外文--在薩爾茨吉特有限公司修改和改造轉(zhuǎn)爐容器

1、<p>　　在薩爾茨吉特有限公司修改和改造轉(zhuǎn)爐容器B </p><p>　　自從薩爾茨吉特有限公司在2007年4月委命其新的轉(zhuǎn)爐B以來，該轉(zhuǎn)爐的能力增加了20 ％以上。新的容器發(fā)生顯著的改善，包括滑移量的減少，更長的壽命和更高的產(chǎn)量。 </p><p>　　在生產(chǎn)過程的進(jìn)行中更換轉(zhuǎn)爐容器</p><p>　　30多年后，薩爾茨吉特有限公司的綜合鋼廠高爐B于

2、2007年3月關(guān)閉，目的是替換轉(zhuǎn)爐B的容器，即安裝一個幫助滿足鋼鐵生產(chǎn)效率的容器。 該容器不得不改變自1976年發(fā)現(xiàn)因高的熱負(fù)荷引起的應(yīng)力變形.這新的容器更大并且與懸掛系統(tǒng)結(jié)合運行，現(xiàn)在已展示了平靜的多的吹氧進(jìn)程，而且已經(jīng)實現(xiàn)其他的積極影響。 這篇文章論述了如期完成的成功的改造和吹氧進(jìn)程的最初結(jié)果。薩爾茨吉特有限公司 薩爾茨吉特在薩爾茨吉特集團(tuán)是最大的鋼鐵子公司，在其薩爾茨吉特，產(chǎn)約四百六十萬噸的鋼。平板產(chǎn)

3、品的最重要的客戶是鋼鐵貿(mào)易公司，汽車制造商和他們的供應(yīng)商以及冷輥和標(biāo)準(zhǔn)大直徑鋼管的制造商，建筑行業(yè)。綜合鋼鐵廠生產(chǎn)從0.4至25毫米不等厚度，寬達(dá)到一千八百五十毫米的熱軋帶鋼，冷軋薄板和表面成品。生產(chǎn)項目包括繪畫，深沖和細(xì)粒鋼，以及高強(qiáng)度鋼。 大約25 ％的薩爾茨吉特鋼鐵產(chǎn)量交付其在阿爾神伯格的寬厚板軋機(jī)作為主要材料。在這個廠，板材厚度達(dá)130毫米，寬度高達(dá)3300毫米。大約5 ％ 的板塊在派納重梁軋機(jī)廠被用作原料。薩爾茨吉特

4、有限公司的氧氣煉鋼廠的每年輸出能力大約是5百萬噸粗鋼。三個轉(zhuǎn)爐每天平均產(chǎn)</p><p>　　國際大地測量公司和萬能（德國）公司生產(chǎn)這種設(shè)備。耳軸引腳焊接需要特殊的技術(shù).這份工作由32名電焊工16天內(nèi)不間斷的輪流執(zhí)行。 總共四部分的轉(zhuǎn)爐容器被審查安裝和全面調(diào)查。尺寸如下： ?頂端部分：7740mm，高度約2640mm ，體重約40噸； ?中間部分：7780mm，高度約900mm ，重量約16 噸； ?中間

5、部分：7740mm，高度約3610mm ，重量約49噸； ?底部：7740mm，高度約2680mm ，重量約40噸。 基于這，轉(zhuǎn)爐容器部分為了裝運和隨后安裝被安裝到指定位置。這批貨物是后勤挑戰(zhàn)：一夜之間從制造業(yè)房地港奧斯納布呂克，用船運到港口，再通過幾個拖拉機(jī)拖車運到煉鋼廠 。 裝配和安裝 除了為工程所做的艱巨的設(shè)計和掌握材料的的任務(wù)外，為規(guī)劃個人裝配和安裝的步驟以期實現(xiàn)在最短時間內(nèi)安裝需要一個全新的辦法。常規(guī)程

