小型钢铁厂50万吨电炉炼钢连铸连轧生产线建设草案.docx

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1、小型钢铁厂50万吨电炉炼钢、连铸连轧生产线建设草案ANNUAL CAPACITY OF 500,000t/a STEELMAKING ANDROLLING PROCESS CONCETP目录 TABLE OF CONTENTS1 总论 SUMMARY1. 1项目提出OBJECTIVE1. 2 建设规模 CONSTRUCTION SCALE1. 3 产品初步方案 PRIMARY PRODUCT SCHEDULE2 炼钢 STEELMAKING2. 1 工艺及设备选择 PROCESS AND EQUIPMENT2. 2 生产方法 PRODUCTION METHOD2. 3 炼钢工艺流程 STEEL

2、MAKING PROCESS FLOW2. 3. 1 流程 PROCESS FLOW2. 3. 2 工艺流程简述 INTRODUCTION TO THE PROCESS FLOW2. 4 炼钢主体设备及主要参数 MAIN STEELMAKING EQUIPMENT AND PARAMETER2. 4. 1 电弧炉 ELECTRIC ARC FURNACE2. 4. 2 钢包精炼炉 LADLE FURNACE2. 4. 3 连铸系统 CONTINUOUS CASTING MACHINE2. 5炼钢、精炼及连铸各项主要指标MAIN TECHNICAL AND ECONOMIC INDEXES2.

3、5. 1 电炉指标 ELECTRIC ARC FURNACE2. 5. 2 LF炉指标 LADLE FURNACE2. 5. 3 连铸机指标 CONTINUOUS CASTING MACHINE2. 6 主要原材料 MAIN RAW MATERIAL2. 6. 1 废钢、生铁 SCRAP、PIG IRON2. 6. 2其它材料 OTHERS2. 6. 3 电极 ELECTRODE3 棒材轧钢生产线 TWISTED STEEL PRODUCTION LINE3. 1 工艺及设备选择 PROCESS AND EQUIPMENT3. 2 生产方法选择 PRODUCTION METHOD3. 3 工艺

4、流程 PROCESS FLOW3. 4 工艺流程简述 INTRODUCTION TO THE PROCESS FLOW3. 5棒材轧机主设备及参数MAIN EQUIPMENT AND INDEXES3. 6棒材规格品种PRODUCT MIX4小型型钢轧钢生产线SECTION STEEL PRODUCTION LINE4. 1 工艺及设备选择 PROCESS AND EQUIPMENT CHOSEN4. 2 工艺流程 PROCESS FLOW4. 3 工艺流程简述 INTRODUCTION TO THE PROCESS FLOW4. 4型材轧机设备及参数 MAIN EQUIPMENT AND I

5、NDEXES4. 5型材轧制规格品种PRODUCT MIX5 动力能源 THERMAL AND POWER SUPPLY5. 1 热力 THERMAL5. 2 供电 POWER SUPPLY6 环境保护 ENVIRONMENTAL PROTECTION7 设备费用 MAIN EQUIPMENT INVESTMENT ESTIMATE8 其它 OTHERS1. 总论 summary1. 1项目提出objective炼钢能力55万吨，配公司现有螺纹钢连轧生产线及另外添置一条小型型钢生产线，共计50 万吨轧钢能力，形成完整的的共计50万吨连铸连轧的生产线，以供市场需求。This plan prepa

6、res to construct 550,000 tons annual steelmaking capacity, 300,000 tons in twisted steel rolling and 200,000 tons in section steel rolling per year, to form an integrated steel production line, so as to meet the requirement of the market.1. 2 建设规模 construction scale按公司现有的螺纹钢连轧生产线为基础，并另配一条小型型钢生产线，上游配

7、套相应的炼钢 连铸生产线，建成炼钢厂、轧钢厂，形成一条完整的生产链。There is a twisted steel rolling line now, a section steel rolling line and steel making line need to be added to form a complete product line.炼钢厂主要装备50吨交流偏心底出钢（50tAC/EBT）电弧炉2座，50吨钢包精炼炉一座， 三机三流多功能方圆坯连铸机一台（R8m或R9m）。在目前条件下以全废钢为原料，形成短 流程炼钢生产线，年产钢水55万吨、连铸坯53万吨（150220方坯或

