giao án đào tạo Cn tháng 2-2014.doc

Mc lc

Mc lc Trang:1. Li ni u 22. Phn A: Khi qut v l thuyt Luyn gang l ca 43. Chng 1: Nguyn liu dng cho l cao 94. Chng 2: Nhin liu dng cho l cao 215. Chng 3: Chun b qung cho l cao 23

6. Chng 4: Cc qu trnh ho l trong l cao 24

7. Chng5: Gii thiu cc cng on cng ngh l cao 268. Phn B: Luyn gang l cao 299. I-Cc nguyn liu chnh v ph dng trong l cao luyn gang 29

10. II- Qung mng gan 31

11. III- Cht to x v tr dung 31

12. IV- Nhin liu dung trong l cao 32

13. V- Cu to l cao luyn gang 33

14. VI- c im l cao luyn gang 35

15. VII- S phn ly cacsbonnat trong l cao 36

16. VIII- S to gang trong l cao 37

17. IX- S to x trong l cao 37

18. X- S chy trong ni l cao 40

19. XI- S to kh trong l cao 41

20. XII- S chuyn ng ca kh trong l cao 42

21. XIII- S chuyn ng ca nguyn liu trong l cao 44

22. XIV Kch thc c bn l cao 55m3 45

23. H thng quy trnh thao tc k thut 45Cng ty c phn LK Thi Nguyn

Nh my Luyn Gang NAM SON-------o0o-------

Li ni u

Trong chin lc pht trin ca t nc ta hin nay cng vi s pht trin ca khoa hc k thut vi su th hi nhp ton cu ho th gii. Nn kinh t Vit Nam ng trc c hi v nhng kh khn v cng to ln. Chnh ph ta xc nh r mc tiu bin nc ta thnh nc cng nghip c c s vt cht k thut hin i, c cu kinh t hp l, c quan h tin b ph hp vi trnh pht trin ca lc lng sm xut i sng vt cht v tinh thn cao, an ninh quc phng vng trc. Dn giu nc mnh, x hi cng bng dn ch vn minh. T nay n nm 2020 ra sc phn u thnh mt nc cng nghip

Trong chin lc cng nghip ho - hin i ho t nc, chnh ph u tin pht trin ngnh cng nghip mi nhn trong c ngnh luyn kim. Trong bi cnh ngnh luyn kim ni chung v ngnh luyn kim en ni ring ang ng trc nhng vn cp thit i hi c s chuyn bin th trng. iu cng ng ngha vi vic cn thit phi c s u t, quan tm ti pht trin ngun nhn lc hot ng trong cc ngnh cng nghip. Mn hc cng ngh luyn gang l mt trong nhng mn hc chuyn ngnh ca ngnh luyn kim en, hc tp v nm bt c tt mi ni dung ca mn hc yu cu mi hc vin phi khng ngng rn luyn, tm ti tch lu nhng kin thc trong nh trng, ngoi ra mi hc vin cng cn phi khng ngng sng to v tch cc nm bt cc dy truyn sn xut trong thc t, vn dng v quan st nhng nguyn l c hc mt cch thc t. Cng vi tinh thn trn v s pht trin ca cng ty, nh my, giai on tip theo t nay n nm 2020. Phng k thut cng ty c s ch o ca cng ty v vic bin son Gio trnh cng ngh luyn gang l cao nhm cung cp kin thc c bn nht cho cc hc vin v cng nhn lao ng trong dy truyn cng ngh luyn gang l cao, h c th hc hi v tch lu nhng kin thc trong thc t sn xut ca nh my. Cng ngh luyn gang l cao gm nhng ni dung sau: Phn A: khi qut chung v l thuyt Luyn gang L cao, gm 5 chng;Phn B: Luyn gang l cao. C lin h thc t sn xut ca Nh my v trong nc.*Ngi bin son. c nhiu c gng xong gio trnh ny khng sao trnh c khi thiu st v hn ch. Rt mong s ng gp ca hc vin, ngi c v ca ng nghip. Ngi bin son Nguyn nh ThpPHN AKhi qut v l thuyt luyn gang l cao1/ Cc cng vic chnh ca nh my luyn ganga/ Cng on chun b liu:- Chun b qung st: Phn c ht

+ Qung sng

Trung ho

+ Qung thiu kt: Phn loi theo c cc

+ Qung cu vin

+ Chun b cht tr dung, p nghin phn loi theo c ht

b/ Cng on np liu: H thng boon ke

Bng ti, xe kp

H thng o, cn liu

H thng trang, cht liu (cn, phu)

c/ Cng on gi nng: Nung nng

Cung cp gi vo l cao

Qut gi ----> L gi nng ----> Vo l cao

d/ Cng on trc l: Thao tc mt gi

Thao tc l gang

Thao tc l x

e/ Cng on lc bi: Lc bi th (lc bi trng lc)

Lc bi ti vi Lc bi tnh in

f/ Cng on thu hi sn phm: Thu gn gang ---> vn chuyn gang lng ---> n c thi, c lin tc v vn chuyn gang thi i n kho nh my ---> vn chuyn gang lng i nh my luyn thp

Thu gn x: To x ht bng nc. to x bng bng kh, to x cc

2/ Cc dng vn chuyn trong nh my luyn gang.a/ Qung st:Qung

Sn qung Thiu kt

i boon ke

Xe kp

L cao Qung c ch n sn qung bng t ... c trung ho bng h thng bng ti, hay gu ngom ri c ch n u boonke bng ti, c khi bng toa xe, qung c a n phn xng thiu kt, qung c trt t i boonke xung h thng cn bng ti, ri rt vo xe kp ri a ln l caob/ Than cc, trm phun than:

Kho cc ---> Xe ch cc ---> Boonke ---> Sng ---> Xe kp

Trm phun than ----------> L caoc/ Cung cp gi:

- Gi t qut gi qua ng ng dn gi vo l gi nng, c gia nhit n nhit nht nh. Kh nng c dn qua ng ng v c phn b cc h thng mt gi ti l cao

Phng qut gi L gi nng L cao

ng khi Thit b lc bi

d/To x:L ra x Mng x Thng cha x Bi x

To x ht

e/ To gang:L gang Mng gang chnh B gt x Thng cha gang Nh my luyn thp

Chuyn gang thi c lin tc

Gang c a sang nh my luyn thp: gang lng luyn thp, phn xng c thi, ri n cc nh my luyn thp

Gang c c a n c thi ri a n cc nh my c kh c chi tit.3/ S thit b cng ngh luyn gang l cao Thi NguynQung sngQung thiu kt vilmiSa thchKcKc

bng ti

ng khi

* Nh my luyn gang Nam Son nm gip ng Tnh l 269 ni th trn Tri cau vi Thnh ph Thi Nguyn.V vy nh my c nhiu iu kin thun li pht trin v nng cao m rng sn xut.Nh my luyn gang c vai tr quan trng trong khu lin hp, k t khi nguyn vt liu c khai thc t m ln qua cc khu chun b liu ... cho n khi ra mt hng cui ca khu lin hp l thp thi, cc sn phm c kh. Nh my c nhim v chnh l sn xut ra nhng m gang cung cp cho cc xng c, cho nh my luyn thp, ngoi sn phm chnh l gang cc sn phm ph khc ca nh my cng c tn dng trong cc lnh vc sn xut khc nh: x bng lm vt liu cch nhit, x ht lm xi mng, x kh lm vt liu ri ng...

Hin ti v tng lai 2 l cao: 60m3 v 55m3 p dng tin b k thut t h s: Pv 3,0 3,5; vi nng sut bnh qun trn 400tn gang/ngy.Cc l cao c b tr theo hng thun li vi lung vn chuyn ca nh my. Vic lin h gia cc b phn vn chuyn v lm vic m bo s vn hnh ca cc l cao khng nh hng n nhau nhng vn nm trong mt th thng nht

Vic m rng nh my giai on 2 v pha ng c xy dng l cao 60m3, nh my thiu kt 27m2 v h thng l luyn thp ... D kin a vo sn xut giai on 2, dy truyn to qung cu v vin c trin khai ng b.Nh my luyn gang l n v tiu th ngun nng lng in nc rt ln, h thng cung cp cng rt phc tp song nh my lun c cung cp y nh c nh my tuyn khong thuc cng ty c phn LK Thi nguyn m nhn.Lung vn chuyn chnh ca nh my ch yu bng ng b v bng ti nn cn c hn ch.V tng lai nh my c hng pht trin nh: Khng ngng ci tin c kh ho t ng ho, u t m rng nng cao nng sut v cht lng sn phm, h gi thnh, tm kim th trng, nng cao tm vc ca nh my trong nn kinh t th trng.* Hin ti nh my luyn gang ang vn hnh l cao s 1 Bin ch khong 110 CB cng nhn vin. T chc cc b phn ca nh my gm cc n v thnh vin

- L cao

- Nguyn liu

- c lin tc

- Phn xng c kh- Trm ho nghim

- Nh n

- Trm yt.Chng1:Nguyn liu dng cho l caoA.Qung st v nh gi qung st:1/ Khi qut chung:

St l mt nguyn t trong nhng nguyn t ch yu cu to nn v tri t, chim t 5 10% trng lng v tri t, hu ht cc t u cha st

Qung st l 1 loi t c th luyn ra c gang thp, cn c vo khong vt ta chia qung st ra thnh 4 nhm:TTLoi hp chtTn ho hcTn khong vt

1Hp cht Fe vi O2- Oxt st t tnh

- Oxt st khan

- Oxt st ngm nc- Manhtt

- matt

- tt, Limlt

2Hp cht FeO vi O2Cc b nt stsirt

3Hp cht FeO vi SiO2 v oxt khcsilict phc tpclort, quc rt, manhtt,matt...

