.5,，,三档,:0,，四档,:-0.5,5,申请调理论值完成情况：,板材,1,月,2,月,3,月,4,月,5,月,6,月,7,月,8,月,9,月,10,月,11,月,12,月,累计,Q235B,1.0480,334310,317348,298802,244320,294470,311490,280522,283667,283029,239543,287908,315594,3491004,Q215B,1.052,12778,7436,18279,13853,11024,5507,6198,8339,5774,12055,11216,357,112817,Q345B,1.045,62012,91181,92905,93795,100209,82980,87723,65886,100882,68022,74612,89753,1009961,Q420B,1.045,295,209,222,60,1017,266,0,0,266,0,1204,622,4161,CCSA,1.056,29475,30497,48278,28597,29400,29842,6536,21156,12227,21841,20195,6262,284306,AB/A2,1.057,0,0,0,0,908,0,1099,1357,0,2103,175,1110,6753,A36,1.044,42795,33415,47120,46692,81691,46917,51936,74941,40014,85503,65970,46820,663813,Q345B(B),1.044,0,0,1419,0,0,2563,373,0,0,1519,3148,0,9021,SS400B,1.048,77017,47480,65603,61675,40602,87749,72151,107456,26853,63318,80259,63994,794156,SS400Crl,1.050,1357,1036,2881,2195,2624,326,0,1701,1871,0,191,6484,20666,SAE1017B3,1.050,2987,0,0,2592,6195,0,1033,9614,7001,4557,4259,5428,43665,09CuPCrNi-A,1.031,0,1410,0,0,1895,0,0,0,0,0,0,0,3305,SPA-H,1.040,17375,14873,24750,23907,22652,22784,31906,22094,17233,28552,37080,56705,319911,产量合计,673975,610751,686975,638815,700998,706440,686315,721759,650173,613764,664592,686450,8041007,理论钢铁料消耗,1050.65,1049.23,1050.25,1049.80,1050.52,1050.22,1049.74,1050.33,1050.22,1049.11,1048.97,1049.40,1049.89,当月全铁,94.31,94.33,94.50,94.42,94.49,94.51,94.50,94.46,94.33,94.41,94.22,94.24,94.39,实际钢铁料消耗,1051.95,1049.85,1049.95,1049.77,1049.71,1049.66,1049.91,1050.44,1051.64,1049.78,1049.78,1049.94,1050.20,自循环,16.89,15.37,15.77,17.49,15.14,14.51,16.33,17.51,19.73,21.92,20.92,18.76,17.55,烧结矿,25.81,27.56,26.97,26.80,30.97,34.73,33.81,33.62,41.33,26.57,27.68,26.79,30.29,金属球,27.18,28.37,29.37,29.89,23.90,20.04,21.75,23.02,13.17,28.36,27.25,28.09,24.96,折算实际钢铁料消耗,1050.78,1049.07,1051.24,1051.43,1049.66,1049.13,1050.77,1052.06,1051.82,1053.25,1050.74,1049.84,1050.83,折算实际钢铁料消耗与理论差,0.13,-0.16,0.99,1.63,-0.85,-1.10,1.03,1.73,1.60,4.14,1.78,0.44,0.94,6,二、降低钢铁料消耗,指标,2014,年平均,2015,年目标,措施,折算钢铁料消耗与理论消耗差值,1.7kg/t,（调整后,0.94,）,1.5kg/t,1,、稳定装入制度，,130+7,（,1,）吨；把握好,入炉金属料结构，继续烧结矿攻关，保证烧结矿（球团）消耗在,55kg/t,左右。