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1、HIsmelt熔融还原技术Smelt Reduction Technology - HIsmelt 汇报人：贾利军Presentor: Jia Lijun,-,HIsmelt熔融还原技术Smelt Reduction,汇报内容Content,1 HIsmelt技术简介HIsmelt introduction2 HIsmelt工艺技术优势Technical advantage of HIsmelt3 生产情况介绍Plant operation experience4 工艺流程的优化Optimization of process5 结论 Conclusion,-,汇报内容Content1 HIsm
2、elt技术简介HIsme,1.1 引言 Background,HIsmelt炼铁工艺是已实现工业化生产的熔融还原炼铁技术之一，属于当今冶金领域前沿技术，经过三十多年的研究开发和生产实践，工艺技术逐渐成熟。 As one of the commercialized smelt reduction iron-making technology, HIsmelt has evolved to a mature solution after thirty years of research and development. HIsmelt炼铁工艺技术是利用非焦煤及铁矿粉采取喷射方式生产液态铁，是解决我
3、国焦煤资源贫乏和环保问题的先进炼铁技术。 HIsmelt uses non-coking coal and iron ore fines, which offers a solution to the coking coal scarcity and environmental problem in China. HIsmelt炼铁工艺在澳大利亚奎那那工厂从2005年至2008年已有3年的生产实践。由于HIsmelt技术上的优势，吸引了全球钢铁行业的目光，受世界金融危机影响，HIsmelt奎那那示范厂2008年年底停产，且不再复产。HIsmelt Kwinana plant in Austra
4、lia had run fours years from 2005 to 2008 and it successfully demonstrated the advantage of this technology . It was forced to shut down due to global economic crisis. 国内某公司自2004年以来一直致力于新炼铁工艺、技术、装备的研究，在2012年决定利用部分HIsmelt奎那那工厂设备，并通过进一步优化工艺流程，建设新的HIsmelt熔融还原炼铁生产厂。 A Chinese company , who has been focu
5、sing on the research of innovative iron-making technology, process and equipment, decided to build a HIsmelt plant in China. This plant uses some of the Kwinana equipment, but also makes some modification by optimizing the existing process.,-,1.1 引言 Background HIs,1.2 HIsmelt工艺描述 HIsmelt Process Des
6、cription,煤气室,烟道,上部燃烧区,渣口,水冷板,喷泉及渣层,残铁口,热风喷枪,水冷板,天然气喷枪（或煤枪）,固体喷枪,带内衬前置炉,带内衬的前置炉通道,带内衬的炉底,铁水熔池,渣区冷却器,-,1.2 HIsmelt工艺描述 HIsmelt Proc,煤中碳素溶于铁水, 矿石溶于渣中 carbon in the coal dissolve in the bath, 含铁原料被还原成液态铁水； Iron-bearing material is reduced to liquid iron 脉石和灰份被从矿石和煤中分离形成炉渣； gang and ash from ore and coal
7、 form slag工艺反应产生的煤气与热风进行二次燃烧产生热能； process gas combust with hot blast to produce energy渣与铁水液体把能量带入熔池以维持反应。 metal and slag droplet bring part of the energy back to the bath to sustain the reaction,SRV 熔融还原炉中发生的反应为：Reaction in the SRV:,-,SRV 熔融还原炉中发生的反应为：Reaction in,1.3 HIsmelt工艺流程 HIsmelt process flow
8、,Iron ore,dolomite,dryer,Pre-reduction kiln,Cyclone,Bag house,Dust injection,Coal mill,Coal,lime,Granulated slag,Coal mill,Ore injection,coal injection,limel injection,Iron recovery,Slag granulation,Ladle car,Steel mill,Pig caster,Knock out vessel,Convective cooler,Waste gas,FGD,Cyclone de-dusting,S
9、toves,boiler,FGD,Suck fan,Oxygen plant,Electrical blower,scrubber,Hot gas generator for the coal mill,Generator,-,1.3 HIsmelt工艺流程 HIsmelt proc,HIsmelt工艺技术优势 Advantages of HIsmelt,投资成本低：与传统的炼铁技术相比，Lower capital cost compared with traditional blast furnace due to: HIsmelt不需要焦炉和烧结厂或球团厂，因此建设成本降低； HIsmel
10、t eliminates coke oven, sinter plant and pellet plant HIsmelt 工艺中的许多设备和设施，如热风炉、喷煤系统、发电等都是高炉炼铁工艺常用的设施，因此工厂建设相对比较简单， HIsmelt shares many common equipment used in blast furnace, such as hot blast stoves, generator etc. HIsmelt技术所使用的原料比较灵活，因此无需大型原料混匀场，极大降低了HIsmelt工厂的占地面积。 HIsmelt is flexible in raw mate