4Hp cht Fe v Ssunpitpyrt, pyrtin

mc kapt

2/ c im ca cc loi qung st chnh2.1.Oxt st t:- Cng thc ho hc: Fe3O4- Tn gi: Manhtt

- Nguyn cht: cha 72,4% Fe v 27,6% O2* C cu to ht nh, mn, c nh kim loi, kh hon nguyn, mu sc xm n xm en.* c im ni bt c t tnh, nung n 580oC mt t, khi ngui li c t tnh; t trng = 4,9 5,2; cng 5,5 6,5

* Tp cht c trong qung manhtt thng l thch anh, silict, ccbnt, t st, pyrt hoc Spalerit (ZnS); hoc Lancopyrit (CuFeS2)

- Trong t nhin Fe3O4 t phn ho thnh Fe2O3 theo paplop th c th vit

Fe3O4 ---> FeO.Fe2O3- V dng t l s biu th mc phong ho ca qung do ta phn ra:+ < 3,5 ta gi l qung manhtt

= 2,333

+ = 3,5 7 gi l na mctt

+ > 7,0 gi l mctt, matt

2.2.Qung matt

- Cng thc ho hc: Fe2O3- Tn gi: matt (qung st )

- Nguyn cht cha: 70%Fe v 30% O2- Mu sc thay i t xm n en, nh m hay nh kim, hon nguyn ca qung st rt tt, cu to t c trc, t trng = 4,2 5,3; cng 5,5 6,52.3.Qung Limnt- Cng thc ho hc: mFe2O3.nH2O

- Tn gi: Limnt (st nu) hay hydrematt

- Nguyn cht cha 35 55 % Fe, cha nhiu phtpho v lu hunh

- Mu sc t nu ti n xm, thng l mu nu

- T trng = 3,3 4,0; cng 4 4,4 HRe- Khi nung nc bay hi do lm cho qung xp v chia qung ny ra lm 2 loi

+ Loi Ett (HFeO2) hay (FeO.OH) khi = 1 gi l tt v = 4,2-4,4, cng 4,0-4,4 (Fe2O3 + H2O = 2HFeO2)+ Limnt: HFeO2aq (aq ch vit tt ca ting la tinh c ngha l nc)

Khi 18-20%) th lm cho x st, nhng nu qu thp (8-10%) th lm cho x c nhit nng chy thp, v vy trong tnh ton phi liu ta phi ch n thnh phn CaO; MgO; Al2O3. Trong thc t sn xut qung thng cha 1 lng ng k Al2O3 v CaO; MgO

b/ Tp cht b kh mt phn trong l cao

- Gm c: SiO2 v cc silict, cc sulpec v cc hp cht ca: Se; Ti; Mn; Cr; V; CO; Nb; Zn

* Si: cc hp cht ca Si l SiO2 v cc silict n chim phn ln trong t chay (gi l khong vt v ch) ca qung st v c CaO trong l cao; mt phn SiO2 hon nguyn thnh Si v Si i vo gang.- Khi luyn thp th Si oxy ho thnh SiO2 i vo trong x. V vy Si c gi l nguyn t c hi i vi gang luyn thp.C trng hp Si l tp cht cn thit cho gang Becsome (v l nguyn t pht nhit khi luyn thp).- Cn gang c th n gip cho s grapht ho cc bon v lm cho gang xm

* Hp cht vi S: S l tp cht c hi rt ln n tnh nng ca gang, thp. Nu thp cha nhiu S th nhit cao km bn, khi cn d b nt (b nng) do mi loi gang, thp phi qui nh gii hn cao nht ca S, nu khng d tr thnh ph phm.- Thnh phn [S] trong gang, thp ch yu l do nguyn liu mang vo, nu qung cha nhiu S th cng nh hng lng S trong gang; Thng thng S trong qung> 0,3% th gi l qung cha nhiu (S) v qung cha S < 0,15% gi l qung cha t S.- Trong l cao (S), mt phn S bc hi, mt phn ln i vo x v ch i vo gang t 1-5 %, do trnh k thut hin nay [S] trong qung khi chy than cc c th cho php 0,15%.*Hp cht vi Mn- Mn trong thp lm tng bn v cng, Mn cao ngn cn s graft ho, gip cho s kh S ngoi l. Ngoi ra oxt Mn bc cao gp cho s cng ho qu trnh thiu kt qung, khi luyn gang c th Mn khng c cao qu v kh gia cng c kh, Mn c th i vo gang t 40-75%.- V vy trong qung ta phi ch t l Mn/Fe, sn xut cc loi gang luyn thp th < 1,5%- i vi gang Becsome tt nht < 0,75%

- i vi gang c th cng phi thp hn na

- Nu s ti 3% th ch dng luyn gang knh

*Hp cht vi Ti:

Ti thng c trong qung manhttFeTiO3; Ti lm tng tnh chu nng v bn ca thp. Trong mt s trng hp th Ti kt hp vi st to thnh Fe Ti nhng trong l cao Ti trong qung s hon nguyn 1 phn cn li i vo x; nu hm lng Ti > 10-20% lm x st, v vy trong phi liu l cao khng i hi Ti phi cao Ti > 10-20% lm x st, v vy trong phi liu l cao khng i hi Ti phi cao.*Tp cht b kh mt phn trong l cao- Hp cht vi Crm+ Cr c trong thp lm tng tnh chng n mn, trong thnh phn thp khng g c Cr, Ni

+ Cr trong qung thng dng FeO.Cr2O3, phn ln qung st nu. Trong qu trnh nu luyn l cao 80-95% Cr c hon nguyn i vo gang

+ Gang cha nhiu Cr ( 0,2%) s lm cho gang cng, kh gia cng c kh

+ Trong luyn thp l bng th Cr b oxy ho i vo x lm cho x st kh thao tc

+ Mong mun Cr trong gang 0,4 0,6% th trong qung khng c > 0,25%, nu hm lng st trong qung > 60% th Cr trong qung cho php 0,4%- Hp cht vi copan (Co)

+ Co l mt nguyn t chnh lm tng tnh bn nng ca thp. Hm lng Co c trong qung > 0,01% th phi tnh:

+ dng Cancopyrit: CuFeS2 . FeS2 ( cancopyrit pyri )

- Hp cht vi Vanadi (V)

+ V l mt nguyn t qu dng lm thp hp kim. Trong qu trnh l cao 70-90% i vo gang.c/Tp cht khng b kh hon ton trong l cao

+ Pht pho (P):

- P thng c trong qung di dng: Ca(PO4);

[(FeO)2.P2O5].8420; P, c trong gang thp lm cho gang thp b b ngui; gim dai va p (ak); P thng tp trung tnh gii ht.

- P lm tng tnh chy long ca kim loi, nn khi c chi tit mng, hnh dng phc tp, bn khng i hi cao lp th c th dng kim loi di [P] cao.

- P l nguyn t pht nhit trong gang t mat l ngun nhit ha hc ch yu trong qu trnh luyn. X l tomat c th lm phn bn. Trong mt s trng hp P li l nguyn t c li, trong sn xut l cao, P hon nguyn hon ton vo trong gang; trong luyn thp l bng l chuyn l in, tnh bagi c th kh c (P) (kh P i hi B x cao tc l (CaO) cao v c nhit tch hp).

- Trong l Bec some (c tnh axt) l khng kh c pht pho (gch xy % SiO2). V vy gii hn cho php % P trong qung xc nh ty theo loi gang bng cng thc:

Trong :

+ [Pg] pht pho cho php trong qung (%)

+ [Pg] pht pho cho php trong gang (%)

+ Pctp pht pho a vo gang t cc,tr dung v ph gia

( Nu khng dng x l mac tanh: Pctp = 0,03%

K =( Feg : % Fe c trong gang (%)

( Feq : % Fe c trong qung (%)

( Khng k [% Fe] do cc ph gia a vo th Feg = 91%

V d: Nu gang t mt [2% P]; Feq = 40%, hm lng pht pho cho php trong qung s l: + Km (Zn):

- Zn trong qung thng dng supatlerit (ZnS).

- nhit na di thn l: 900 ( 1000oC. Zn bay hi, tuy Zn khng vo gang nhng c hi v nhit si ca Zn thp (905oC), nn Zn hon nguyn b bc hi ngay. Hi Zn bay ln theo kh l nhit thp ng li cc khe h ca tng l, phn trn thn l v cc l xp ca gch. ng thi b xy ha thnh bu l gy th tch tng lm v gch do hm lng Zn trong qung quy nh khng c ln hn 0,1%.

- Nu qung cha > 0,3% Zn th tuyt i khng c dng n lm nguyn liu n c cho l cao m phi pha vi loi qung t km; trong thiu kt qung cng c th kh mt phn Zn.

+ Asen (AS):

- Khi hm lng AS > 0,1%, lm thp dn lnh tnh hn km, trong l cao AS hon nguyn hon ton vo gang; Thiu kt qung AS cng gim mt phn qung dng: FeAS2S; AS2O3; AS3O5;

+ ng (Cu):

- C mt t trong thp: 0,02 ( 0,3% lm cho thp tt, c bit tnh chu n mn, hm lng Cu, trong thp qu cao, thp c tnh dn nng kh cn, tnh hn xu i.

- Quy nh hm lng [Cu] trong qung ( 0,2%, nu qung khong c Cu > 1,0% gi l qung ng; ng c trong qung st t dng FeCuS2.

+ Niken [Ni]:- Ni, c kh nng nng cao hu ht tnh cht ca thp. c bit l chng g v chu nng t ct rong qung (qung st nu: Limnt).

+ Ch (Pb):- Pb, ch yu dng PbS; (Pb l nguyn t c t trong qung; trong l cao (Pb) hon nguyn hon ton vo gang, do t trng ln nn chui xung y l; qua khe h ca gch ph hoi y l.

- C mt phn ch bay hi 1550oC lm hi sc khe cng nhn.

- Trong qung c nhiu (Pb) th phi pha vi qung ngho ch s gim i, trnh hin tng ph hoi y l, ngi ta lm rnh sn cch y l 1,5m dn ch ra ngoi.

II. NH GI QUNG ST V TNH N NH V THNH PHN HA HC.

- Ta bit rng qung a vo l cao, thnh phn lun lun bin ng, s bin ng gy ra:

+ kim x lun lun bin ng, ta thy rng khng th phi liu kp cho tng m liu v thnh phn ha hc.

+ Ch nhit ca l cao lun bin ng v nu qung giu hn mc trung bnh lm ngui ni l. Qung ngho hn trung bnh bnh s lm nng ni l. Do vn hnh l khng th n nh c, nng sut l khng cao; v khng tit kim c than cc.

+ V lun lun d tr nhit ni l cao bng cch tiu th than cc cao hn phng l ngui do qung st giu hn; cho nn gang luyn thp nu ra thng cha nhiu [Si] hn yu cu ca l thp. + Mt khc t s ; trong qung khng n nh th thnh phn gang nu ra cng bin ng v Mn, P; do nh hng xu n qu trnh nu luyn, v vy qung l cao phi n nh tng i v thnh phn ha hc mi t hiu qu cao v gim cc; cht lng gang mi m bo hp cch.

+ Thc t sn xut l cao, yu cu thnh phn st SiO2 bin ng khng ln hn (0,5%; qung t nhin khng t c yu cu ny nn ta phi dng phng php trung ha qung bi liu trc khi s dng vo nu luyn l cao.III. TNH HON NGUYN CA QUNG

- Tnh hon nguyn ca qung l ch tiu quan trng nht, nh ga cht lng lng ca qung; nu dng qung c tnh hon nguyn tt th gim c tiu hao nhin liu cho mt n v gang, nng cao c nng sut l.

- Hin nay vic nghin cu qu trnh hon nguyn ca qung trong l cao cha c bin php hon chnh no, vi qu trnh hon nguyn c nhiu nhn t nh hng nh: Nhit , p sut, thnh phn v vn tc ca kh hon nguyn, ht, tc nung, ... nhn t nh hng thay i tng ni tng lc trong phng th nghim kh to iu kin ging trong thc t l cao. Cho nn ch xc nh c tnh hon nguyn tng i ca qung mt iu kin no .

- Thng thng o hon nguyn ca qung bng th nghim:

+ Kh hon nguyn l kh H2, CO, l c nung dn n nhit nht nh thng l: 900oC (( 1000oC);

+ Mu qung trong l nung, sau khi ui ht hi nc ra ngoi n lc trng lng mu khng i th ta cho kh hon nguyn vo vi lu lng 300 ( 600m3/pht; lc kh hon nguyn cp xy ca oxyt st ha tr cao thnh oxyt ha tr thp.