普碳钢生白控制在,25kg/t,以内，低碳钢生白控制在,30kg/,以内，,2,、,合理控制炉型，尤其是出钢口位置厚度，保证钢水出净。,3,、,规范枪位、氧压、过程加料时机、终点压枪等操作，控制喷溅。,4,、,终点控制，普碳钢终点,C,控制在,0.0850.135%,，出钢温度在,16251645,，保证终渣流动性良好，钢,-,渣分离充分。,5,、提高矿回收率，常规操作下，终点前,3min,不允许加矿；双渣炉次前期带,2t,左右烧结矿起渣、尽可能不带球团矿。普碳钢必须将出钢,C-T,提起来，创造矿还原条件,。,6,、保证钢水质量的前提下，严控大包注余。,7,、,人员管理，严格执行工艺纪律，违规责任人落实考核与检讨,。,8,、加强渣道管理，保证自循环回收力度，避免含铁物料外运。,7,二、降低钢铁料消耗,针对,Q235B,等普碳钢种随机抽取,26,个炉次不同终点,C,、终点温度的终渣进行研究，分析认为转炉在保证终渣流动性较好的前提下，拉碳,C 0.085-0.135%,、,T 1625-1645,时终渣含铁料总和较低，有利于提高钢水收得率，降低钢铁料消耗。,炉渣空冷研磨后，部分炉次有包裹钢珠出现，利用磁铁吸取含铁物料后，通过对比称重估算炉渣含铁物料,如何优化终点控制？,从终点渣入手？,8,转炉终点优化,炉号,毛重,g,去铁重,g,表观含铁率,%,Tfe%,碱度,R,拉碳,%,温度,总铁,(%),3812160,89.54,78.64,12.17,13.49,3.03,0.137,1616,25.66,3812162,77.57,66.18,14.68,16.53,3.27,0.083,1628,31.21,3613662,69.69,65.3,6.30,16.73,3.8,0.106,1635,23.03,3712482,75.97,68.95,9.24,11.97,2.24,0.129,1638,21.21,3513395,105.28,98.29,6.64,13.47,2.85,0.1248,1637,20.11,3613844,63.27,53.72,15.09,14.95,3.44,0.1083,1611,30.04,3712632,76.26,72.53,4.89,13.77,2.78,0.11,1631,18.66,3812347,88.01,70.06,20.40,10.43,2.62,0.10,1616,30.83,3513616,107.11,96.13,10.25,12.62,2.64,0.13,1634,22.87,3614019,105.71,102.64,2.90,13.39,3.19,0.102,1632,16.29,3712851,92.37,78.01,15.55,16.39,3.05,0.13,1649,31.94,3812534,89.98,74.92,16.74,18.91,2.72,0.043,1642,35.65,3812578,51.65,48.35,6.39,16.77,2.91,0.0951,1659,23.16,3712940,70.53,64.97,7.88,16.47,2.81,0.1118,1660,24.35,3614109,82.51,80.19,2.81,16.8,3.46,0.0999,1657,19.61,3712941,72.02,53.78,25.33,15.54,3.05,0.1645,1649,40.87,9,普碳钢终点,C,控制在,0.0850.135%,，出钢温度在,16251645,；有利于提高金属收得率。,转炉终点优化,10,三、原辅料消耗,转炉使用的辅料有活性石灰、白云石、镁球和球团矿。转炉使用的造渣材料在炼钢成本中占有相当大的比例，特别是,石灰消耗,的高低对炼钢生产中的各项指标有重要的影响。,为降低石灰的消耗，转炉造渣操作上由,高碱度高,MgO,操作向低碱度低,MgO,操作的根本性转变；炉渣的碱度和,MgO,含量分别稳定在,2.8,、,8.2,；根据铁水,Si,及带渣量调整石灰消耗。炉前加强管理，杜绝随意加料压渣的习惯。,原料方面：针对石灰石杂石较多情况，石灰石卸车时工长及料场接收工必须到现场监督,。,设备方面：根据设备影响情况调整工艺参数，避免石灰生过烧。,操作方面：看火工在异常操作下的应变能力。