6、序的轉(zhuǎn)爐拆卸、裝配和安裝，最終留給德瑪格公司一個新的概念去開發(fā)。裝配和急救設(shè)備已經(jīng)安裝在工廠，以求在工地快速和安全地調(diào)整組成部分。 在煉鋼廠的安裝由被承包者魏瑪有限公司（薩摩亞）正常操作 。對安裝工作進(jìn)行具體調(diào)整，以適應(yīng)在工廠的空間條件</p><p>　　新設(shè)備的安裝 安裝碼頭的選擇，例如，該轉(zhuǎn)爐容器可以安裝在靠近海灣地區(qū)的起重機(jī)附近。沿著整個海灣繼用海灣起重機(jī)縱向運輸，該轉(zhuǎn)爐容器在轉(zhuǎn)移，提升和轉(zhuǎn)向裝

7、置上定位。此設(shè)備被用來將轉(zhuǎn)爐容器精確到毫米地插入圍墻，。一旦轉(zhuǎn)爐容器被完全定位并在其最終的位置存放，該轉(zhuǎn)爐容器齒輪組合就被安裝。最后階段的工作開始，其中包括越來越多的剩余渣裙，干擾和耐火襯里的檢查，卸載一部分的安裝。相反，該平臺，沒有任何疑慮的，順利地運行，試運行之后接著調(diào)查并研究槍的位置。隨后的時間來加熱，管理；在32天之后發(fā)起第一次吹氧進(jìn)程來進(jìn)行加熱，。 新轉(zhuǎn)爐的運行情況 下面是過去三個轉(zhuǎn)爐容器系列的老轉(zhuǎn)爐與最初的三新轉(zhuǎn)

8、爐容器系列的新轉(zhuǎn)爐的對比?；跈z測氧氣流量和爐渣數(shù)額的轉(zhuǎn)爐的水浸情況（見圖6 ），在薩爾茨吉特的轉(zhuǎn)爐具體要求是體積約1立方米/噸鋼。這由于結(jié)構(gòu)性條件而無法實現(xiàn)。然而，有可能接近最佳條件，以及具體的數(shù)量可能增加到0.68立方米/噸至0.83立方米/噸。這顯然增強(qiáng)的水浸條件也給期望一個相應(yīng)的生產(chǎn)參數(shù)的改進(jìn)一個理由。 </p><p><b>　　氧槍 </b></p>&l

9、t;p>　　較大的轉(zhuǎn)爐容器減緩了氧槍噴頭的形成。許多分析中被證明，與其他兩個轉(zhuǎn)爐相比轉(zhuǎn)爐B的氧槍有更長的使用壽命： ?舊轉(zhuǎn)爐B： 168單位熱量。 ?新的轉(zhuǎn)爐B： 212單位熱量。 相較于這些價值觀念，135立方米左右的轉(zhuǎn)爐A和C的氧槍壽命是100單位的熱量 。截至2008年1月5日轉(zhuǎn)爐B 氧槍的最長壽命是445單位熱量。 冶金 在熱量的均一化的基礎(chǔ)上，推斷在爐渣中鐵的損失更穩(wěn)定的狀況。隨著轉(zhuǎn)爐

10、的老化，鐵在爐渣中的價值會更好這一趨勢在過去的好幾種情況下被確認(rèn)。縱觀轉(zhuǎn)爐的前三個系列，它顯示出即使氧氣流量一直在增加，它也有可能減少0.1 ％的鐵的含量，這相當(dāng)程度地降低了吹氧時間。</p><p><b>　　耐火壽命</b></p><p>　　在轉(zhuǎn)爐容器中更好的冶金條件也會導(dǎo)致耐火材料的壽命增長。盡管由于容器的體積較大而導(dǎo)致耐火材料的絕對成本較高，但有可能降低

11、具體耐火材料的成本（磚和內(nèi)修補(bǔ)混合）的7 ％ 。 回收轉(zhuǎn)爐廢氣 另一個積極的影響是已實現(xiàn)回收轉(zhuǎn)爐廢氣：它有可能增加回收的廢氣里CO平均含量的4.4 ％ ，而每單位熱量回收的氣體流量保持不變?；厥諝怏w的質(zhì)量得到改善。 總結(jié) 薩爾茨吉特有限公司煉鋼廠的改造帶來了更符合鋼鐵生產(chǎn)嚴(yán)格的要求的轉(zhuǎn)爐B。該轉(zhuǎn)爐已利用試用和測試板懸掛系統(tǒng)來適用有關(guān)的熱負(fù)荷的進(jìn)程;進(jìn)行了轉(zhuǎn)爐容器和耳軸環(huán)合理的間隙的設(shè)計;并采用高品位，耐熱性，細(xì)粒度