3Fe2O3 + H2 = Fe3O4 + H2O

Fe3O4 + H2 = 3FeO + H2O

+ Trng lng mu s gim xung ( n khi trng lng mu khng i th qu trnh hon nguyn kt thc. Ly tng trng lng mu gim i so vi trng lng mu lc u nh gi hon nguyn ca qung. Cn c vo th nghim ta sp xp th t hon nguyn t d n kh nh sau:

LIMNT - XIRIT - EMATIT - MCTT MANHTT

+ Cc loi qung limnt, xirit, d hon nguyn nht khi nung nc v {CO2} bay ra nn chng tr nn xp, mt khc bn thn n xp.

IV. NH GI V TNH CHT VT L CA QUNG

1. xp v tnh thng kh ca qung:C nh hng rt ln n tnh hon nguyn ca qung. Nu qung c xp cng ln, tnh thng kh cng tt, qung d hon nguyn;

* xp ca qung c hai loi:

- xp th tch: l tng th tch cc l so vi th tch ca qung tnh bng (%) l t s th tch l so vi tng th tch ca cc. (%) + Qung st nu t rn chc nht xp: 40 ( 50%

+ Qung st matt xp: 5 ( 30%

+ Qung st t xp th tch: 5 ( 10%

+ Qung xirt (FeCO3), cha nung xp khng ln lm.

( xp b mt:

+ L din tch mt ngoi ca cc l trong mt n v th tch qung n v [m2/m3];

+ o xp b mt rt kh khn, thng thng dng phng php hp ph, bng cch nhng mu qung vo dung dch ru giy mu hoc xanh trong mt thi gian nht nh, a vo s gim mu on c xp b mt.

2. Tnh bin mm v nhit bin mm ca qung- Nhit bin mm ca qung cao hay thp c nh hng ln n thng kh ca ct liu v qu trnh hon nguyn trong l cao. Sau khi bin mm nu cn nhiu oxyt st cha hon nguyn, qu trnh tip tc gp nhiu kh khn.

- Trong l cao phm vi nhit t lc bt u bin mm n khi chy lng hon ton cng ln th lp x u cng dy; vng ny qung th nho chng dnh kt qung vi cc cc cc lm cho ct liu kh thng kh, v th mong mun phm vi nhit bin mm ngn.

Ni chung nhit bin mm ca cc loi qung t 850o ( 1500oC. Phm vi nhit bin mm t 100 ( 500oC gi l khong nhit bin mm.

- Nhn t nh hng n tnh bin mm.

+ Loi khong vt: Khong vt trong qung phn b cng u, khong bin mm cng hp.

+ Tnh hon nguyn: Qung c hon nguyn cao, khong bin mm cng hp.

+ Hm lng cc oxyt baz ch yu l CaO c nhit chy cao. Bi vy qung c cha nhiu chng nhit bin mm cao, khong bin mm cng hp.

3. T trng v t trng ng ca qung- T trng quyt nh bi hm lng st v xp ca qung.

- T trng ng l trng lng 1m3 qung ng, nu khng tnh thng kh ct liu th qung c t trng ng ln cht vo l c nhiu qung hn.

- Nu lng gn ti vo l khng i th thi gian liu trong l di hn. iu c li cho qu trnh nu luyn, qung c nung nhiu hn v hon nguyn gin tip tng ln.

- T trng ng cn dng trong vic tnh ton th tch v trng lng m nu.

4. bn v ht ca qung- bn ca qung phi ln, trnh v vn trong l, trnh tn tht c hc, kh p nh.

- ht ca qung: Yu cu c ht nht nh, c ht phi ng u. Nu c ht qu ln kh hon nguyn. Nu nh qu, khng ng u vn hnh l kh khn, bc bi nhiu theo kh l, do tn tht ln hn, ty theo tng loi qung quy nh c ht.

+ Lin X quy nh:

( MANHETIT : 10 ( 35mm

( EMATIT MACTIT: 10 ( 40mm

( Qung st nu : 10 ( 60mm

+ Thi Nguyn quy nh:

( MANHETIT : 10 ( 25mm

( EMATIT MACTIT: 10 ( 38mm

Trong qung bao gi cng tn mt lng vn c ht di mc qui nh yu cu khng ch ( 8%.

V. NH GI QUNG ST V MT KINH T

1. ngha:Vic nh gi, gi tr luyn kim, mc ch dng loi qung khc nhau v xy dng xng mi ni ny, ni khc khng ch da vo gi tin nh nc quy nh. Ch yu da vo gi tr nu luyn, t tm hiu phi liu vo l nn chn loi qung khc nhau nh th no, va c li v kinh t, va c li v k thut. T vic nh gi qung st ny ta bit vic xy dng xng mi, ni ny hay ni khc c li v kinh t, k thut nh th no.

2. Tnh ton v gi tr nu luyn ca qung st:- C nhiu phng php, nhng phng php n gin nht l phng php ca Paplop (nabob). (1)

Trong : P = gi thnh phn xng 1 tn gang (/T)

f/F = t s hm lng st trong gang so vi st trong qung; v mt l lun m ni s qung luyn 1 tn gang khng k bi l do tn tht c hc. Nu bi l nhiu ta hiu chnh s liu ny.

- P1, P2, P3 = gi thnh ca mt tn qung, than, tr dung [/T]

- K = sut tiu th cc [T/Tgang]

- ( = sut tiu th cht tr dung [T/Tgang]

- g = kinh ph phn xng cho mt tn gang (lng cng nhn, tin khu

hao thit b, ng lc)

- T cng thc (1) suy ra: (2)

- T (2) ta thy:

+ P v f = hng s, th P1 t l thun vi F; nu F cng cao lng cht tr dung ( cng t. Do lng x gim sut tiu th cc gim.

Ngi ta thy khi F thay i th (, k, g cng thay i theo.

C. QUNG ST VIT NAM

+ Thi Nguyn: Gm c Manhetit, mc tt, limonit, qung giu st: Fe > 50%; it S, P. C mt s qung cha Pb, Zn nh qung Tri cau, Quang Trung, Linh Nham, Tin B. Tr lng khong trn 40 triu tn.

+ M Bo H: MANHTT, MATT, c thnh phn st trn 30% t P, S; Lo Cai - Yn Bi gm cc m Qu Xa, Lng Vinh, Lng Pht; tr lng trn 100 triu tn.

+ Thanh Ha: Qung MATT c thnh phn st trn 50% t Mangan, nhiu Pht pho, cc m Tam Quy, Yn M, Vm, Phi Lai, Bi Sim (t hn).

+ Ngh Tnh: Qung st c cha nhiu mangan (>2% Mn) m Ph Thn, Ph Cm, Ha Nguyt, Hong Mai, Yn c (t).

+ Qung Ninh: tr lng trn 40 triu tn ri rc.

+ Cao Bng: trn 20 triu tn

+ Bc Cn: trn 5 triu tn.

D. NGUYN LIU THAY QUNG ST

I. X L MCTANH

1. X l kim tnh thng thng:

+ Fe + Mn = 25 ( 35% trong 2/3 l Fe, 1/3 l Mn.

+ Cc loi oxyt kim: 20 ( 30% trong : MgO = 5 ( 10%, cn li l CaO

+ Cc oxyt axit: chim khong 20 ( 30%.

- Nhc im: X l Mc tanh c hm lng (P) cao. Khong 0,4 ( 1,0%, do tiu th x mc tanh trong l cao khng qu 1% sn lng gang. V sut lng x tng, tng tiu hao cc, gim thng kh ct liu v gim nng sut l. Do khi dng x l mc tanh lm nguyn liu cho l cao phi tnh ton k li hi v knh t - k thut.

2. X l chuyn:

a. X l chuyn axit: C thnh phn ch yu sau:

Mn = 10 ( 20%; Fe = 10 ( 28%; SiO2 = 48 ( 60%

Al2O3 = 0,5 ( 1,5%; CaO = 1,0 ( 1,5%

S = 0,0 ( 0,15%; P = 0,0 ( 0,03%

* Hu nh khng ch nhiu (P) nn thng dng x ny khi l cao luyn gang: BECSOME.

b. X l chuyn baz: C thnh phn ch yu sau:

Mn ( 10%; Fe = 15 ( 30%; oxit kim t 40 ( 50%; oxit axit t 4 ( 20%; P = 1,5 ( 4 %. X l chuyn cha pht pho cao. Vic dng n trong l cao phi ty tnh hnh c th m s dng.

II. PH LIU CA XNG CN1. Vy cn: C hm lng st tn ti dng Fe3O4. Khong 7%, khng c tp cht c hi. Thng dng vy thp cm lm nguyn liu thiu kt hoc dng iu chnh hm lng st cho phi liu l cao.

2. X l nung

- Vy thp cn v v gch xy y l kt hp vi nhau to thnh, c thnh phn P, S khng cao.

- Loi x ny thng dng cc ln, mt phn FeO v SiO2 to thnh silict st, d chy nhng kh hon nguyn. V vy trong l cao d to thnh x u cha (FeO); Do x ny lm nguyn liu ra bu l cao tt.

- Nu trng hp y l nung xy bng gch Manhtt, xt l ny c hm lng (MgO) c li cho qu trnh to x trong l cao.

III. CC PH PHM CNG NGHIP KHC

1. B ferit (pyrit) - L x ca s thiu pyrt (FeSiO2), trong qu trnh sn xut axit sunfuaric. Thnh phn ch yu l (Fe2O3) c cha hm lng st t 40 ( 55%; Cu = 0,7 ( 1,5%; c khi cn cha lng nh Zn v P; Thnh phn S rt cao nn qua thiu kt to cc kh S (S = 1,5 ( 4%) v to cc.

- Vit Nam ch cn s dng B (pyrit) khi nh my luyn kim gn nh my sn xut axit.

2. Phoi tin ca my ct gt kim loiC th dng cho l cao hoc l thp, loi g nhiu khng nn dng cho l thp. Ring phoi gang dng cho thiu kt.

3. St ht mt s nc dng st ht thu hi qua qu trnh hon nguyn qung st ngho trong l quay vo phi liu l cao. Trong st ht thnh phn S cao = 0,6 ( 1,8%; hm lng st ( 80 ( 92%.

IV. PH PHM PHI LIU L CAO

1. Bi l cao- L sn phm tt yu trong qu trong sn xut l cao thng cha 40 ( 58% Fe; 3 ( 20%C. Ngoi ra cn cha oxyt kim, Mangan...

- Bi l cao l hn hp qung vn, vi, cc bon...

- Ht bi l cao nh trn 70% c ht < 1mm, nn bi l cao qua thiu kt thnh cc ln mi dng cho l cao c.

2. X l cao

Cha nhiu Mangan, khi luyn fero Mangan trong l cao thng thu c x mu xanh l cy dng cc cha 10 ( 20% Mn, khng cha (P), c kim CaO/SiO2 = 1,3 ( 1,5; cha nhiu (S), rt t st. X xanh cng dng cho l cao luyn gang khi cn thit iu chnh thnh phn x.