8、150220圆坯）。The main equipment in steelmaking plant are composed of two 50tAC/EBT electric furnace, one 50t ladle furnace and one R8m(or R9m) threemotor and threeflow continuous casting machine. The materials are mainly scrap. The production capacities are 550,000 tons per year for steelmaking and 530

9、000 tons per year for casting bloom. The cast product section size ranges from 120mmx120mm to 220mmx220mm.轧钢厂分两部分，其一以我公司现有棒材连轧生产线为基本模式，由20架全水平式机组组 成棒材连轧生产线，除生产螺纹钢外，考虑生产圆钢管坯钢等产品，年生产能力30万吨； 同时另建一条半连轧小型型钢生产线，年生产能力每年20万吨。The steel mill is made up of two parts, one is Chanrongs existing continuous steel

10、 rolling production line, which consists of 20 full horizontal mill trains, and the production capacity is 300,000 tons per year for twisted steel. Another is the half-continuous steel rolling production line planned to be built for section steel; its production capacity is 200,000 tons per year.1.

11、3 产品初步方案 product primary mix棒材产品方案为大、小规格比较齐全的II级III级螺纹钢，低合金结构钢种圆钢及碳素管坯圆 钢。螺纹钢可为3210系列，圆钢可为50120系列；型钢产品方案为小型角钢、槽钢、 工字钢，规格为10 #-20#。For twisted steel, the production capacity is 300,000t per year; the product size is 10-32mm. The grade is HRB335 and HRB400.For section steel, the production capacity is

12、 200,000t per year. The products includes angle, channel and I-beam, the production size is from 10# to 20#.2 炼钢 steelmaking2. 1 工艺及设备选择 process and equipment choice炼钢厂主要原料为各种工业、民用及军用废钢，根据资源情况可配入生铁，同时寻求铁水或 还原铁等其它资源。The main raw material is scrap steel, mainly industrial, civilian and military suppli

13、es. Depending on condition, pig iron, molten iron and DRI etc could be used.工艺流程为：废钢生铁加入50吨偏心底出钢电炉初炼脱P、脱C去除夹杂气体及有害物质 后进入50吨钢包精炼炉脱气精炼，并除S、调整化学成分和钢液温度。精炼后的钢水用行 车吊至连铸机后铸成坯，铸机连浇炉数N5炉。Process flow: scrap and carbon-added pig iron are fed into 50t EBT electric furnace to be melted; phosphorus, carbon, gas

14、 and impurity in the liquid steel are removed. Then the liquid steel will be tapped into the ladle furnace for refining, de-airing, desulfurization and adjustment of chemical composition as well as temperature. Finally, the ladle containing the qualified liquid steel is hoisted to casting machine wh

15、ere the qualified liquid steel is casted into blooms. There are casting machines with capacity to mach the more than 5 furnaces.工艺设计与设备选型以简单实用为原则，采用不带加热隧道的50吨高功率偏心底出钢交流 电弧炉2座配1台精炼炉配1座连铸机的模式，即2+1+1模式。In choosing the process and equipment , we follow the principle of simplicity and economical. The mai

16、n equipment in steelmaking consists of two 50t EBT high power electric arc furnaces with no pre-heating device, one ladle furnace (LF) and one continuous casting machine; it is the so-called 2+1+1 model.主要设备选型为：Main equipment:50吨偏心底出钢高功率电弧炉2座；Two 50t EBT high power electric arc furnaces;50吨LF钢包精炼炉1座

17、One 50t ladle furnace (LF);R9米三机三流弧形连铸机1座。One R8m threemotor and threeflow continuous casting machine;以上设备均为中国成熟设备，结构简单，维护方便，一般的备品备件均可就地解决。The above equipment are all made in China, with matured technology, simple construction, excellent capability, easy maintence and the spare parts are easily ava