11、rials selection and no blending facility is needed.,-,HIsmelt工艺技术优势 Advantages of HI,2 HIsmelt工艺技术优势 Advantages of HIsmelt,操作成本低：Lower operational cost直接使用矿粉和煤粉作为原燃料炼铁，不用焦炭、球团和烧结。HIsmelt uses iron ore fines and coal directly; no coke, sinter or pellet will be needed.,-,2 HIsmelt工艺技术优势 Advantages,更大的
12、原料灵活性Great flexibility in raw material：HIsmelt技术可直接喷吹传统高炉烧结厂不宜使用的低品位铁矿粉。 HIsmelt can use low grade iron ore fines which otherwise can not be used by the blast furnace sinter plant.,-,更大的原料灵活性Great flexibility in r,铁水质量稳定，磷含量很低，基本不含硅，因此可进行少渣炼钢，降低炼钢成本。 Stable hot metal quality, low P content, almost n
13、o silicon; so less slag is needed in the steel mill and thus reducing steel mill cost,Himselt工艺与高炉生产铁水成分对比HIsmelt Hot Metal vs. BF Hot Metal,铁水质量好 Superior hot metal quality,-,铁水质量稳定，磷含量很低，基本不含硅，因此可进行少渣炼钢，降,降低环境影响，通过变革性的工艺创新，取消焦炉、烧结，HIsmelt极大的降低了SO2和NOx、基本遏制二恶英、焦油和酚的排放。Almost no emission of dioxins,
14、 phenols or tars due to the revolutionary process and elimination of coking oven and sintering process.,更绿色环保的炼铁技术 Less Environmental Impact,-,降低环境影响，通过变革性的工艺创新，取消焦炉、烧结，HIsm,3 生产情况介绍 Production Experience,3.1 奎纳纳情况概览 Kwinana summary 从2005年11月开始了为期3年的达产运行：2006年底实现50%，2007年实现80%，2008年实现85%three year r
15、amp-up period beginning in November 2005: 50% by 2006, 80% by 2007, 85% by 2008期间主要问题大多由外围设备引起，在这些问题得以解决后生产率逐步上升。Major problems caused by ancillary equipment and production rate continued to rise as bottlenecks removed 2008年12月，由于经济危机影响，生铁市场低迷，工厂因此关闭。Plant put under care and maintenance and then clo
16、sed due to sluggish market demand caused by global economic crisis from end of 2008,-,3 生产情况介绍 Production Experi,3.2 HIsmelt的生产情况 Production Data of HIsmelt,由上图中可知，2008年12月日产最大达到1834t。Daily production reaches a maximum of 1834t in December of 2008.,-,3.2 HIsmelt的生产情况 Productio,3.2 HIsmelt的煤耗 Coal Ra
17、te of HIsmelt,-,3.2 HIsmelt的煤耗 Coal Rate of,4 工艺流程的优化 Process Modification,基于奎纳纳工厂的经验，山东省冶金设计院、力拓公司和业主决定对部分工艺流程和设备进行改进，以降低成本和浪费。 Based on the Kwinana experience, SDM, Rio Tinto and the end user decided to modify some of the process and equipment to reduce cost and waste.,-,4 工艺流程的优化 Process Modifica
18、tio,4.1 新矿粉预热系统 Modification of the Iron Ore Preheating,为降低工程投资，矿粉预热采用了技术可靠的双回转窑工艺 A double kiln system is used which help reduce capital cost,-,4.1 新矿粉预热系统 Modification of,特点 Advantage:改进后的工艺既能实现矿粉的加热、预还原的目的，且技术成熟、设备运行稳定、作业率高。The kiln system is capable of preheating and pre-reducing the iron ore. I
19、t is a mature, stable and efficient solution. 同时，改进后的预热还原系统既可以采用煤粉也可以采用SRV煤气作为燃料，设计独立的煤粉供应系统，有助于提高HIsmelt工艺整体的作业率。At the same time, this system can run on both coal and SRV offgas, which help increase the utilization rate.,-,特点 Advantage:-,4.2 矿粉喷吹系统Modification of Iron Ore Injection System,考虑新的矿粉预热
20、系统的收尘系统收集的粉尘中含有大量的含铁氧化物及少量未然碳粉，为提高资源的利用率，新的HIsmelt工艺设计中增加一套细粉喷吹系统，其主要作用：将工厂产生的含铁、含碳粉尘喷入SRV内，完成含铁废弃物的合理利用，提高铁水产量，同时喷入SRV内的含碳粉尘可以为铁矿石的融化还原提供热源和还原剂，有利于降低吨铁工序能耗。The new HIsmelt plant added a dust injection system to recover the iron bearing dust and carbon bearing dust, which will help reduce waste and