,关键：石灰质量、,CaO%,11,三、原辅料消耗,12,球团、烧结矿成分,供货名称,Tfe,Mfe,金属化率,%,残,C,S,抗压,含末量,%,产线,金属化球,55.03,33.79,61.40%,0.38,0.363,无整球,5.8,污泥线,54.40,34.34,63.12%,0.38,0.367,无整球,5.8,海砂线,54.72,34.09,62.30%,0.51,0.381,无整球,5.8,海砂线,54.24,31.06,57.26%,0.31,0.387,无整球,5.8,污泥线,55.42,38.05,68.66%,0.47,0.334,无整球,5.8,污泥线,55.09,32.68,59.32%,0.50,0.325,无整球,5.8,海砂线,供货名称,TFe,FeO,SiO2,CaO,MgO,S,P,MnO,烧结矿,55.91,9.47,5.43,9.49,2.65,0.002,0.084,R:1.75,54.50,7.77,5.23,10.72,2.88,0.006,0.083,54.75,9.96,5.15,10.17,3.16,0.007,0.073,R:1.97,55.43,7.83,5.16,9.90,2.92,0.005,0.062,R:1.92,55.76,9.05,5.31,9.33,2.69,0.005,0.066,R:1.76,54.90,10.42,6.39,9.83,2.71,0.025,0.070,13,四、合金、脱氧剂消耗,首先，提高终点命中率降低钢水的氧性；其次是优化脱氧工艺，调整合金的加入时间和时机；第三，提高挡渣成功率。第四，加强管理，提高转炉及精炼窄成分控制合格率。,一次拉碳合格率,挡渣成功率,压枪时间,30S,钢水,O,温低补吹,后期加矿,1t,矿富含,150m,3,氧。,碳氧积,14,脱氧合金化工艺,15,优化挡渣成功率,编号,存在问题,采取措施,1,挡渣时机失误,1,、稳定装入制度，摇炉工必须严格控制兑铁量并如实记录。,2,、炉长及摇炉工应掌握本炉次装入量、本炉所坐钢包渣线位置出钢量。,3,、氩站站长必须及时查询所坐钢包信息，并通知炉前，一助手做好记录。,4,、炉长根据出钢口寿命，把握好钢流速度及出钢时间。,5,、出钢过程临近挡渣时，炉长应适当调小钢包底吹流量，防止钢水翻腾影响挡渣时机。,2,挡渣车故障,1,、接班必须检查挡渣车状况，挡渣锥夹持过紧或偏松及时通知维修处理。,2,、挡渣工装好锥子后，合金工配合其试投一次，确保投掷顺畅。,3,、接班确认挡渣车限位，严禁私自掰动导向杆挡渣，各班必须靠限位挡渣，限位有问题，联系调度室及维修及时处理。每次调节限位交接班时炉前挡渣人员要与接班人员交接清楚，避免不清楚设备引起的挡渣失利。,4,、挡渣车故障时，出钢,4/5,时必须推挡渣球挡渣。,5,、挡渣车进入炉内后，必须等车停稳后再投掷挡渣锥。,3,挡渣锥、挡渣塞、挡渣球、导向杆质量不稳定,1,、每班必须烘烤,15,支以上挡渣锥（含导向杆），减少炸爆几率。,2,、挡渣工必须用耐火泥将锥、杆之间的缝隙填实，并提前,2,炉钢烘烤。,3,、合金工与挡渣工联合确认挡渣锥质量，有破损或残缺的退回；导向杆端部螺纹钢有过粗、偏细的、导向杆耐火泥包裹过长、偏短的退回。,4,、炉前工捅出钢口时，确保锥子投掉；装挡渣塞时，确保填堵结实，出钢口过大可将挡渣塞用石棉布包裹后使用,大塞已打申请报告。,5,、挡好挡渣塞，做到挡严、挡实，减少前期带渣量，吹炼终点测温取样后炉长必须确认挡渣塞是否挡严。,16,优化挡渣成功率：,编号,存在问题,采取措施,4,压炉速度、角度不当,1,、出钢前期确保压炉速度和角度（,76,），避免钢渣混出。出钢后期，压炉速度要慢，,1,2,动炉，避免出钢卷渣。,2,、挡渣锥挡住渣后，及时落炉到位，控制到,105,左右；炉长安排炉前工压渣，防止大炉口下渣影响生产。,5,出钢口维护不到位,1,、炉长维护好出钢口内口及外口形状。内口不规则（过高、高低不平）及时用拆炉机清理，外口不圆出钢散流及时喷补、胡子过长及时清理。,2,、对于出钢口过大、放钢时间,3min,，炉长联系车间及调度室及时更换。,3,、针对出钢口寿命小于,300,次，且由于出钢口过大、出钢时间过短必须提前更换的，按协议考核乙方。,4,、炉长、一助手加强终点控制，提高终点拉碳,0.075-0.125%,合格率，控制拉碳过低、温度过高的比率，减少出钢口强氧化性侵蚀。,6,工艺违规,1,、严禁温低、渣粘、,C,高（,0.15%,）、点吹加料未化透出钢，以确保挡渣锥能顺利投入出钢口。终点,C,高即使倒炉时炉渣流动性好，出钢过程,C,消耗渣中,FeO,，放钢后期渣仍会偏粘，挡渣锥投掷不顺畅而下渣。