3. Gang vnGang bm dnh mng, thng rt, gang bn t mng c... dng cho l cao.

E. TR DUNG CHO L CAO

1. Tc dng cht tr dung dng cho l cao- t trong qung v tro than cc u c im nng cha cao; vi nhit trong l cao chng khng th chy lng c, khng th tch ra khi kim loi c. Do nh hng khng tt n thao tc l cao.

- V vy ta cn cho cht tr dung trong l cao nhm mc ch:

+ Kt hp vi t trong qung v tro ca than cc to thnh hp cht d chy gi l x l cao.

+ m bo cho x l cao c khi lng nht nh, thnh phn ha hc nht nh v tnh cht l ha thch hp, luyn ra gang hp cch.

+ Ty theo thnh phn t v tro ca than cc ta dng khong vt rn dng lm cht tr dung cho l cao.

- Khong vt cha oxyt kim: CaO, MgO, thng l vi, lomit, Apatit.

- Khong vt cha oxyt axit: SiO2, sa thch, si.

- Khong vt cha cc silyclumin (SiO2 + Al2O3) thng l bocxit, gch ngi.

2. Cht tr dung kim: Dng to x trong l cao.

a. vi:

* ngha v tc dng: CaCO3T trc n nay ngi ta ch dng vi lm cht tr dung l v:

- Thnh phn ha hc ca t chay trong qung v tro than cc thng l SiO2, Al2O3 nn kt hp vi to x.

- Nhin liu dng cho l cao thng l cc c %S

- vi d khai thc, nhiu, bn, c thnh phn ha hc n nh.

* Yu cu cht lng

- Hm lng (CaO v MgO) phi cao, cn (Al2O3, SiO2) v oxyt khc.- Thnh phn ha hc: CaCO3

+ vi nguyn cht 50% CaO thc t 55%

+ (MgO)thc t 4%

- Hm lng P, S trong vi nh nn b qua

+ Yu cu ht:

Quy nh gii hn trn ca ht vi phn gii hon ton < 10000C lm tiu chun.

- L cao va v ln: ( = 25% ( 75 mm

- L cao nh: ( = 10% ( 30 mm

- Thi Nguyn: ( = 10% ( 50 mm

b. lmt: [CaMg(CO3)2] l khong vt ccbonat-magie

- Hm lng:

(CaO + MgO) 55%

MgO ( 17%

- Nu: MgO < 17% gi l vi lmt

c. Vi:

- bn km; Xong c li tn nhit, khng c CO2 sinh ra, gim tiu th than cc, tng nng sut l (ch bo qun).

- Thng phun vi bt vo ni l; khi phun ch tng 200C cho 100 kg vi/tn gang.

d. Apatit: l khong vt ca phootphat canxi [3.CaO.P2O5]

- Dng n trong phi liu l cao luyn gang nhiu pht pho. ng thi gim c tiu th vi.

- Ch : c cha (F) c hi, thng kt hp vi cng ngh phn ln nng chy vi l cao n mn kt cu l.

e. Hunh thch: CaF2- Lm cht tr dung cho l thp

- Dng cho l cao khi to x siu kim nhm luyn gang rt sch [S] ( 0,01%.

- Lm long x rt mnh, ra bu l.

3. Tr dung axit - SilicoAlumin SiO2 - Al2O3+ Sa thch cc hay si, trong thiu kt tr dung thng l ct (SiO2) ( 90% (sa thch + quc rt).

+ Trong trng hp luyn gang nng [Si]CaO, khi trong qung v trong tro than c SiO2/Al2O3 rt cao c th dng cht tr dung silico-Alumin, cht cha nhiu Al2O3 nh bc xt ( gch ngi t hn bc xt).

4. Cht tr dung Vit Nam: c tr dung trn cc ni.- vi Ni voi Thi Nguyn;

- Quc rt ph th;

- lmt Thanh Ha;Chng 2NHIN LIU DNG CHO L CAO

1. Yu cu ca nhin liu dng cho l cao+ Cha t tro, nhit t ln, nhit chy cao

Hot tnh v tnh chy thch hp, m bo cc phn ng ti cc khu vc ca l cao xy ra bnh thng, thun li.

+ Cha t tp cht c hi c bit l S, luyn gang hp cch.

+ m bo bn c hc v nhit hc

+ C xp, ht thch hp

+ R tin, tin cung cp

2. Than g: l sn phm ca s phn ha khng hon ton ca g khi nung nng g n nhit cao trong mi trng thiu khng kh.

3. Than hm: Cht g thnh ng, trt kn bn ngoi bng t. li 1 l nh ht gi cn thit cho g chy. Than thu c gi l than hm (6000C, mt sn phm ph).

+ Than l: l xp g vo trong l, xy kn bng gch, dng kh nung nng. Sn phm thu c hon ton, than g thu c gi l than l (350 ( 4000C)

* Nhn xt: Xt v mt k thut than g t tro, mang tnh kim, xp, tnh chy tt l nhin liu l tng cho l cao 200m3 ( 300 m2 luyn gang cht lng tt.

4. Than gy v than ANTRAXIT+ Than ANTRAXIT: l loi than gi tui c mc cc bon ha cao nht.

- Cc > 900; V < 10%

- xp km cc

- bn km

+ Than gy: (na antraxit), tnh cht ging antraxit (than khng khi).

* Hai loi than ny khng c kh nng to cc, khng dng ring trong sn xut cc.

5. Than ccKhi nim: Than cc l loi than nhn to dng cc, ch to bng cch nung bt than c tnh kt dnh c bit trong mi trng thiu khng kh nhit khong 1000oC.

* c im cht lng cc luyn kim:

+ Thnh phn ha hc:

- Ccbon c nh trong cc cng cao cng tt.

Cc = 100% - (%A + %V + %S); ( 80%

( Tro (A) yu cu cng t cng tt v: A tng th Cc gim, bn km, W gim, cc tng, C~(82 ( 86%)

( yu cu AK 9 ( 10% (TN: 13 ( 16%)

- Lu hunh: (S)K trong phi liu l cao trn 80% S, do tro ca cc nung vo. Do SK cng t cng tt; S < 1% (TN: 1,0 ( 1,32%)

- Pht pho (P): trong cc t ( 0,01%

- Cht bc (V): Nu V nhiu chng t luyn cc cha tt, nu V cao chng t cc cn sng. bn c gii km.

Nu %V: t qu chng t ti cc qu la, dn d v, thng (0,9 ( 1,25%)

- m (W): cng t cng tt: 2 ( 6%.

* Tnh cht c l ca cc:

- bn c gii l kh nng chu va p, mi mn, chu nn ca than cc, ch s trng quay 315kg/410 kg

- bn nng: l kh nng chng v vn than nhit cao.

- ht: l cao ln 40 ( 80 mm

l cao nh 25 ( 40 mm

TN (25 ( 60 mm); ng u: K 3,7

- xp ca than cc trung bnh 45 ( 55%

- Cu to b mt ngoi ca cc: nu bn tt c c im b ngoi nh: vt nt khng ln, l xp phn b u, mu xm bc, hnh dng ngay ngn, khng c u en, cc xu thng c hnh dng khng ngay ngn, c u en.

* Tnh cht ha l ca than cc:

- Hot tnh ca cc: biu th bng tc phn ng gia C v CO2 nhit nht nh; thng thng 900 ( 10000C ton b CO2 kt hp vi C to ra CO; C + CO2 2CO; (~ 9500C).Cng thc: R = Nu:R = 50 ( 100% than c hot tnh va

R = 100 ( 200% than c hot tnh cao

R = 30 ( 50% than c hot tnh thp

- Nhit bc chy ca cc yu cu 600 ( 7500C

6. Cc loi nhin liu khc dung cho l cao+ Than bt

+ Du than

+ Du ma zt

+ Va than

+ Kh thin nhin

+ Cc st

Chng3CHUN B QUNG CHO L CAO

1. p sng v phn cp qung

2. Lm giu qung: Tuyn t, tuyn ni.3. Trung ha qung - Dng gu ngom

- Phng php bng ti, my xc

- Phng php bng ti ton b

- Phng php dng my nh ng v my co

- Dng h thng boonke

* Mc ch chun b nguyn vt liu cho l cao

( n nh thnh phm ha hc v ht lm giu, vn hnh l thun li, nng cao nng sut.

( m bo thnh phn n nh, giao ng cho php

( m bo ht liu nm gii hn yu cu

( Tit kim nguyn liu v qung vn thng rt ln nu khng x l th lng ph.

( Chun b liu nhm cng nghip ha nu liu l cao m bo cht lng gang.

Chng4CC QU TRNH HA L XY RA TRONG L CAO

I. CC QU TRNH HA L XY RA TRONG L CAO

Gm cc qu trnh sau:

- Qa trnh bc hi v phn ha;

- Qu trnh hon nguyn, cc ban ha st v to gang;

- Qu trnh to x v kh lu hunh;- Qu trnh to kh;* c trng qu trnh ha l m t theo s sau:VngToC (K-L)Qu trnh ha l

Sy400 ( 380H2O ( H2Ohi; H2Ohyrat ( H2Ohi

Phn ha cc bon nt, hon nguyn s b750 ( 700FeCO3; CaCO3; MgCa(CO2)2 ( Me + CO2 - Q

Fe2O3+CO(H2)(Fe3O4+ CO(H2) ( FeO + CO2(H2O) + Q

MnO2 + CO ( Mn2O3 + CO ( MnO4 + CO ( MnO + CO2 + Q

Hon nguyn

gin tip1100(900Fe2O3+CO(H2)(Fe3O4+CO2(H2O).

Fe3O4+CO(H2) (FeO + CO2(H2O)

FeO+CO(H2) ([Fe] + CO2(H2O)+Q

Hon nguyn trc tip v to x1500 ( 1100FeO + C = [Fe] + CO - Q

MnO + C = [Mn] + CO - Q

SiO2 + 2C = [Si] + 2CO - Q

Nng chy to gang ( x1800 ( 1500C + O2 = CO2

CO2 + C = CO - Q

C + CO2 = CO

Ti H.NFeO(Fe3O4;Fe(FeO; M2O (M4O4

Gang + x lng2000 ( 1500SiO2 + 2C = [Si] + 2CO - Q

M2O + C = [Mn] + Q; FeS + Cr = [Fe] + Q

FeO + C = [Fe] + CO - Q

Fe + C = [Fe3C]

II. KHI QUT CU TO, CHUYN VN CA L CAO

A. Cu to(Trc phn sau):- Ngi ta luyn gang trong l cao. L cao hin i xy bng gch chu nng v bc bng v thp. N c th cao ti 40m v hn na; n c th sn xut trn 2000 tn gang trong 24 gi v hot ng lin tc t khi khai l n khi ngng liu l sa cha (l cao Thi Nguyn c chiu cao hu ch l 15,66m).

