不锈钢基料的生产.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,*,.,*,不锈钢基料的生产,.,1.,国外、国内镍铁合金生产状况,2.,镍铁合金吨产品生产成本的理论计算,3.,镍铁合金吨产品生产成本分析,4.,铁合金及不锈钢基料生产工艺流程,5.,镍铁矿热炉设计原则,6.,镍铁生产的节电与节能,报告提纲,2,.,1.,国外镍铁合金生产状况,20,世纪,50,年代,10%,2005,年,2012,年,45%,51%,51,万,t,从红土矿中提取镍金属量,回转窑,电炉法（,REKF3,.,2006,年,3.2,万,t,（镍金属量）,2007,年,8.5,万,t,（镍金属量）,烧结机,高炉法 烧结机,电炉法,红土镍矿,配矿烧结,铁水,预处理,高炉,冶炼,转炉,冶炼,连铸或铸,造面包铁,矿热炉,冶炼,电炉,冶炼,国内镍铁合金生产状况,4,.,2.,镍铁合金吨产品生产成本的理论计算,H,H,1,H,2,生成物,镍铁水,炉渣,T1500,T=25,T=25,H=H,1,+H,2,反应物,炉气,镍烧结矿,焦炭,Ni,Fe,Si,CO,SiO,2,MgO,CaO,Ni,Fe,Si,CO,SiO,2,MgO,CaO,计算原理：,5,.,物料平衡和热平衡项目,收入项,支出项,镍烧结矿,焦炭,电能,成渣反应热,金属溶解热,镍铁水、炉渣,挥发份、炉气,金属还原热,镍铁水、炉渣物理热,炉气物理热,热损失,矿热炉,6,.,物料平衡,7,.,元素还原热,30.3%,镍铁水物理热,8.3%,炉渣物理热,43.0%,炉气物理热,8.4%,热损失,10.0%,热 平 衡 表,8,.,1,吨镍铁理论电耗：,4313.8kwh,镍铁合金吨产品理论电耗计算结果,1,吨烧结矿理论电耗：,725.0kwh,名称,Ni/NiO,Fe/Fe,2,O,3,CaO,MgO,SiO,2,灰分,P,S,镍烧结矿,2.0/2.5,20/28.6,12,20,35,1.5,0.01,0.02,名称,Ni,FeSi,C,P,（设定值）,S,（设定值）,镍铁水,11.9,83.3,1.8,3.0,0.045,0.070,0.030,0.035,9,.,2007,、,2008,年成本比例比较,名称,消耗量,单价（元）,金额（元）,百分比（,%,）,2007,年,2008,年,红土矿,(t),5.951.33=7.91,750/260,5 932.5,63.2,37.29,粉煤,(t),5.9593/1000=0.55,600,330,3.5,5.98,焦炭,(t),476.0/1000=0.48,750,360,3.8,6.53,石灰,(t),5.9593/1000=0.55,190,104.5,1.1,1.89,电耗,(kwh),4313.8,0.60,2 588.3,27.6,46.93,煤气,(Nm,3,),5.9516=95.2,0.80,76.2,0.8,1.38,合计,/,/,9 391.5,100.0,100,3.,镍铁合金吨产品生产成本分析,10,.,镍铁合金生产成本中各原料比例,11,.,4.,镍铁合金及不锈钢基料生产工艺流程,节约能源和资源,矿料性质和特点,产品质量指标,基建投资费用和经营管理费用,环境效应,均衡生产,12,.,红土矿原料特点,名称,Ni,TFe,MgO,SiO,2,CaO,P,S,MgO/,SiO,2,粉矿,1.94,15.63,17.44,30.262.90,0.006,0.027,0.58,块矿,1.28,6.73,31.46,32.82,3.00,0.005,0.021,0.96,矿石代表性成分：,含水镍镁硅酸盐,(xNiO,yMgO),2,SiO,2,nH,2,O,，,以及针铁矿,Fe,2,O,3,H,2,O,、,赤铁矿,Fe,2,O,3,和磁铁矿,Fe,3,O,4,矿石形态：,粉矿,(80%),、块矿（,20%,）,矿物组成：,13,.,红土矿理化性质,38.8,245.3 549.8 829.8,86.0 283.9 