鋼銷、鋼渣粒子鋼液壓壓制成型系統技術說明

Technical Description of Hydraulic Pressing Forming System for Steel Pin and Slag Particle Steel

一、項目背景

  Project Background

宏觀層面看，《“十二五”循環經濟發展規劃》明確指出，發展循環經濟是我國經濟社會發展的重大戰略任務，是推進生態文明建設、實現可持續發展的重要途徑和基本方式。因此，全國鋼鐵企業必須圍繞提高資源產出率，健全激勵約束機制，構建循環型產業體系，推動再生資源利用產業化，推行綠色消費，加快形成覆蓋全社會的資源循環利用體系。從中微觀層面看，未來鋼廠對鋼渣處置利用將提出更高的價值訴求，鋼渣循環再利用產業化勢在必行。

Macroscopically, the 12th Five-Year Plan for the Development of Circular Economy clearly points out that the development of circular economy is an important strategic task for Chinas economic and social development and an important way and basic way to promote the construction of ecological civilization and achieve sustainable development. Therefore, the national iron and steel enterprises must focus on improving the resource output rate, improving the incentive and restraint mechanism, building a circular industrial system, promoting the industrialization of renewable resources utilization, promoting green consumption, and speeding up the formation of a resource recycling system covering the whole society. From the micro and meso level, steel mills will put forward higher value demands for the disposal and utilization of steel slag in the future, and it is imperative to industrialize the recycling and reuse of steel slag.

國際形勢來看，一些發達國家利用節能環保方面的技術優勢，已在國際貿易中制造了較高的綠色技術壁壘。國內形勢來看，面對嚴峻資源環境約束，“十三五”時期是我國節能環保產業發展難得的歷史機遇期，發展前景廣闊。據有關部門測算，到2016年節能潛力超過4億噸標準煤，可帶動上萬億元投資；節能服務總產值可突破3000億元；產業廢物循環利用環境服務總產值將達5000億元規模。

In the international situation, some developed countries have created high green technical barriers in international trade by taking advantage of their technological advantages in energy conservation and environmental protection. In view of the domestic situation, facing the severe resource and environment constraints, the 13th Five-Year Plan period is a rare historical opportunity for the development of energy-saving and environmental protection industry in China, with broad prospects for development. According to estimates by relevant departments, by 2016, the energy-saving potential will exceed 400 million tons of standard coal, which will lead to trillion yuan of investment; the total output value of energy-saving services will exceed 300 billion yuan; and the total output value of environmental services for industrial waste recycling will reach 500 billion yuan.

鋼鐵工業“十三五”發展規劃也明確指出：“要加快鋼鐵行業資源能源回收利用產業發展；促進鋼鐵與其他產業的融合，發展循環經濟；開展能源審計、清潔生產審核和清潔生產方案的實施”?？梢?，鋼渣處理生產將面臨達標排放的剛性需求。

The thirteenth five-year development plan of iron and steel industry also clearly points out that "the development of energy recovery and utilization industry in iron and steel industry should be accelerated; the integration of iron and steel with other industries should be promoted to develop circular economy; and the implementation of energy audit, cleaner production audit and cleaner production plan should be carried out". It can be seen that steel slag treatment production will face the rigid demand of meeting the discharge standards.

二、鋼銷、鋼渣粒子鋼液壓壓制成型技術介紹

Introduction of Hydraulic Pressing Technology for Steel Pin and Slag Particle Steel

唐山市鑫虎冶金科技有限公司，經過大量研發和科研實驗，研究成功將鋼銷、鋼渣粒子鋼、鋼渣精粉、高品位鐵粉還原等通過液壓壓制成型的設備，現已經批量投入生產使用

Tang Shan  Xin Hu metallurgy Technology Co., Ltd. has successfully reduced steel pins, steel slag particle steel, steel slag powder and high-grade iron powder by hydraulic pressing through a large number of R&D and scientific research experiments. Now it has been put into production and use in batches.

1.本系統設計依照的基本原則是：

  （1）采用先進的低能耗裝備。

（2）堅持可持續發展戰略，提高能源，資源的利用效率。

（3）以環境效益和綜合經濟效益為中心，實現企業的清潔生產。

（4）優化工藝方案，總體布局緊湊合理，工藝流程簡潔順暢。

（5）厲行節約，降低投資。

1.     The basic principles of the system design are:

(1)  Use advanced low-energy equipment.

(2)  Adhere to the strategy of sustainable development and improve the utilization efficiency of energy and resources.

(3)  Centering on the environmental and comprehensive economic benefits, the clean production of enterprises.

(4)  Optimizing process plan, compact and reasonable overall layout, simple and smooth process.

(5)  Strictly economize and reduce investment.