18、ilable.为长远发展考虑，钢包精炼炉可预留抽真空工位。With future development in mind, there will be space allocated in the LF zone for vacuum device.2. 2 生产方法 production method炼钢方法为2对1对1的短流程冶炼工艺设置，即2座50吨偏心底电弧炉配1座50吨LF 精炼炉配一台R8米三机三流连铸机以及其它辅助设备。所有设备特别是30吨电炉都是国 内成熟可靠的设置，简单易行，维护方便，备品备件容易就地取材。配置2台50吨电炉还 可以在其中一台出故障时，仍可继续维持生产，避免全

19、线停工。The steelmaking production line is composed of two electric furnaces, one LF, one R8m threemotor and threeflow continuous casting machine. The two furnaces will ensure that when one malfunctions, the other can continue to be used so that there will be continuous production.根据目前中国冶炼水平及国际炼钢发展的趋势，在

20、炼钢车间建设中尽可能地配置成熟的先进 工艺装备。应用如下成熟的先进技术：Based on current Chinese and international metallurgy technology level and current, matured and advanced technologies should be applied in the construction of the mill, as follows:(1) 偏心炉底无渣出钢与炉中留钢留渣操作；(1) EBT mechanism for tapping, during tapping process, no slag

21、 output, slag and excess steel remained in electric arc furnace for next steelmaking process.(2) 炉门C-O枪喷吹助熔、炉壁天燃气喷吹助熔及二次燃烧技术；(2) There is a carbon oxygen lance in the furnace door and oxygen burner on the furnace wall to assist the melting of the burden.(3) 密排式水冷炉壁及水冷炉盖；(3) Closed water-cool furnace

22、 wall and furnace cover.(4) 泡沫渣埋弧冶炼技术；(4) Slag foaming technology.(5) 电炉除尘采取半密封罩和屋顶罩排烟、袋式除尘器净化；(5) New-fashioned dusting technology.(6) 炉外精炼技术；(6) LF refining method.(7) 全连铸；(7) Continuous casting.(8) 管坯钢连铸时采取保护浇铸；(8) If necessary, protected casting method could be used.(9) 短流程生产线；(9) Short process

23、in steelmaking.(10) 电气控制采用可编程序控制器(PLC)；(10) PLC is used in electrical system.(11) 电炉机械系统采用全液压控制。(11) Hydraulic technology is used in steelmaking mechanical system.2. 3炼钢工艺流程process flow2. 3. 1 流程 process废钢、生铁炉料装入电炉一给电熔化一碳氧枪吹氧助熔一炉料熔清一造泡沫渣去P去碳、 调整钢液成份与温度一电炉偏心底留渣出钢、钢包中初步合金化、造渣一进入精炼工位一精 炼炉通电化渣热平衡同时全过程底吹

24、氩一脱氧造白渣一调整合金成份与温度一出精炼工位 -钢包上回转台一钢包开浇钢水到中间包一中包开浇钢水到结晶器一拉坯一定尺切割一精 整及分炉号一红送至轧钢加热炉Scrap and carbon-added pig iron are fed into electric furnace electricity is used to melt the material carbon oxygen lance and oxygen burner are used to work to assist melting melting finished to make foaming slag, dephosp

25、horization, carbon elimination, as well as adjusting the chemical composition and temperature tapping to ladle where primary alloying and slagging are to be made to put the ladle on LF position refining, argon blowing deoxidation, desulfurization, slag whitening adjusting chemical composition and te

26、mperature the ladle leaving LF position to put the la dle on ladle rotator of continuous casting machine molten steel drops down into surge tank(tundish) molten steel drops down into crystallizer casting cutting bloom according to size inspection bloom is sent to steelmaking workshop这是一条比较先进的电炉初炼、LF

27、炉精炼、全连铸短短炼钢生产线。This is an advanced short process production line.2. 3. 2 工艺流程简述 introduction to the process flow炼钢炉料由废钢、生铁组成，其比例由资源情况而定，一般生铁量不超过30%，由天车电 磁吊将废钢装入料罐进行配料。每炉不超过两次料。经检斤后由过跨车由配料跨送至炼钢跨， 由炼钢跨天车由炉顶加入原料。The scrap and pig iron are mixed in certain proportion which depending on resource conditio

28、n, the proportion of pig iron is generally less than 30 percent. These raw materials are charged into bucket by electromagnetic lifter. After the bucket is weighed, it is conveyed from the raw material span to smelt span by platform car. In smelt span, the bucket is hoisted to the position above the