622.1 808.0,57.4,550.5 826.0,83.2 648.8 811.8,红土粉矿,DTA,曲线,红土块矿,DTA,曲线,14,.,焙砂收得率低,除尘困难,粉矿结晶水,分解,大量矿粉,进入炉气,我国实际装备水平节能降耗,粉矿、块矿特点,镍铁合金及,不锈钢基料,生产工艺流程,15,.,以烧结机,电炉为主、回转窑,电炉,为辅的工艺流程图,16,.,回转窑,电炉工艺流程图,17,.,不锈钢基料产品质量标准,类型,牌号,化学成分,/%,备注,C,Si,Ni,Cr,P,S,镍铁合金,ZNi,3,3,3,5,10,2,0.05,0.03,铸铁,ZNi,1,1.0,10,10,0.05,0.05,铸铁,不锈钢,基料,Ni,10,2,3,10,0.03,0.03,铸铁粒铁,Ni,15,1.5,1.515,0.025,0.03,铸铁粒铁,Ni,25,1.5,2,10,15,0.03,0.03,铸铁粒铁,P,含量：,0.070%,0.050%,以下,18,.,低硅、高硅镍铁水的精炼,低硅镍铁水精炼流程图,高硅镍铁水精炼流程图,19,.,含,Ni10%Cr18%,的不锈钢基料生产工艺设计,以低硅镍铁水为主原料的,不锈钢基料生产工艺流程,以高硅镍铁水为主原料的,不锈钢基料生产工艺流程,20,.,两种不锈钢基料冶炼成本的比较,名称,以低硅镍铁水为主原料,以高硅镍铁水为主原料,消耗量,/kg,金额,/,元,百分比,/%,消耗量,/kg,金额,/,元,百分比,/%,粗镍铁水,0.73,6855.8,41.0,0.88,7712.3,56.4,石灰,0.08,15.2,0.1,0.18,34.2,0.2,萤石,/,/,/,0.02,9.4,0.1,氧气,0.05,60,0.4,/,/,/,SiCaBa,/,/,/,0.01,75,0.5,中碳铬铁,0.31,7440,44.5,/,/,/,铬精矿,/,/,/,0.52,2080,15.2,纯镍,0.013,2340,14.0,0.021,3780,27.6,共计,1.18,16711.0,100.0,1.63,13690.9,100.0,21,.,5.,镍铁矿热炉设计原则,三种冶炼模式,供电方式,炉体结构,电极布置,22,.,硅铁及硅铁合金炉炉膛结构的示意图,1,预热区；,2,烧结区；,3,还原区；,4,电弧区；,5,熔池区；,6,假炉底；,7,死料区；,8,电极；,9,炉衬；,10,出铁口,23,.,高碳锰铁、高碳铬铁、硅锰合金矿热炉炉膛结构示意图,松散的烧结料；,2.,软熔带；,3.,渣焦混合物；,4.,焦炭层；,5.,渣层（有焦炭）；,6.,渣层；,7.,金属；,8.,死料区；,9.,电极碎块；,10.,电极；,11.,碳砖；,12.,出渣口；,13.,出铁口,24,.,镍铁合金矿热炉炉膛结构示意图,埋弧电极,遮蔽电弧,25,.,33MVA2,双极串联供电模式,A,X,Na,B,Y,Nb,C,Z,Nc,图,1,炉底电极碳砖炉衬碳砖,11 MVA3,变压器,电极,Ia,Ix,In,CTa 150/5,CTb,CTc,CTn 10000/5,Ua,Ux,V,V,V,V,V,V,26,.,电极布置方式,电极平面布置示意图,27,.,6.,镍铁合金节生产的节电和节能,炉料热装,热渣的潜热利用,28,.,热装法冶炼镍铁合金节约电耗计算原理,Ni,Fe,Si,CO,SiO,2,MgO,CaO,H,（已知）,H,1,H,2,镍铁水,炉渣,T1500,T=25,T=500/600,/,700,H=H,1,+H,2,反应物,炉气,镍烧结矿,焦炭,镍烧结矿,焦炭,生成物,29,.,镍铁合金冷装、热装法理论电耗比较,4313.8,3566.4,3396.9,3220.1,747.4,916.9,1093.7,一吨镍铁理论电耗,（,kwh),低硅镍铁,低硅,500,低硅,600,低硅,700,30,.,普通热回收设备,31,.,普通热回收设备,32,.,流化床式热回收设备,33,.,流化床式热回收设备,34,.,谢 谢！,欢迎提出宝贵意见！,35,.,