2、鋼銷、鋼渣粒子鋼、鋼渣精粉、高品位鐵粉還原等液壓壓制成型系統工藝流程

2.     Process flow of hydraulic pressing forming system for steel pin, steel slag particle steel, steel slag concentrate powder and reduction of high-grade iron powder

⑴    工藝流程描述

Process description

鋼銷、鋼渣粒子鋼、鋼渣精粉、高品位鐵粉還原等液壓壓制成型系統工藝是將鋼銷、鋼渣粒子鋼由上料機加入到系統設備，由低溫對流烘干器和精確調溫器進行溫度控制，對鋼渣粒子鋼進行烘干，然后經中間轉運器輸送到液壓成型機，經液壓按需求調整液壓壓力（0-315bar動態可調）壓制成型后將壓制好的粒子鋼塊由裝載機吊運至成品庫，期間部分熱量由高效換熱器進行回收利用，設計有除塵系統對生產過程中產生的廢氣、粉塵等污染進行環保處理。

Steel pin, steel slag particle steel, steel slag powder, high-grade iron powder reduction and other hydraulic pressing forming system technology is to add steel pin and steel slag particle steel to the system equipment by feeder, temperature control by low-temperature convection dryer and precise thermostat, drying steel slag particle steel, and then conveyed to the hydraulic forming machine through intermediate conveyor, hydraulic pressure adjusted according to demand (0. - 315bar dynamic adjustable) After pressing, the pressed steel particles are hoisted from loader to finished product warehouse, during which part of the heat is recovered and utilized by high efficiency heat exchanger, and a dust removal system is designed to deal with environmental pollution such as waste gas and dust produced in the production process.

⑵    工藝流程圖

Process flow chart

⑶主要設備部件包括鋼渣粒子鋼上料機、低溫對流烘干器、精確調溫烘干器、余熱回收、除塵器、中間轉運器、液壓成型機、循環風機、成品輸送設備、管道、自動控制系統等。

⑶    The main equipment components include steel slag particle feeder, low temperature

convection dryer, precise temperature regulating dryer, waste heat recovery, dust collector, intermediate transporter, hydraulic forming machine, circulating fan, finished product conveying equipment, pipeline, automatic control system, etc.

3、安全可靠、優勢明顯

Safety, reliability and obvious advantages

A、渣鋼根據粒度不同以不同方式回收利用

Slag steel is recycled in different ways according to its particle size.

 （1）A1級渣鋼，TFe≥80%，粒度>75（mm）為初選渣鋼，經電磁除鐵器選出，供給轉爐煉鋼使用。

Grade A1 slag steel with TFe (> 80%) and particle size > 75 (mm) is the primary slag steel seleced by electromagnetic iron remover and supplied to converter steelmaking.

（2）A2級渣鋼，TFe≥80%，粒度10-75（mm）2#棒磨機提純后，進入2#振動篩，篩上產物，供給轉爐煉鋼使用。

Class A2 slag steel with TFe (> 80%) and particle size of 10-75 (mm) 2 # bar mill is purified, and then it enters 2 # vibrating screen. The products are screened and supplied to converter steelmaking.

（3）B1級磁選粉，TFe≥80%，粒度5-75（mm），經2#棒磨機提純后，進入2#振動篩，篩下產物，再進行二次篩分，篩上產物，供給轉爐煉鋼使用。

Level B1 magnetic separator powder, TFe (> 80%) and particle size 5-75 (mm), purified by 2# bar mill, enters 2# vibrating screen, sieves the product, then carries on the second sieve, sieves on the product, supplies the converter steelmaking use.

（4）B2級磁選粉，TFe≥42%，粒度<5（mm），經2#棒磨機提純后，進入2#振動篩，篩下產物，再進行二次篩分，篩下產物，返燒結使用。

B2 grade magnetic separator powder, TFe (> 42%) and particle size (< 5 mm), purified by 2 # bar mill, enters 2 # vibrating screen, sieves the product, then sieves the product twice, sieves the product, and returns to sintering.

（5）   尾渣，MFe<3%，粒度＜10（mm），經破碎、磁選、提純后的產物。

Tailings, MFe < 3%, particle size < 10 (mm), after crushing, magnetic separation, purification products.

B、 小顆粒渣鋼燒結和直接入爐的弊端

Disadvantages of Sintering and Direct Furnace Entry of Small Particle Slag Steel

●燒結設備大型化和自動化，投資和運行費用較高

Large-scale and automation of sintering equipment, high investment and operation costs

●由于煤中含硫，所以燒結會排放出有害氣體產物二氧化硫，必須進行煙氣脫硫處理。

Because of the sulfur content in coal, sulfur dioxide, a harmful gas product, will be discharged from sintering, so flue gas desulfurization must be carried out.

●由于燒結溫度很高，燒結礦不能熱送高爐，即使回收部分余熱，還是要排出大量廢熱

Because of the high sintering temperature, sinter can not be hot-fed to blast furnace. Even if part of the waste heat is recovered, a large amount of waste heat must be discharged.

 ●氧化鐵皮為片狀形態，在燒結過程中影響料層的透氣性，從而降低燒結產量。并且細小的顆粒容易被氣流抽走增加除塵系統負荷。

The sheet shape of iron oxide sheet affects the permeability of the material layer during sintering process, thus reducing the sintering output. And fine particles are easily sucked away by airflow to increase the load of dust removal system.

●粒子鋼直接加入轉爐產生較大的火焰和噴濺，存在人員和設備的安全隱患。

Particle steel directly added into converter produces larger flame and splash, which has potential safety hazards for personnel and equipment.