12、結(jié)構(gòu)鋼材。越來越大的空間已被最好方式利用，這就是為什么有可能擴(kuò)大轉(zhuǎn)爐容器的大小，以至最大，與過去設(shè)計概念相比，大大增加轉(zhuǎn)換量。 利用特種車輛和適當(dāng)?shù)囊簤荷?，旋轉(zhuǎn)，移動設(shè)備，包括拆除和重新順利安裝一個平臺的組成部分的一種新型的裝配和安裝的概念被落實。這減少了這個尺寸的轉(zhuǎn)爐容器典型的調(diào)整時間，準(zhǔn)確的轉(zhuǎn)爐和耳軸環(huán)力矩平衡已經(jīng)允許現(xiàn)有的轉(zhuǎn)爐容器驅(qū)動部件的重復(fù)使用。 新的轉(zhuǎn)爐的吹氧過程只比以前更平靜，吹氧時間減少了，耐火材料和氧槍

13、的</p><p>　　Modification and Revamp of BOF Converter B at Salzgitter Flachstahl GmbH</p><p>　　When Salzgitter flachstahl commissioned its new converter B in April 2007,the converter capacity incr

14、eased by more than 20%. The new vessel geometry led to significant improvements,including less slopping,longer lining lifetime and higher yields.</p><p>　　Replacement of the converter vessel during ongoing p

15、roduction</p><p>　　The shutdown of blast furnace B in the integrated steel mill of Salzgitter Flachstahl GmbH in March 2007 was utilized to replace the vessel of converter B after more than 30 yeas, and henc

16、e to install a vessel that helps meet the requirements of efficient steel production. </p><p>　　The vessel that helps had to be changed dated from 1976 and showed deformations from the stress of the high the

17、rmal loads.the new vessel,which is larger and operates in conjunction with lamella suspension system,has demonstrated that the blowing process is much calmer now and that other positive effects have been achieved.</p&

18、gt;<p>　　The paper deals with successful modification,which was completed on schedule,and the first results of the blowing process.</p><p>　　Salzgitter Flachstahl GmbH </p><p>　　Salzgitte

19、r Flachstahl is the largest steel subsidiary in the Salzgitter Group, with an output of approximately 4.6 million tons of steel at its Salzgitter location.</p><p>　　The most important customers of the flat r

20、olled products are steel trading companies, vehicle and their suppliers, cold rollers , manufacturers of both standard and large-diameter tubes,and the building industry. The integrated iron and steel works produces hot

21、rolled strip, cold rolled sheet, and surface-finished products ranging in thickness from 0.4 to 25 mm and up to 1850 mm wide. The production program includes drawing, deep-drawing and fine-grained steels, as well as high

22、 –strength steels.</p><p>　　Approximately 25% of Salzgitter's steel production output is delivered as primary material to its heavy plate mill at Ilsenburg. In this mill, plates up to 130mm thick and up

23、to 3300mm wide are rolled. Approximately 5% of these plates are used as feedstock for rolling beams in the Peine heavy beam mill.</p><p>　　The oxygen steelmaking plant of Salzgitter Flachstahl GmbH has an ou

24、tput capacity of approximately 5.0 million tons of crude steel per year. The three converters produce an average of 65 heats per day with a tap weight of 210 tons per heat.</p><p>　　Overview of the Oxygen St

25、eelmaking Plant</p><p>　　The identical converters A and C were in operation since 1978 and 1977,respectively,and had already been replaced by SMS Demag in 1999 and 2000.Converter B, which remained to be rene

26、wed, was in use since 1976,producing more than 200000 heats.</p><p>　　This converter was subjected to high thermal loads and, as a result of the stresses involved, it showed deformations. Over the years, the

27、 cylindrical section of the converter shell had become so deformed that is nearly touched the trunnion ring at some locations.</p><p>　　The resulting reduction of the clearance between converter vessel and t

28、runnion ring decreased the cooling effect. For this reason, it was decided to replace converter vessel B after more than 30 years of production.</p><p>　　The following benefits were expected from the convert