29、 top of electric furnace, and then scrap and pig iron are fed into the furnace. The raw materials could be charged not more than twice into the furnace.关闭炉盖通电冶炼，电炉采用强化冶炼的措施，采用高功率送电，造泡沫渣，炉门口碳氧喷 枪强化用氧，用氧强度达到45Nm3，炉壁喷枪喷吹天然气。所需造渣材料石灰、萤石等由 炉顶加料机或炉门口人工加入。炉渣处理采用热泼渣工艺，由铲车送出车间集中处理。Then, the furnace cover is

30、closed, high power electrifying begins. At the same time, carbon oxygen lances on the furnace door and oil-oxygen burner on the furnace wall assist the melting of the burden and make foaming slag. Oxygen consumption is about 45Nm3 /t. The other materials such as lime and fluorite etc are added into

31、the furnace by feeding-machine or manual labor. Electric furnace slag will be treated with water spraying, collected and transported out of the workshop for treatment.电炉由人工热电偶测温，人工取样送化验室分析成份。当电炉冶炼的钢水符合初炼要求时， 经偏心底无渣出钢到钢包车上的钢包中，再送至精炼炉精炼。钢包出钢前通好氩气并加入造 渣材料。出钢时将事先准备好的铁合金随钢流加入包中。电炉内留钢大约为5吨。Electric thermo

32、meter is used to measure temperature of the furnaces. The specimen is collected manually and sends to laboratory for composition analyzing. When the results meet the initial set requirements, the melted burden will be tapped through an EBT mechanism to a receiving ladle that is on a special platform

33、 car. Before tapping, ensure argon flow and slag former will be put into the ladle. while tapping, ferroalloys are poured into the ladle. There will be about 5t of excess melted steel left in the furnace.接钢后的钢包在精炼工位上进行精炼。钢液精炼全过程吹氩搅拌，用造渣材料和脱氧剂调渣， 调整电流进行调温，加入铁合金进行成分的调整。精炼炉投产初期不上真空工位，但预留此 功能，以为今后的发展留有余

34、地。After tapping, the ladle is put on LF refining position. LF refining is conducted through arc heating and argon blowing. During this process, the steel deoxidization, desulfurization, the adjustment of steel temperature and chemical composition are completed.In primary phase, there is no vacuum fu

35、nction in LF, but space for vacuum device may be allocated in LF zone for future development.精炼合格的钢水以大包滑动水口至中间包，再将钢水浇注到结晶器中。从结晶器中拉出的钢 坯经多点矫直，剪切后，成为合格的坯料。生产管坯料时，将采用长水口无氧化浇注技术。The ladle containing qualified liquid steel is hoisted to a ladle rotator of the continuous casting machine. The liquid steel

36、is then tapped from the base of the receiving ladle to tundish, after that, it drops down into crystallizer to be casted into bloom. The bloom will be straightened, cut according to dimensions and sent to a cooling bed through a roller table. It will then become qualified bloom.中间包采用10吨容量，以减少中间包内的温度

37、损失，并可稳定连铸的浇注速度。The tundish has a capacity of 10 tons, so as to reduce the loss of temperature and to keep the casting speed steady.2. 4炼钢主体设备及主要参数 main steelmaking equipment and parameter2. 4. 1 电弧炉 electric furnaceModel: high power EBT alternating current electric furnace.台数：2 台。 Quantity: 2公称容量：50

38、 吨。 Nominal capacity: 50 tons.单炉出钢量：56 吨。 Average tapping: 56 tons.炉壳内径：4700mm inside diameter of fUrnace shell:4700mm炉变容量：24MVA Transformer capacity: 24MVA一次电压：35KV Primary voltage: 35KV二次电压：430V170V Secondary voltage: 430V170V电极直径：450mmElectrode diameter:450mm驱动方式： 液压。 Driving force: hydraulic pre