三、原料供應

Raw Material Supply

1、 原料：鋼渣選出的粒子鋼、鋸口屑、各種小顆粒、鋼銷、鋼屑、氧化鐵

Raw materials: particulate steel, sawdust, various small particles, steel pins, steel chips and iron oxide seleced from steel slag

2、 粒度分級：0.5mm--30mm（按不同原料比例調配）成分：待測

Particle size grading: 0.5mm-30mm (dispensing according to different raw material proportions) Composition: to be measured

四、處理目的

Purpose of treatment

將鋼渣粒子鋼在0-315bar動態可調的液壓壓力下，液壓壓制成粒子鋼塊。鋼渣粒子鋼經過本設備的液壓壓制成型后的成品指標為：Si≤1.25%，P≤0.15%，S≤0.07%，C≤2.5%，單質鐵≥90%，密度為6.5g/cm3，此產品能有效降低煉鋼成本，提高鋼產量。

The steel slag particle steel was pressed into the particle steel block under the dynamic adjustable hydraulic pressure of 0-315 bar. The finished product index of steel slag particle steel after hydraulic pressing is: Si < 1.25%, P < 0.15%, S < 0.07%, C < 2.5%, elemental iron (>90%) and density 6.5g/cm. This product can effectively reduce steelmaking cost and increase steel output.

五、鋼銷、鋼渣粒子鋼烘干液壓成型系統組件

Components of Hydraulic Forming System for Steel Pin and Slag Particle Steel Drying

 鋼渣粒子鋼烘干液壓成型系統主要設備及部件包括：上料機、低溫對流烘干器、精確調溫設備、余熱回收換熱器、除塵器、中間轉運器、液壓成型機、排煙機、循環風機、成品輸送設備、管道、自動控制系統。

The main equipments and components of the steel slag particle steel drying hydraulic forming system include feeder, low temperature convection dryer, precise temperature regulating equipment, waste heat recovery heat exchanger, dust collector, intermediate transporter, hydraulic forming machine, smoke exhaust machine, circulating fan, finished product conveying equipment, pipeline and automatic control system.

六、成本測算：

 Cost estimation:

1、鋼銷、鋼渣粒子鋼、鋼渣精粉、高品位鐵粉還原烘干液壓成型系統運行費用(預估值 )

Operation cost of reduction drying hydraulic forming system for steel pin, steel slag particle steel, steel slag powder and high grade iron powder (estimated)

七、鋼渣粒子鋼液壓壓制成型系統的技術優勢

Technical Advantages of Hydraulic Pressing Molding System for Steel Slag Particle Steel

 1、粒子鋼鐵水降低率低

Low reduction rate of particulate molten iron and steel

系統采用特殊調節手段對粒子鋼上料、液壓壓制成型等方面進行自動化精確控制，粒子鋼在此過程中氧化率很低，因此與原料相比，粒子鋼成型后含鐵量降低幅度可以控制在2%以下。

Particle steel feeding and hydraulic pressing are controlled automatically and accurately by special adjusting means. The oxidation rate of particle steel is very low in this process. Therefore, compared with raw materials, the reduction of iron content after particle steel forming can be controlled below 2%.

 2、粒子鋼質量耗損率低

Low mass loss rate of particulate steel

此設備采用高效收塵措施，小粒級粒子鋼直接返回烘干二段，且系統封閉性較好，因此，系統粒子鋼幾乎沒有損耗。

This equipment adopts high efficiency dust collection measures, small particle steel directly returns to the second drying stage, and the system has good closure, so the system particle steel has almost no loss.

3、系統降低能耗

System Reduction of Energy Consumption

系統采用全自動化進行精確控制，對生產過程中的各個環節進行精確控制和先進的液壓伺服裝置，在運行過程中電耗低，系統總功率比常規系統降低20%左右。

The system uses full automation for precise control, precise control of all links in the production process and advanced hydraulic servo device. In the operation process, the power consumption is low, and the total power of the system is reduced by about 20% compared with the conventional system.

4、系統造價較低

Lower system cost

系統設計中將烘干過程分級設計，系統尺寸大幅度降低，與常規設計相比，本系統造價降低約30%左右。

In the design of the system, the drying process is graded and the size of the system is greatly reduced. Compared with the conventional design, the cost of the system is reduced by about 30%.

5、系統事故率低

 Low system accident rate

通過模擬計算和自動化系統預警和調節，設備某一環節出現故障或系統檢測傳感器參數有異常時會及時進行報警和優化設備運行，系統作業率大幅度上升。

Through analog calculation and automatic system early warning and adjustment, the system will alarm and optimize the operation of the equipment in time when a fault occurs in a part of the equipment or the parameters of the system detection sensor are abnormal, and the operation rate of the system will increase greatly.

6、  系統流程簡單，運行穩定性好

The system process is simple and the operation stability is good.

系統流程設計非常簡潔、順暢，調節手段靈活，系統運行穩定性很高。

  System flow design is very simple, smooth, flexible means of regulation, system operation stability is very high.