29、er replacement and the concurrent increase in converter volume:</p><p>　　·Less slopping, and less cleaning required.</p><p>　　·Fewer lance skulls/longer life of the lances.</p>

30、<p>　　·Less iron in the slag.</p><p>　　·Improved converter offgas quality.</p><p>　　·Longer refractory durability.</p><p>　　Requirements to Be Satisfied by the D

31、esign Concept</p><p>　　For the execution, a design concept was developed that aimed to increase the converter volume to the maximum possible extent and to reuse the converter drive and existing steel structu

32、res.</p><p>　　The scheduled period of time to perform the modification for the mechanical revamp was 30 days at the most. In the end, the modification took only 26 days. The contract was awarded to SMS Demag

33、, which has established the concept in detail and implemented it. The solution was an entirely new design of the converter from the point of view of view of suitability of the vessel for operation at high temperatures.&l

34、t;/p><p>　　It was possible to reuse the existing converter drive assembly. The existing free space was utilized in an optimum manner to enlarge the specific converter volume. For the vessel and trunnion ring, a

35、 high-grade, heat-resistant, fine-grained structural steel was used. The converter components were designed to be mostly maintenance-free or to require only low maintenance.</p><p>　　Experience that had been

36、 acquired with the old converter vessel was taken into account during the design of the trunnion ring and in determining the clearance.</p><p>　　The latest generation of the lamella suspension system, which

37、was developed by SMS Demag ,and the specifically adapted clearance between vessel and trunnion ring have allowed optimum natural cooling and hence axial and radial thermal expansion of the vessel. No extra cooling by air

38、 or water is required.</p><p>　　Manufacturing and Transport </p><p>　　The companies IAG and Magnum (germany) manufactured the equipment. Particular skills were demanded for welding in the trunni

39、on pins. This job was carried out without interruption by 32 welders taking turns over a period of 16 days.</p><p>　　The vessel in four parts was trial-assemled and entirely surveyed. The vessel in four part

40、s was trial-assembled and entirely surveyed. The vessel in four parts was trial-assembled and entirely surveyed. The dimensions are as follows:</p><p>　　·Top part:7740mm,height approx.2640mm,weight appr

41、ox.40 tons.</p><p>　　·Middle part :7780mm,height approx.900mm,weight approx,16 ·tons.</p><p>　　·Middle part: 7740mm,height approx.3610mm,weight approx,49tons. </p><p>

42、;　　·Bottom part: 7740mm,height approx.2680mm,weight approx,40tons.</p><p>　　Following this, the converter vessel parts were taken into assembly position for shipment and subsequent assembly. The shipmen

43、t was a logistic challenge; overnight from the manufacturing premises to the port of Osnabruck , then by ship to the port to the steelmaking plant by means of several tractor-trailers.</p><p>　　Assembly and

44、Installation</p><p>　　Apart from the demanding tasks in terms of design and materials to be mastered for the project, an entirely new approach was required for planning the individual assembly and installati

45、on steps with the aim of achieving the shortest possible installation time .The conventional procedure of converter dismounting and assembly and installation was finally left aside to develop a new concept together with

46、SMS Demag AG.</p><p>　　Assembly and installation aids were already fitted in the manufacturing facility in order to align the components rapidly and safely on the jobsite.</p><p>　　Preassembly

47、in the steelmaking plant was performed without problems by the contractor Weimarer Spezialmontagen Industrieservice GmbH (WSM).The preassembly jobs were specifically adjusted to the space conditions in the plant .These w

48、ere as follows:</p><p>　　·Assembly of the complete vessel.</p><p>　　·Slipping over of the trunnion ring .</p><p>　　·Mounting of the vessel suspension system.</p>

49、;<p>　　·Mounting of the slag skirts (main part ).</p><p>　　For removal and installation ,it was necessary to dismount part of the converter platform located at an elevation of 8.50 m to enable th

50、e old converter vessel to be removed on sa special shifting ,lifting and turning device .The clearance to the side walls was only a few millimeters at places .Given the space available ,the primary derives aere dismounte

51、d beforehand to allow the main gear nuit to be pulled off the trunnion pin .</p><p>　　The installation work was performed without any restrictions for production .Only the installation of the removed part of

52、 the platform involved a certain ristk ,as the steel structure of this platform has been in use for more than 30 years .</p><p>　　Installation of the New Equipment</p><p>　　The preassembly yard