,2,、加强终点控制及出钢工艺纪律检查，规范考核管理制度。,3,、非特殊情况，严禁不向前倒炉直接出钢。,17,五、能源、燃料动力,首先，氧气作为主要动力方面的主要成本指标。一炉钢吹氧时间相差,30,秒，耗氧量即相差约,202.5m,3,，价格,101.25,元，吨钢成本就相差,0.81,元。,其次，转炉出钢温度为炼钢工序的核心，适当的出钢温度对于顺行节奏、降电耗起到至关重要作用；但出钢温度过高，不利于成本控制；,1645,以上每增,1,，成本增加,0.8,元,/t,钢。,温度为炼钢工艺流程的核心,监控出钢温度、压钢、钢包包况,控制热平衡，提高命中率，减少后吹,合理搭配烧结矿，增加摄入氧含量,温度,氧耗,18,温度,氧耗,19,出钢温度可用下式计算：,T=T,f,十,T,1,十,T,2,T,3,T,f,钢水凝固温度；,T,1,钢水过热度，；,T,2,出钢、吹氢、运输、镇静过程降温，；,T,3,浇注过程降温,温度,氧耗,20,六、可变成本之外,制造费用,21,本日产量,t,19005.917,2015-3-31,本月产量,t,555808.512,成本项目,计量单位,本日计划,本月计划,本月累计,成本比较,计划单价,计划单耗,单位成本,单位消耗,单位成本,总消耗,本日,-,计划,本月,-,计划,一、直接原材料,1.,钢铁料,1.05428,2319.41,1.04983,2310.61,-5.64,-8.80,（,1,）铁水,(,自产,),t,2200.00,0.81814,1799.91,0.98258,2161.68,546,128.45,381.14,361.77,（,3,）铁块（自产）,t,2200.00,0.22250,489.50,0.05165,113.64,28,709.22,-402.61,-375.87,（,5,）废钢,t,2200.00,0.01364,30.00,0.01346,29.61,7481.28,-0.03,-0.39,2.,合金料,t,0.01101,82.59,0.01,64.79,4782.69,-11.57,-17.80,（,1,）硅铁,t,5400.00,0.00177,9.56,0.00120,6.48,666.58,-1.81,-3.08,3.,脱氧剂,t,32.12,0.00357,30.20,2493.28,0.89,-1.92,（,4,）硅铝钡钙,t,6370.76,0.00030,1.91,0.00083,5.31,463.68,4.98,3.40,4.,冲减物,-0.02650,-6.10,-5.38,1.09,0.72,（,1,）氧化铁皮：,t,400.00,-0.00400,-1.60,-0.00268,-1.07,-1487.86,-0.47,0.53,（,2,）回收污泥,t,200.00,-0.02250,-4.50,-0.02155,-4.31,-11978.04,1.56,0.19,二、辅助材料,t,0.12411,80.16,0.12525,73.60,69614.47,-7.25,-6.56,（,3,）自产石灰,t,250.00,0.04202,10.51,0.03650,9.12,20286.47,-0.85,-1.38,(11),金属球,t,550.00,0.00000,0.00,0.02519,13.85,14000.6,14.29,13.85,三、燃料及动力,173.73190,61.68,0.00000,71.46,8.23,9.78,（,1,）氧气,m,3,0.50,56.14061,28.07,49.27532,24.64,27387642.00,-3.62,-3.43,（,2,）氮气,m,3,0.09,25.00000,2.35,38.28614,3.59,21279762.00,1.92,1.25,（,4,）电,kwh,0.49,50.55858,24.72,66.66198,32.59,37051294.00,6.70,7.87,（,5,）水,m,3,1.40,0.38000,0.53,1.11403,1.56,619187.00,0.83,1.02,（,8,）霞普气,t,4012.00,0.00015,0.61,0.00031,1.26,174.50,0.63,0.65,四、直接人工,元,10.00,18.36,7.31,8.36,五、制造费用,元,32.00,35.07,0.00,3.07,六、制造成本,元,2611.86,2598.71,-6.95,-13.16,炼钢成本报表,谢谢，结束,22,