- Theo chiu t trn xung, l cao gm cc b phn sau:

+ Ming l;

+ Thn l c hnh nn ct, chp rng v pha di

+ Bng l c hnh tr

+ Phu l hnh nn ct, chp rng v pha trn

+ Ni l hnh tr

B. Np liu l- Qung, than v cht chy (tr dung) vo l qua ming l khng kh nng c dn vo bng nhng ng t pha trn ni l. Nh vy, cht rn dn dn chuyn xung v cc cht kh bay t phn di l ln trn.

- Cc cht dng luyn gang c chuyn ch n l bng nhng toa gong, c mng nng a cht y ln ming l theo mt ng dc (xe kp, bng ti). Ngi ta nhng lp cc xen k vi nhng hn hp qung v cht chy.

- B phn np liu gm 2 ci "phu", ci nh lp kht trn ci ln, y mi ci y bng mt ci "nn" p. Khi y nn nh xung th vt liu ri xung phu di (cn nh).

- Sau ngi ta ko nn nh ln v y nn ln xung; vt liu ri xung l, lc y nn nh y kn y phu trn, 2 phu khng thng c vi nhau, nn cc kh trong l khng thot ra ngoi c (cn ln).

- Trong l cao hin i, cng vic liu vo l lm t ng, ch cn 1 ngi iu khin ton b h thng np liu.

C. Qu trnh to thnh gang xa. Cc cht kh i ln

1. phn ni l, than cc chy v ha kh nhit ln n 18500C. p sut kh trong l cao hn ngoi. Hiu sut ca l cao cng tng ln do thi gi, kh m, oxy (khong 0,7 atm).

2. Cc cht kh chy, bc t phn di l ln trn, phn phi nhit cn thit thc hin tt c cc qu trnh bin ha xy ra trong l. Oxyt cc bon cha trong cc kh gii phng st ra khi qung v to thnh kh ccbnc, nhit cao kh cabonic b than cc kh thnh oxyt cacbon.

3. ming l, nhit thng l 2500C. Kh l thot ra theo mt h thng ng n cc thit b lc ra lm sch tp cht. Kh l cha oxit cacbon l mt loi kh chy c nn dng cho vic lm cht t.

b. Cc cht rn v cht nng chy i xung1. St bt u c gii phng ra khi qung ngay v phn ln thn l.

2. + Thn l m rng dn v pha di cc cht phi nng chy chuyn xung v tip xc vi cc cht kh bc t di ln.

+ Gang v bt st bt u to thnh bng l v tip tc sinh ra phu l. n y, gang v bt st nng chy dn xung ni l.

y ni l c 2 lp: di l gang (t khi ( 7,2), trn l x (t khi ( 2,5). V c cc ht st ph ln trn, nn gang khng b oxy ha.

+ Tho gang x ra khi l:

- Gang x trong ni l ngi ta tho ra khi l theo chu k v thi gian.

- C th tho 15 ln/24 gi (T.N)

- Thi gian vt liu vo l n lc ly c gang x ra (thi gian lu liu khong 4 n 5 ting (l cao T.N khong 3,5 ( 4 gi)).

D. Khng kh c sy nng trc khi vo lNu tit kim than cc vo tng nhit trong l th trc khi thi khng kh vo l ngi ta sy cho nng ln t 600 n 14000C (TN: 800 ( 9000C). Vic thc hin bng cch t chy 1 phn kh l.

a. Thp sy kh l mt ci thp bng thp cao 40m (TN ( 22m), ng knh 8m (TN ( 5,0 m).

- Pha trong lt bng gch chu nng. Trong thp c chng gch xp (gch ) v bung t kh dn t l cao sang.

- Cnh mi l cao c 3 thp vt nhit ly li nhit ca kh l, sy khng kh t ngoi vo (l caupo ( l gi nng).b. Cc thp vt nhit v l cao trao i vi nhau nh sau:- Kh l chy trong bung t v nung nng chng gch (gch )

- Khi gch nng trng ra, ngi ta dn kh l sang thp khc. Cho khng kh vo thp nng n thu ly nhit ca gch v thi khng kh nng sang l cao.

Chng 5GII THIU CC CNG ON - CNG NGH L CAO LUYN GANG1. Cng on trc l+ Thit b sng bn bn

+ Thao tc k thut:

- Cc ch tiu thao tc k thut

- Bo h l gang

- Bt l gang

- Thao tc sng bn bn

- Thay vng t l gang

- Thay vng gch l gang

- Thao tc khoan l gang

- Mng gang chnh

- Thao tc hm nh

- X l s c trc l

(S c l gang, l x, ngng gi khn cp)

- Ra gang

- Ra x

- Thay thit b lm lnh

- Ch giao nhn ca

+ Xem quy trnh k thut cng on trc l (chc trch, nhim v).

2. Cng on gi nng+ Chc trch, nhim v

+ Ch bo dng thit b

+ Thao tc k thut

- Cc ch tiu thao tc

- Thao tc thay l

- Thao tc thi gi

- Thao tc ngng gi

- Thao tc o liu, ngng o liu

- Thao tc ngng kh than ca 1 l cao sn xut c lp

- Thao tc ngng kh than ca 2 l sn xut 1 l ngng

- Thao tc thng kh than ca 1 l sn xut c lp

- Thao tc thng kh than ca 2 l sn xut 1 l ngng

- Thao tc ngng gi v ngng kh than khn cp 1 l sn xut c lp

- Thao tc ngng gi v ngng kh than khn cp 2 l sn xut 1 l ngng

- Thao tc thi bi thng lc bi

- Thao tc n bi trong thng bi

- Thao tc lm ngui l

- Thao tc dn bung tch nhit

+ Nhng iu ch trong thao tc k thut khi ngng l o liu, thao tc ngng kh than, thng kh than, ngng gi v kh than khn cp, thi bi thng lc bi kh.

+ An ton k thut

+ Ch giao nhn ca

* Xem quy trnh k thut cng on gi nng

3. Cng on coi nc+ Gii thiu thit b lm lnh

- H thng ng ng ngoi tri

- H thng cp nc vo l cao

- H thng nc cao p

- Thit b mt gi v l x

+ Cc ch tiu cht lng nc v mt s phng php x l nc

- Cc ch tiu cht lng nc

- S to thnh cu nc

+ Chc trch, nhim v

+ Ch bo dng

+ Thao tc k thut

+ Thao tc bm cao p

+ X l s c khn cp

+ An ton k thut

+ Ch giao nhn ca

* Quy trnh k thut cng on coi nc

4. Cng on np liu+ Quy trnh an ton

+ Thao tc k thut

+ Tnh nng k thut

- My ti xe liu

- My ti chung liu

- My ti thc liu

- My ti phu qung

- Van phu cc

- Sng rung

- Bng ti cc vn

- Xe cn

- Bng ti qung

+ Ch bo dng thit b

+ Ch kim tra thit b

+ Chc trch, nhim v

* Quy trnh k thut cng on np liu.

Phn B:LUYN GANG L CAO

1- Khi nim: Gang l hp cht st vi cc bon (Fe3C), c thnh phn cc bon(%C) trn 2% v cn c mt s nguyn t khc.

2- Luyn gang l cao l gi?

L a cc loi nguyn liu bao gm qung st, than kok v cc ph gia ( vi, lomit) np t trn nh l vo l. T mt gi pha di thi khng kh qua gia nhit nhit > 9500C, di tc dng ca nhit cao, cc bon trong than kok v oxy trong khng kh thi vo l s t chy v sinh ra nhit. Kh CO bc t di ln trn, qung st trong qu trnh i xung ni l gp nhit cao s c hon nguyn bng kh CO ly O2 trong qung. Qung st c hon nguyn thnh st (Fe) i xung ni l thnh nc gang v c tho ra ngoi l ra gang. Cc tp cht xit cng cc ph gia vi, lmy kt hp vi nhau to thnh x c tho ra l x ca l cao (l cao nh gang v x cng tho ra l gang). Kh than theo ming l qua h thng lc bi cung cp kh t cho l gi nng, thiu kt v cc vic khc.

3- Sn phm luyn gang l cao.

3.1 Sn phm ch yu l gang

-Sn phm gang: + Gang c Si 1,26 %, Mn 1,50% .

+ Gang luyn thp Si 1,25%

Thnh phn Mn >4% trong qung st s khng luyn thp c.

Kh than CO: Kh l cao cha 22 32 %CO, 2 3%H2.

Tr s nhit 850 950Kcal / m3.

Lng kh than l cao sn xut ra rt ln, mi tn kok c th sinh ra 3500 4000m3 kh. V vy kh than l cao thng c lm sch tn dng.

Kh CO c chy n cn c c bit quan tm lu .

3.2 Sn phm ph l x l v kh than.

i vi x l cao: Trong x ch yu cha CaO, MgO, SiO2, Al2O3 v mt s t MnO, FeO, CaS

kim x thng ln hn 1; (CaO / SiO2 > 1) c th x nc lm x ht dng lm nguyn liu cho xi mng.

X c kim < 1 (CaO / SiO2 < 1) l x axit c th bng phng php bc hi p lc cao hoc thi kh nn lm x bng dng lm vt liu cch in cch nhit, x kh ri ng.

I- CC NGUYN LIU CHNH V PH DNG CHO LUYN GANG

1- Qung st:

1.1 Phn loi qung st.

a, Hp cht ca qung st vi xy gm c:

- Qung st t (manhtt) Fe3O4- Qung st khan (matit) Fe2O3- Qung st ngm nc Fe2O3,mH2Ob, Hp cht ca st vi Lu hunh c:

- Qung sunfuast FeS

c, Hp cht ca qung st vi ccbonat c:

- Qung Cacbonat st FeOCaCO3.

1.2 c im ca mt s qung st chnh.

a, Qung st t:

- Thnh phn ch yu l Fe3O4, hm lng st Fe 72%, c t tnh do c th lm giu bng phng php tuyn t, khi nung n 5800C th qung mt t tnh. Qung st t c kt cu c chc do tnh hon nguyn km, ci thin tnh hon nguyn ca qung st t ngi ta tin hnh thiu xy ha chuyn qung st t thnh qung st theo phn ng:

2Fe3O4 + 1/2O2 = 3Fe2O3b, Qung st khan (qung st ) matit.

- Thnh phn ch yu Fe2O3 hm lng st Fe 70%, c tnh hon nguyn tt hn qung st t.

c, Qung st ngm nc (Hydro hmatit) hay cn gi l qung st nu. Thnh phn ha hc l Fe2O3mH2O, sau khi phn ha ht hi nc th hm lng st c th ln n 70%. Khi phn ha nc hydrat cc qung tr nn rt xp do tnh hon nguyn ca qung tt hn so vi qung st t v qung st .

d, Qung Xirit (FeOCaCO3). Thnh phn trong qung xirit cha 48,3%. Ngha l trong qung xirit cha 62%FeO v 38% l CaCO3. Qung Xirit thng ch tn ti lp su cn lp b mt thng l qung st v qung st t. c im d phn ha to ra FeO: (FeOCaCO3 = FeO + CaO + CO2), FeO b xy ha to thnh Fe3O4 hay Fe2O3 theo phn ng: 3FeO + 1/2O2 = Fe3O4 2FeO + O2 = Fe2O3u im ca qung xirit.

Ch cn phn ha l nhn c FeO.