39、ssure结构形式：高架式。高架式比地面式有优越的工作环境。同时可采取水泼渣，节省渣罐及渣 罐车。Structure: hoist up model. This model is preferable to the ground level model as it gives favourable working conditions. Water spraying may be used to treat electric furnace slag, saving cost on slag basket and slag car.二次出线和电炉横臂间由集束式水冷电缆连接，横臂采取复合式导电横

40、臂，横臂中腔水冷。 这些大大提高了导体导电性能，同时具有很高的设备可靠性。The connection between transformer-output and furnace-arm, is by bunch water-cooling cable.The furnace-arm is a combined type and can conduct electricity. To improve electro conductibility and equipment dependability immensely, the cavity of the furnace-arm is wa

41、ter-cooled.电极升降动作采取液压系统驱动，电液比例阀进行控制，动作灵敏可靠。The electrode movement is driven by hydraulic pressure. Electro-hydraulic proportional valve controls the movement, it is sensitive and reliable.炉盖为密排式水冷炉盖，使用寿命可达30004000次。炉体上部采用挂渣水冷块，寿命长， 并节约大量耐火材料。Furnace cover consists of closed up water-cooling pipes. T

42、he cover can be used for 30004000 times. Topside of furnace wall consists of water-cool parts; it has long useful life and save cost of refractory.2. 4. 2 钢包精炼炉 ladle furnace型式：桥架式Model: Bridge.台数：1 台Quantity: 1单台容量：50 吨 Nominal capacity: 50 tons.炉变容量：10MVA Transformer capacity: 10MVA一次电压：35KV Prima

43、ry voltage: 35KV二次电压：300400V Secondary voltage: 300V400V钢包自由空间高度:350mm The ladle free height: 350mm （注：若将来上真空工位时，自由空 间大大增加，钢包需重新选型）电极直径：350mm Electrode diameter:350mm主要驱动方式： 液压。 Driving force: hydraulic pressure 采用水冷炉盖、集束式水冷电缆。Water-cooling cover and bunch water-cooling cable are used.精炼炉附近附设吹氩装置，精炼

44、过程全程吹氩。Near by the LF, there is an argon blow device. Argon blowing is performed throughout the refining process.2. 4. 3 连铸系统 continuous casting machine三机三流 R9 米弧形连铸机。Casting machine: R9m, 3-motor and 3-flow.中间包容量：10 吨。Tundish capacity: 10 tons.结晶器结构：管式弧形，窄水缝导流水套式。Crystallizer: tube-arc type with na

45、rrow water crack.浇注钢种：ii级与m级螺纹钢及小型型钢所涵盖的所有钢种的钢坯，碳素管坯钢，低合金钢。Steel grade: the bloom to be casted is material for type II and m twisted and section steel.铸坯断面尺寸：1202mm, 1502mm, 2202mm, 180X220mm矩形坯及220mm圆坯等。Cast product section size: 1202mm, 1502mm, 2202mm.连浇炉数：N5炉。2. 5炼钢、精炼及连铸各项主要参数指标main technical an

46、d economic indexes2. 5. 1 电炉指标 electric furnaceNo序号Name名称Unit单位Index数值1Nominal capacity电炉公称容量T吨502quantity of furnace电炉座数座23Inside diameter炉壳内径mm4700mm4Transformer capacity电炉变压器额定容量MVA245Electrode diameter电极直径mm450mm6Average tapping平均出钢量t567Average Smelting period平均冶炼周期min908Annual Operation days电炉年

47、作业天数d3109Annual capacity年产钢水量t277760x2=55552010Electricity consumption电炉吨钢冶炼电耗kwh/t45011Electrode consumption吨钢单极电耗Kg/t3.512Oxygen consumption吨钢综合用氧量M3/t482. 5. 2 LF炉指标LFNo序号Name名称Unit单位Index数值1Nominal capacity容量t502QuantityLF炉座数座13Transformer capacity变压器额定容量MVA104Electrode diameter电极直径mm03505Refining period of LF精炼周期min30556Electricity consumption吨钢精炼电耗kwh/t407Electrode consumption吨钢精炼电极耗Kg/t0.58Argon consumption段钢精炼耗氩量M3/t0.32. 5. 3 连铸机指标 continuous casting machineNo序号Name名称Unit单位Index数值1Arc Semi diameterm8半径2Flow