53、was selected such that the converter ready for installation was located within the approach area of the bay crane .Following the longitudinal transport by the bay crane across the charging bay ,the converter was position

54、ed on the shifting ,lifting and turning device .This device was used to insert the converter accurately to the millimeter into the enclosure .Once the converter was exactly aligned and deposited in its final position ,th

55、e converter gear unit was fitted .</p><p>　　The final phase of jobs started ,which included mounting of the remaining slag skirts ,inspection for interferences and refractory lining ,and of course the instal

56、lation of the dismounted part of the platform ,which ,contrary to any misgivings ,took place smoothly.</p><p>　　The test run followed to survey the lance position .Then the time came for heating ,charging an

57、d launching the blowing ,process for the first heat after a total shutdown period of only 32 days ,including refractory relining .</p><p>　　Operating Results of the New Converter</p><p>　　Below

58、,the last three converter campaigns of the old converter vessel are compared with the first three campaigns of the new converter .</p><p>　　On the basis of the flooding conditions of a converter (see Figure

59、6)as a function of the O2 flowrate and the amount of slag ,the specific volume requirement was to be approximately 1立方米/ton steel for the converters in Salzgitter.This could not be achieved due to the structural conditio

60、ns .It has ,however ,been possible to come close to the optimum condition ,and the specific volume could be increased from 0.68立方米/ton to 0.83立方米/ton. The significantly enhanced flooding conditions have also given</p&

61、gt;<p>　　Blowing Lance </p><p>　　The larger converter vessel bowers the formation of lance skulls .It has been demonstrated in many analyses that the blowing lances of converter B have a much longer s

62、ervice life than those of the other two converters:</p><p>　　·Old converter B:168 heats.</p><p>　　·New converter B:612 heats.</p><p>　　In comparison to these values ,the l

63、ance lives of converters A and C with a volume of 135 立方米are around 100heats .The longest life of the blowing lance of converter B as of Jan.5,2008,was 445 heats .</p><p>　　Metallurgy</p><p>　　O

64、n the basis of decreased slopping and better homogenization of the heat, far more stable condition in Fe losses in the slag can be assumed. The tendency for Fe values in the slag to be better as the converter got older w

65、as confirmed in several cases in the past.</p><p>　　A look at the first three campaigns of converter B shows that it has been possible to reduce the Fe value by 0.1%,even while the oxygen flowrate has been i

66、ncreased. This has decreased the blowing time significantly.</p><p>　　Refractory Life </p><p>　　More favorable metallurgical conditions in the converter vessel also lead to a longer life of the

67、refractory material. Even though the absolute costs for refractories are higher due to the larger vessel volume,it has been possible to cut the specific refractory costs(bricks and inside patching mixes) by 7%.</p>

68、<p>　　Converter Offgas Recovery</p><p>　　Another positive effects has materialized for the recovery of the converter offgas: it has been possible to increase the average CO content of the recovered of

69、fgas by 4.4%,while the recovered gas flowrate per heat has remained unchanged. The quality of the recovered gas has hence been improved.</p><p><b>　　Summary</b></p><p>　　The revamp i

70、n the oxygen steelmaking plant of Salzgitter Flachstahl GmbH has brought converter B in line with the more demanding requirements of steel production. The converter has been adapted to the process-related thermal load by

71、 utilizing the tired and tested lamella suspension system;the design of an optimized clearance between trunnion ring and converter vessel;and by using high-grade,heat-resistant,fine-grained structural steels. Sufficient

72、cooling is ensured solely by the natural thermal</p><p>　　The mounting space has been utilized in the best possible way,which is why it has been possible to extend the converter vessel size to a maximum and

73、considerably increase the specific volume at a given tapping weight as compared with the previous design concept.</p><p>　　A novel assembly and installation concept,using special vehicles and suitable hydrau

74、lic lifting,turning and shifting equipment,and including the removal and smooth reinstallation of part of a platform,was implemented.</p><p>　　This has decreased the typical revamp time for converters of thi

75、s size. Accurate balancing of the torques of the converter and trunnion ring has allowed for the reuse of the existing converter drive assembly.</p><p>　　The blowing process in the new converter vessel is mu