Gim c mt lng ln cht to x v tr dung.

Khi kh CO2 thot ra ngoi s li cc l xp trong cc qung do lm tng tnh hon nguyn ca qung.

Qung Xirit d hon nguyn nht Qun st nu Qung st qung st t kh hon nguyn nht.

2- Cht lng qung st.

a, Thnh phn ha hc: L c tnh c bn ca qung st, ngi ta ch dng cc loi qung st c hm lng st ln hn 20% v c chia ra lm cc loi sau:

- Qung giu: Hm lng st 60 70%Fe

- Qung trung bnh c hm lng t 50 60%Fe.

- Qung ngho hm lng Fe 50%

b, Thnh phn t chay: ch yu l cc xit bao gm: CaO, MgO, Al2O3, MnO, SiO2 . V x l cao l x trung tnh c baz = 0,8 1,1 do thnh phn tt nht ca t chay l bo m t s.

%CaO + %MnO / %SiO2 + % Al2O3 = 0,8 1,1. Tuy nhin thnh phn SiO2 v Al2O3 trong t chay rt ln nn trong thc t luyn gang ngi ta vn phi cho vi vo to x.

c, Cc nguyn t tp cht:

- Cc nguyn t c hi. S, P, Zn, Pb.

- Cc nguyn t c ch. Mn, Cr, Mo (molipden), vanadin.

d, Tnh n nh v thnh phn ha hc.

- Nu qung cht vo l cao c thnh phn ha hc giao ng nhiu s lm cho qu trnh vn hnh l khng n nh v cht lng sn phm khng n nh v:

+ Thnh phn v kim khng n nh.

+ Ch nhit ca ni l lun thay i.

e, Cc tnh cht c l ha:- Tnh hon nguyn ca qung ( hon nguyn). hon nguyn ca qung l lng qung c hon nguyn trong mt n v thi gian.

- Tnh bin mm v nhit bin mm ca qung: Nhit bin mm ca qung c nh hng n thng kh ca ct liu v qu trnh hon nguyn. Khong nhit bin mm l khong thi gian t khi bt u bin mm cho n khi qung nng chy hon ton. Khong nhit bin mm cng ln th lp x cng dy, nhit thng kh ca ct liu cng km do vy i vi l cao qung c nhit bin mm cng cao khong bin mm cng hp th vn hnh l cng thun li.

- T trng ng ca qung: L khi lng ca 1m3 ng qung.

+ T trng ng ca qung cng cao th lng qung st cht vo l cng nhiu thi gian lu liu cng ln do nng xut ca l cng cao. Tuy nhin t trng ng ca liu cng cao th cht ca liu cng ln do thng kh ca ct liu cng thp.

II- Qung Mng gan.

Qung Mn c s dng kh ph bin trong sn xut luyn kim trn 90% lng qung Mn trn th gii c khai thc v s dng. luyn mt tn thp qung th trung bnh cn s dng t 80 100kg qung Mn, vic s dng qung Mn vo cc mc ch:

+ Dng lm cht kh xy trong qu trnh luyn thp:

Mn + FeO = Fe + MnO

+ Dng lm cht kh Lu hunh trong qu trnh luyn gang l cao:

Mn + FeS = Fe + MnS

+ Mn c dng lm cht hp kim ha i vi cc loi gang thp lm tng bn c hc, tng cng v tnh chng mi mn.

III- Cht to x v tr dung.

1. Cht to x: L cht c a vo l vi khi lng ln nhm to x v l mt thnh phn c bn ca x.

2. Cht tr dung: L cht c a vo l vi khi lng khng ln khng nhm l thay i thnh phn ha hc ca x m nhm lm tng tnh chy long ca x.

3. Cht to x v tr dung kim tnh.

3.1 Cc cht thng dng.

* vi: L khong vt dng Cacbonat canxi tn ti bn vng thnh cc dy ni v hang ng hu ht cc m vi l l thin. vi tinh khit th c 56% l CaO v 44% l CO2, thc t hm lng CaO cn thp hn v cn cc tp cht khc nh SiO2, Al2O3, S, P. Trong S khng ng k, P l nguyn t c hi thng khng ch nh hn 0,005 0,1%.

* lmit: L khong vt c thnh phn ch yu l CaO v MgO, trong l cao thng dng lmit lm tng hm lng MgO trong x vi mc ch ci thin tnh lu ng v s n nh cc tnh cht ha l nhit cao ng thi tng kh nng kh S ca x.

3.2 Cc yu cu.

- Thnh phn ha hc:

+ Hm lng cc oxit CaO, MgO phi t c mc quy nh ty theo yu cu s dng nhn chung hm lng CaO cng cao cng tt.

+ Hm lng cc oxit, axit, cc oxit lng tnh cng thp cng tt (SiO2, Al2O3).

+ Hm lng P, S cng thp cng tt.

+ C ht: vi phi hp l nu qu nh th bc bi nhiu gy lng ph v nhim mi trng ng thi lm gim thng kh ca ct liu. Nu qu ln th thi gian phn ha ko di khi xung n ni l vi vn cha c phn ha ht, khi phn ha thu nhit s lm ngui nhit ni l

3.3 Tr dung axit v alumin.

- Khi hm lng oxit nhm trong qung v tro ca than cao th phi thm tr dung axit lm tng chy long ca x; Cc loi tr dung axit thng dng cho l cao l: Sa thch, qung bc xt hoc vn sa mt.

IV- NHIN LIU DNG CHO L CAO1- Cc yu cu i vi nhin liu dng cho l cao.* Mc ch:

t cp nhit cho qu trnh cng ngh sy ra trong l cao.

Cung cp cht hon nguyn v to ra mi trng hon nguyn trong l cao.

Tin hnh ccbit ha to gang.

* Yu cu:

Khi chy pht nhit ln c hot tnh v tnh chy thch hp m bo cc phn ng sy ra trong l lun bnh thng v thun li.

Cha t tro, t tp cht c hi c bit l Lu hunh (S).

C bn c hc v bn nhit cao khng b v vn trong l.

C ht v xp thch hp m bo thng kh ca ct liu.

2. Cc loi nhin liu dng cho l cao luyn gang.

2.Than koke.

a. Cng ngh ch to:

Than koke c ch to bng cch nung than m trong iu kin thiu khng kh hm lng cht bc v hi nc thot ra than bin mm v kt tinh li to thnh cc cc than koke c xp cao.

Cng ngh luyn than koke bao gm cc bc:

+ Chun b phi liu: Nghin than m thnh bt sau tuyn phn loi thnh 3 cp: Than sch dng luyn koke, loi ln tp cht dng vo cc l nung, tp cht loi b.

b- Cht lng than koke:

- Thnh phn ha hc: Cng cao cng tt, hm lng C tnh theo cng thc: %C = 100 (%A + %V + %S) %

+ Tro (%A) cng thp cng tt v nu hm lng tro cao th khng ch lm gim hm lng C m cn lm tng lng x gy kh khn cho qu trnh cng ngh.

+ Lu hunh (%S): Trong thc t c n 85% hm lng S trong gang l do than koke mang vo do hm lng S trong koke cng thp cng tt.

+ m (%V): L hm lng nc trong than koke, yu cu phi liu l cao phi c m n nh. m cng thp cng tt v koke lm ngui bng nc nn m ca koke thng l khong 6%.

Tnh cht c, l, ha:

+ Tnh cht c l: L kh nng chu ti trng, va p ca than koke m khng b v vn, tnh cht c l ca than koke thng c xc nh bng t l than koke vn khi chu ti trng va p trong tang quay.

+ Tnh cht ha l: L kh nng tham gia vo cc phn ng ha hc trong l cao, than koke khng ch c tc dng chy cp nhit m cn tham gia vo cc phn ng trong l do phi c hot tnh cao.

IV- CU TO L CAO LUYN GANG Gm 5 phn chnh: C l, thn l, bng l, hng l v ni l.

1. C l: C dng hnh tr trn l ni trc tip nhn liu t b phn cp liu, c l cng cao th vic vn hnh l cng thun li, ng liu cng ln th mo liu cng cch xa tng c l do dng kh bin s pht trin mnh. Nu ng knh c l nh th khi np liu , liu s p nhiu vo tng l s mi mn tng ca l.

2. Thn l: - Thn l c dng hnh cn trn to di nh, s d nh vy l v cng chuyn ng xung di nhit cng cao th th tch liu cng ln do phi lm thn l hnh cn m bo ti xp ca ct liu v chuyn ng i xung c d dng.

- nghing ca tng thn l c xc nh bi gc nghing , thng thng gc nghing giao ng trong khong t 75 850.

3. Bng l: L b phn c ng knh ln nht trong l, bng l c dng hnh tr trn c ngha lm tng dung tch l cao rt ln m khng phi tng nhiu chiu cao ca l.

4. Hng l: C dng hnh cn, trn to di nh s d nh vy l v n vng ny liu bt u chy lng do th lch liu gim dn. m bo tc xung liu v phn b dng kh ng u th ph thu hp tit din l mt cch ph hp. Mc thu hp ca hng l c xc nh bng gc nghing , thng ngi ta khng ch gc nghing = 45 550. 5. Ni l: C dng hnh tr trn l ni lu tr gang x lng, chiu cao ni l cng ln th lng gang x cha trong ni l cng nhiu. Tuy nhin nhit gang trong ni l cng thp. phn di ni l thng c lp gang cht c nhim v bo v y l khi b bo mn khi ra gang cng nh qu trnh nu luyn.

V- c im cng ngh luyn gang. L cao lm vic t khi khai l n khi ngng hn l khong t 4 10 nm c khi lu hn.

L cng chy lin tc cng n nh cc ch tiu kinh t k thut cng cao.

1. Qu trnh vn hnh l ph thuc rt nhiu yu t, thng s. Cc thng s ny li lun bin i v tc ng ln nhau bi vy cc din bin c l ha nhit, trong l sy ra rt phc tp v hay dao ng cho nn rt kh duy tr tnh hnh n nh ca l v cng rt kh t ng ha ton b qu trnh l cao.

2. Gang v x lng nm thnh lp ring bit v trng lng ring ca chng rt khc nhau ( gang = 7,2t/m3, x = 2,3t/m3) do l ng gang x ra theo l ra gang v vy x phi chy lng tt th vn hnh l cao mi thun li.

3. Trong l cao lc no cng c hai lung vt cht chuyn ng ngc chiu nhau; nguyn, nhin liu rn mt phn mm v lng chuyn ng t trn xung v dng kh l chuyn ng t di ln, nhit tng dn t trn xung di do hiu sut nhit ca l cao ln hn so vi cc l luyn kim khc.

4. Cc bon ca than koke trong l cao khng ch c vai tr cung cp nhit m cn lm nhim v hon nguyn qung st v cc bon ha st do c phn ng hon nguyn v s chy l cao thng khng hon ton nn kh nh l bao gi cng chim CO, CO2 v mt s kh khc na. T s thnh phn %CO / %CO2 = 1,3 3,3 do vy ch c mt na nhit nng ca C c li dng cho l, na kia th chuyn vo kh nh l v thot ra ngoi. Ngha l hiu sut s dng C trong l cao chim vo khong 50%.