21、improve raw material utilization rate.,-,4.2 矿粉喷吹系统Modification of Ir,4.3 铁、渣系统的改进Modification of the slag and metal handling system,残铁回收：当SRV事故状态时，一次残铁量约300t铁水需从SRV炉内排出，因此新设计中通过增加残铁回收跨，残铁回收跨内设置有残铁受铁设施，设置有通向铸铁厂房的80t铁水罐电动平车，使SRV炉残铁能至铸铁机铸铁，有利于残铁的再利用。End tapped metal recovery: about 300t hot metal will
22、 be discharged to the pit if there is an emergency. A end tap metal recovery facility is designed and 80t ladle cars are used to transfer the end tap metal to the pig caster.,-,4.3 铁、渣系统的改进残铁回收：当SRV事故状态时，一,熔渣处理及渣中铁的回收技术 Slag handling and iron recovery,该流程能有效回收HIsmelt熔融还原技术生产熔渣中携带的铁，能提高HIsmelt工艺铁水收得率
23、，降低HIsmelt工艺的工序成本。This process helps recover the iron trapped in the slag during slag tapping, thus reducing the production cost.,图中：1熔渣沟；2渣罐；2渣罐；3专用起重机；4渣罐运输车；5渣罐倾翻装置；6熔渣沟；7熔渣处理设施；8铁水罐运输车；9铁水罐；,HIsmelt熔融还原工艺熔渣中铁的回收流程如下图The following is the process of recovering the iron trapped in the slag:,-,熔渣处理及
24、渣中铁的回收技术 Slag handl,4.4 煤气余热回收系统 Modification of offgas waste heat recovery system,去除煤气中携带的较大颗粒烟尘，防止后续煤气管道积灰堵塞。Remove the large particles in the dust and avoid blocking the offgas pipes,降低气体的含尘量，提高气体的对流换热系数。Reduce dust content and increase heat exchange efficiency,回收余热，产生蒸汽用于发电；Waste heat is recover
25、ed to generate electricity,当余热锅炉故障时，高温气体可以直接进入湿法洗涤系统，不影响SRV正常生产。When the boils stops, hot offgas will goes to scrubber.,-,4.4 煤气余热回收系统 Modificati,4.5 锅炉及动力系统 Modification of the Boiler and Power system,原鼓风发电机组利旧 Old TAB will be re-used新增一台中温中压抽汽凝汽式汽轮发电机组。 Add a new medium pressure turbine generator增
26、设一台电动鼓风机备用。 Add a back up electrical blower制氧驱动方式改为电动。 Oxygen plant is driven by electricity燃气锅炉采用自然循环，在炉膛下部采用强化传热传质的SRV煤气锅炉炉内蓄热稳燃装置，保证了难以燃烧的SRV煤气的充分燃烧。 The boiler uses natural circulation. There is a thermal storage device in the lower chamber of the boiler which help stabilize combustion.,-,4.5 锅炉
27、及动力系统原鼓风发电机组利旧 Old T,特点：各系统相互独立，互不影响。 Characteristic: the function of each equipment is not solely reliant on the upstream equipment, which provides redundancy.,-,特点：各系统相互独立，互不影响。 Characteri,5 总 结 Conclusion,Hlsmelt熔融还原炼铁技术是实现工业化生产的非高炉炼铁技术之一，其工艺可看作是冶金行业中各种成熟技术的新组合，和当前的耐火材料技术、喷吹技术、烟气余热回收和净化技术以及其他的冶金技
28、术的发展是相辅相成的，是高炉最有力的竞争者, 是有希望革高炉命的新技术。 HIsmelt is one of the commercialized non-BF technologies. HIsmelt consists of many common and mature technologies, such as refractory, injection, waste heat recovery and scrubbing. It is regarded as the most competent competitor of blast furnaces.,-,5 总 结 Conclus
29、ionHlsmelt熔融还原炼铁,在HIsmelt工艺国产化过程中吸取奎那那工厂的生产经验，对原有工艺进行了优化完善，新的工艺既改善了工艺的稳定性，提高系统的作业率，又采取了有效节能降耗、资源合理利用措施，有效降低吨铁工序能耗，为提升HIsmelt的竞争力提供了强有力的技术保障。Based on Kwinanas experience, the Chinese plant modified the old process and equipment. It is expected that the new process is more stable and energy-efficient,
30、 therefore more competent.,-,在HIsmelt工艺国产化过程中吸取奎那那工厂的生产经验，,-,-,祝愿HIsmelt技术为炼铁节能环保做出伟大贡献Wish HIsmelt achieves more in terms of energy efficiency and environmental friendliness,请各位领导、专家批评指正！Any questions?,本文的部分参数、图表由力拓提供，在此表示感谢。Thank Rio Tinto for the courtesy of some pictures and diagrams.,-,祝愿HIsmelt技术为炼铁节能环保做出伟大贡献请各位领导、,