5. Do c im v thnh phn kh nh trn cng vi nhit cao v lng C trong phi liu nhiu nn mi trng l cao c tnh hon nguyn mnh. Do t l thc thu Fe trong l cao ln hn bt c thit b luyn kim no. Nhng cng chnh v mi trng c tnh hon nguyn mnh nn l cao km kh nng hon nguyn tuyn la n hon nguyn ton b P, phn ln Mn, phn ng k Si.

Ring i vi kh S v tnh hon nguyn nn hm lng FeO trong x thp do phn ng kh S bng kh th hn ch v khng xy ha c S thnh SO2, do phi gi xut lng x mc thch hp kh S t yu cu l mt trong nhng l do tng tiu hao than koke nng cao nhit ni l to thun li cho qu trnh kh S.

VI- S PHN HA PHN LY CACBONAT TRONG L CAO

1- Cc dng cac bo nt trong phi liu l cao

* a s l cc bo nt canxi CaCO3 nm di dng vi hay lmt. vi v lmt khc nhau ch yu hm lng MgO trong chng, nu hm lng

%MgO < 17% gi l vi

%MgO > 17% gi l lmt.

Ngoi ra trong phi liu l cao cn cha mt lng Cacbonat st FeCO3 v MnCO3 nu ta s dng qung sirit hay qung Mn.

3- S phn ha Ccbnt trong l cao.

3.1 S phn ha Ccbnt canxi v ccbnt magi.

a. Phn ng phn ha CaCO3.

CaCO3 = CaO + CO2 42.520Cal. (1)

b. Phn ha MgCO3.

MgCO3 = MgO + CO2 26.470Cal. (2)

c. Phn ha lmt.

CaMg(CO3)2 = CaCO3 + MgCO3 36.010Cal. (3)

MgCO3 = MgO + CO2 26.470Cal. (*)

CaCO3 = CaO + CO2 42.520 Cal. (*)

Cng 2 phn ng (*) trn ta c:

CaMg(CO3)2 = MgO + CaO + 2CO2 Q = 72.600Cal. (4)

Trong l cao Cacbonatmagie phn ha nhit < 8000C nhng CaCO3 th kt thc phn ha nhit > 10000C. Do kh CO2 to thnh s tc dng vi (C) tin hnh kh ha cc bon.

CO2 + C = 2CO 39.600Cal. (5)

Qu trnh phn ha vi trong l cao c thc hin theo phn ng:

CaCO3 = CaO + CO2 42.520Cal (*)

CO2 + C = 2CO 39.600 (*)

Cng 2 phn ng (*) li ta c:

CaCO3 + C = CaO + 2CO 82.120Cal (6)

2. S phn ha cc bon nt st (FeCO3)

VIII- S TO GANG TRONG L CAO1- S to gang: L qu trnh tc dng gia ccbon v st to thnh ccbit.

1.1 Cc phn ng:

nhit 400 5000C st c ccbon ha theo phn ng.

3Fe + 2CO = Fe3C + CO2 + 43110cal

nhit t 550 6500C st c ccbon ha bng ccbon rn.

3Fe + C = Fe3C + (5400 150) cal.

S c mt ca x nhiu FeO s km hm qu trnh cacbon ha st v cacbon lm nhim v hon nguyn FeO.

Lng C c hp th vo st c th c tnh gn ng theo cc cng thc sau:

+ nhit 800 9000C th qu trnh cacbon ha st mi pht trin v lng C trong st c tnh theo cng thc.

%CFe = [ 0,25 0,0006 (1000 T0 )] * t (1)

Trong : - T0 l nhit phn ng. (0C)

- t l thi gian (h)

+ nhit 1150 20000C lng (C) hp th vo st c tnh theo cng thc.

%CFe = 1,3 + 2,57 * t * 10-3 (%) (2)

2- Cc nhn t nh hng.

2.1Nhit .

Theo cng thc (2) nhit cng cao hm lng (C) ha tan vo st cng ln. VD: nhit 11500C th trong st cha n 4,26% C v sau c tng nhit ln 1000C th % CFe tng l 0,26%.

2.2 Hm lng ca cc nguyn t khc trong gang.

Cc nguyn t lm tng kh nng cacbon ha st l cc nguyn t khng c kh nng to thnh ccbit m to thnh hp cht vi st nh P, S

Trong thc t ngi ta ch ch ti nh hng ca Mn, Si, P, S ti hm lng C trong gang v dng cng thc thc nghim tnh ton hm lng C trong gang theo cng thc:

%Cgang = %CFe + %CMn,Si - %Cp,s (3)

Trong : % CMn, Si = 0,0265[%Mn] [ 0,44 0,002 (%Mn)][%Si]+( 11,2 0,17 [ %Mn] * 10-3*[%Si]2 (4)

%Cs, p = 0,4 ([%P] + [%S]) + 0,0009 [%P]2 (5)

Khi hm lng Si khng ln hn 12% v P < 1% th c th xc nh nh sau:

%Cgang = 4,6 0,27 [%Si] + 0,03 [%Mn] 0,32 [%P] (6)

*. Nhit ni l cng cao gang cng nng th cng hon nguyn v chuyn ha c nhiu Si, Mn, P, C vo gang ng thi cng kh c S. Quan h ny l quan trng nht, v vy ngi ta thng dng hm lng Si nh gi nhit ni l v nhit gang.

IX-S TO X TRONG L CAOTri qua 3 giai on:

1. Phn ng pha rn.

nhit thp c th sy ra phn ng gia cc xit trong ni b cc liu v trn b mt tip xc cc cc liu phn ng pha rn. Phn ng ny xy ra thng c s tham gia ca cc pha lng v hi hn hp. Kt qu l to thnh nhng hp cht d chy t nhng cht kh chy, thng xy ra nhit 650 8500C.

2. Bin mm qung.

Do ccn phn ng pha rn lm xut hin nhng cng tinh d chy nn pht sinh hiu ng ha mm nguyn liu lm cho cng tinh d chy b chy ra. S ha mm qung sy ra trong mt phm vi nhit xc nh, nhit bt u bin mm v khong bin mm ca cc loi qung khc nhau th khc nhau.

3. Nng chy x. Sau khi nng chy hon ton hay gn hon ton nguyn liu s bin mm thnh mt hn hp pha lng tch khi pha kim loi th c gi l x nng chy. X nng chy ny u tin s to thnh git ri xung v chy dn xung ni l. Vng x nng chy c nhit 1000 13000C vng ny gi l vng to x. Phn b nh sau:

350(C vng pha rn t c l n ng nhit 6500C

1 550(C 650

2 750 (C vng phn ng pha rn 650 8500C

850 (giai on thiu kt)

3 950 Vng ha mm NL trng thi nho v lng cc 1000 (C b 4 1050(C Vng nng chy (NL trng thi lng ton b)

1150 hay gn ton b vng to x 1000 11500C

5 2000(C Vng ng tr pha lng

4- Cc nhn t nh hng n qu trnh to x l cao:

Thnh phn ca qung. Nu thnh phn t chay trong qung cha nhiu SiO2 bao vy xit st th cc giai on bin pha to x s xy ra sm; Khi kim trong qung thiu kt thp cng c tc dng tng t.

Cch phn b nhit . Ty theo iu kin nu luyn phn b nhit trong l s thay i v do nh hng ti s phn b vng to x.

5- Phn bit x u, x trung gian v x cui.

5.1X u: c hnh thnh vng to x, nhit vng ny thng ln hn 1000 12000C bi vy cn c cha mt lng xit st v MnO cha hon nguyn do hm lng FeO v MnO trong x u s cao hn x cui, hm lng CaO, MgO trong x u cng cao.

5.2X trung gian:

L x chy t vng to x xung ti ni l, c im ca n l c nhit tng dn v hm lng FeO, MnO gim dn. Cn hm lng SiO2, Al2O3 th dao ng theo hm lng ban u ca cc xit khc. Nu x u cha FeO, MnO, CaO, MgO th hm lng SiO2, Al2O3 trong x trung gian c th tng ln v ngc li, ngoi ra x trung gian cn c c im l tng dn khi lng v cng xung di khi lng pha lng cng tng.

5.3X cui:

L x hnh thnh vng mt gi ch yu do kt qu ca vic kt hp gia x trung gian vi tro ca than koke ri tch t li ni l. Chng nm thnh lp ring bit trn mt gang lng, nu thnh phn tro ca koke khc bit vi thnh phn t chay ca qung th thnh phn x u x cui khc nhau.

6-Cc yu cu i vi x l cao:

6.1ng u v thnh phn, nu khng xy ra s bt ng b gia cc qu trnh v ko di vng to x, ngoi ra cn lm bin ng v tr vng to x khin cho mt s pha lng sinh ra li c th ng c do gy nn biu l.

5.2 Vng ha mm nguyn liu v vng to x phi mng v tng i thp thch hp.

6.3 X u cn phi long v hp th c nhiu nhit khi chy xung ni l cn x cui phi rt long.

6.4Xut lng x cng t cng tt n c quyt nh bi yu cu kh [S] v hon nguyn [Si], thc t cho thu c th chy l bng than koke bnh thng vi xut lng x 0,3 0,35t/tn gang, ch tiu thp nht 0,28t/tn gang.

7- kim v chy long ca x phi kh (s) ti mc yu cu.Bin php: Dng qung thiu kt t tr dung, a qung Mn vo trong phi liu thiu kt trung ha k.

Chn qung v sn xut qung thiu kt c nhit ha mm cao v phm vi nhit ha mm hp, phi liu sao cho x c nhit nng chy cao.

Tng hm lng MgO trong x, tng tnh n nh ca x, tng bn ca than koke phi liu sao cho x c tnh chy long thch hp.

Lm giu qung v than thi kh t thin nhin, du marut, hoc than bt vo l, chy x axit ng thi dng bin php kh (S).

X- S CHY TRONG NI L 1- Cc phn ng chy nguyn liu.

Nguyn liu c np vo l t nh l v chuyn ng theo liu rn t trn xung, trong qu trnh chng c nung nng dn nh trao i nhit vi kh nng chuyn ng t di ln n vng mt gi. Nhin liu hn hp vi xy t ngoi thi vo v tin hnh cc phn ng chy ty thuc vo hm lng O2, nhit vng phn ng m cc phn ng sy ra v sn phm nhn c ca cc phn ng chy khc nhau.1.1 ngay trc mt gi:

Do lng xy cung cp y nn phn ng chy l phn ng chy hon ton, sn phm nhn c l kh CO2. Do vy nhit vng ny rt cao c th n 1800 20000C. V sn phm ca phn ng chy l kh CO2 nn vng ny c tnh xy ha do mt phn gang khi i qua vng ny st s b xy ha.

1.2 su trong tm l:

Cng vo su trong tm l th hm lng O2 trong hn hp kh cng gim do phn ng chy ch yu l khng hon ton.

C + O2 = CO + Q1 (1)

Do vy trong pha kh xut hin kh CO v do phn ng khng hon ton nhit ta ra t nn nhit l gim dn t ngoi vo trong theo tit din ca l.

Kh CO2 bc ln gp C nng s tin hnh phn ng kh ha cc bon.

CO2 + C = 2CO Q2 (2)

Phn ng kh ha cc bon l phn ng thu nhit do nhit ca l gim mnh t vng mt gi ln trn.

* Kt lun: T cc phn ng (1) v (2) ta thy phn ng chy nhin liu ni l l phn ng chy khng hon ton v kt qu nhn c ca phn ng l kh CO. Chnh v l do mi trng l cao l mi trng hon nguyn mnh.

2- Hnh xoy koke

2.1 M t v hnh xoy koke.

Do tc dng mnh ca gi thi qua mt gi vo l, trc ming mi mt gi hnh thnh mt vng xoy koke trong vng , koke trng thi l lng nhy ma gn ng theo qu o hnh khi elip xn. Nhng cc to c th chuyn ng vi vn tc t 3 10m/s, cc cc nh chuyn ng vi vn tc v = 15 16m/s. Do vng koke l vng rt ti liu.

2.2 Yu cu v c dim vng xoy koke.

m bo cho l cao vn hnh thun li th khi thit k h thng mt gi v xc nh ch gi cung cp (lu lng, p xut, nhit gi) phi m bo tha mn cc yu cu:

+ Cc vng xoy koke phi tip xc nhau hoc lng vo nhau.

+ Vng xoy koke c lm thnh mt hnh vnh khn v phi c v tr thch hp, v nu vng xoy koke nm qu st tng l th tm l s b ngui, tng l qu nng do lm gim tui th ni l. Ngc li nu vng xoy koke nm qu xa tng l th dng kh bin pht trin km, tng l ngui s gy bm dnh liu. Do vy cn phi xc nh s lng mt gi thch hp ng thi xc nh p xut gi hp l vi lu lng v lng gi.

XI- S TO KH TRONG L CAO1- Phn phi tiu th cac bon v ngun to kh trong l cao.

- Cc bon ca nguyn nhin liu a vo l phn ln b t chy ni l ngoi ra cn b san s bi cc ngun tiu th khc nh:

+ Mt do bc bi.

Cbi = 0,5 1% (% C c nh ca than)

+ Mt do cc bon ha st to gang.

Cto gang = 40 kg C / t.gang

+ Mt do tiu th C kh O2 cho kh CO2 (do vi phn ha) C kh O2 = 0,7 1,7 kg C / t. vi

+ C to kh CH4 CH4 = 0,8% C c nh

+ Hon nguyn trc tip Si, Mn, P.

CSi, Mn, P = 10 25 kg C / t.gang

+ Hon nguyn trc tip st:

CFe = 0,24 kg C / 1kgFe

+ Dng a S vo x:

Cs = 0,37 kg C / kg S vo x.

Do lng C chy vng mt gi ch chim khong 70 80% tng lng C ca nhin liu hoc bng 80 85% tng lng C b xy ha trong l cao.

Quan h gia tng lng C ca nhin liu vi tng lng C b xy ha trong l cao nh sau:

COXH CNL (Cbi + CCH4 + Cgang).

Vy ngun to kh ch yu trong l cao chnh l s chy C vng mt gi, lng kh sinh ra chim ti 90% tng lng kh l cao phn cn li do cc ngun sau sinh ra:

Qu trnh hon nguyn trc tip: Cung cp khong 5% lng kh

Phn ng phn ha cabonat.

Phn ng to kh CH4.

Qu trnh thot cc cht bc.

Tng lng kh l cao sinh ra: ng vi 1 tn gang c gi l sut lng kh theo gang thay i ty theo sut tiu th than, ngoi ra cn dng ch tiu sut lng kh theo koke, ch tiu ny tng i n nh bng 3,7 4m3 kh / 1kg koke.

2.Thnh phn kh l cao.

Ty theo m v hm lng xy ca gi, sut tiu th githnh phn kh bc ra khi vng chy c th cha trung bnh t 35 45% l kh CO, t 1 12% kh H2, t 45 64% l N2. Sau khi ra khi vng chy, trong pha kh bt u xut hin kh CO2 do c s hon nguyn gin tip v phn ha cacbonat nn tng hm lng kh CO2 v CO tng ln cn hm lng N2 gim xung, Hm lng CO2 tng ln r rt bt u t phn di thn l. Nhng n khng ng nht nhng im khc nhautheo bn knh l. S thay i hm lng kh CO2 ph thuc vo s phn b liu v phn b dng kh, ni no c nhiu qung v qung vn th kh i qua t nhng li c iu kin li dng c nhiu kh nng hon nguyn do lng kh CO2 sinh ra nhiu hn.

S phn b thnh phn kh CO v CO2 theo tit din ngang ca l c biu th theo (hnh v)

+Nhn xt: ng cong thnh phn kh CO theo bn knh l c hnh tng phn vi ng cong thnh phn % kh CO2.

ng cong % CO2 c dng hnh cnh chim vi cc i l ni tp trung nhiu qung v qung vn tng ng vi v tr mo liu st bin l. Thnh phn % CO2 thp v y tp trung nhiu koke v cc cc liu to nn c thng kh cao tng l li m rng xung pha di v vng chy nm sy bin l do dng kh y pht trin mnh, kh nng hon nguyn km do lng kh CO2 to thnh t. trc l l ni tp trung cc cc liu to do c thng kh tt tuy nhin lng kh to ra tm l nhiu nn tc dng kh khng cao. Tuy nhin iu kin tip xc gia qung v kh hn ch do kh nng hon nguyn km lng kh CO2 to thnh khng ln.

S phn b nhit theo bn knh l cng c dng tng phn vi ng cong CO2 ngha l ng dng vi ng cong CO v ni no nhiu kh CO chng t c nhiu kh i quav ni c nhit cao.

Sau khi ra khi ct liu l cao cc dng kh s ha ln vo nhau to thnh kh nh l c thnh phn nh sau:

CO2 = 10 19% CH4 = 0,2 1%

H2 = 1 3%

CO = 23 30%

N2 = 25 60%

Vi tng % CO + % CO2 = 38 42%

T s % CO / % CO2 = 1,3 3.3 . V kh nh l cao cn cha nhiu cc thnh phn kh chy c do ngi ta s dng lm nhin liu sau khi c lc sch bi.

XII- S CHUYN NG CA KH TRONG L CAO

1-Quy lut t nhin ca dng kh.

Cc dng kh chuyn ng trong ct liu l cao theo cc ng ng rt khc nhau v hnh dng v trng thi v vy dng kh khng th phn b u theo cc ng ng .

Dng kh pht trin mnh nhng ni nhiu than t qung nhiu cc to t cc nh, ni phi liu c c ht ng u v tr lc vi dng kh l t nht.

Trong l cao lun c xu hng t nhin pht trin mnh dng kh bin v tr lc st tng l bao gi cng c tr s thp nht, tng l c nghing vng chy koke nm st tng l ng thi trong qu trnh xung liu c hin tng koke b dn ra ng bin cng lm tr lc vi dng kh. V th ngi ta phi c bin php phn b tht hp l trong l cao.

2- Cch phn b dng kh hp l theo tit din l.

- Nhim v ca kh trong l rt nng n va thc hin cc phn ng ha hc va cung cp nhit nung nng ct liu va m bo cho ct liu chuyn ng t trn xung. V vy trong k thut nu luyn ngi ta c gng iu ha dng kh cho thch hp c th:

+ Dng kh bin khng c pht trin mnh v s lm tng l qu nng nh th s lm gim tui th tng l, liu xung qu nhanh lm ngui ni l, nu dng kh bin qu yu s lm dnh bm liu tng l.

+ Pht trin mnh dng kh tm l th khng tai hi nh ng kh bin, v tit din ca n chim t l nh hn ng kh bin. Trong thc t ngi ta thng khng ch cho ng kh bin pht trin hn ng kh trc mt t liu xung d, khc phc c bm dnh v trnh ngui tng l, tng cng cho l vn hnh n nh.

3-Tc chuyn ng ca kh v thi gian lu kh trong ct liu.

- Tc trung bnh theo chiu cao ct liu v thi gian lu kh trong ct liu.

Vk = h/tk (m/s)

Thi gian lu kh:

+ Thi gian lu kh trong ct liu khng ng nht trn tit din ngang ca l, n giao ng trong khong 2 14s.

+ Thi gian ngn nht bin l (khong 2-3s) v kh i qua nhiu v nhanh.

+ khu vc tp trung nhiu qung (tng ng vi thnh phn CO2max) kh i qua t v chm nn thi gian lu kh di (8-9s).

+ Thi gian lu kh lu nht tm l v y tp trung nhiu kok, ct liu c rng ln kh i qua khng nhiu nn chuyn ng chm chp (thi gian lu kh y khong 9 -14s). Do vy luuw kh trung bnh 4-6s

Tk = .Vliu / Vkh (s)

Trong : - l xp ca ct liu.

Vliu Th tch khng gian cha ct liu l cao (tnh t trc mt gi n l cao).

Vkh l lu lng kh l cao tnh theo iu kin nhit v p xut thc t trung bnh trong l.

+ Tng cng nu luyn s lm tng thi gian lu kh trong ct liu v thi gi mnh mt cch hp l s lm ct liu ti hn do m rng tit din cc ng ng.

+ Nu coi xp ca ct liu khng thay i th khi cng ha vn hnh l lu lng tng s lm gim thi gian lu kh do vic li dng nhit nng v ha nng ca dng kh km i dn n lm tng xut tiu th than koke.

+ Thc t vn hnh cc l cao hin i cho thy khi tng cng vn hnh l th lm tng thi gian lu kh do lm gim xut tiu hao than koke. V khi lu lng kh tng ln s lm tng rng ca ct liu.

XIII- S CHUYN NG CA NGUYN LIU TRONG L CAO

1-Nguyn nhn v iu kin chuyn ng nguyn liu trong l cao.

1.1. Nguyn nhn:

- Khi chy l bnh thng ct liu lun lun chuyn ng i xung v phn di l sy ra cc qu trnh lm gim th tch ct liu nh:

+ Chy than: Lm gim t 40 52% th tch ct liu.

+ Hon nguyn trc tip v cac bon ha st lm gim t 11 16% th tch ct liu.

+ To x lng v gang lng lm gim t 25 35% th tch ct liu.

+ Cc cc qung v koke xen ln vo nhau trong qu trnh xung liu lm gim t 5 -15% th tch ct liu.

+ Do tho gang, x ra khi l theo chu k.

1.2. iu kin:

- Mun cho ct liu tt xung thun li th sc nng ca kh phi nh hn hiu s trong lng hot ng ca ct liu v lc ni ma st trong ct liu. Vy iu kin chuyn ng i xung ca liu l lc nng ca kh l bt c tit din no ca ct liu cng phi nh hn p lc thng ng ca ct liu ti .

2- Quy lut chuyn ng ca nguyn liu trong l cao.

2.1 Chuyn ng cc vng khc nhau th khc nhau, tit din ni no rng th nguyn liu chuyn ng chm v ngc li.

2.2 Trn cng mt tit din tc nguyn liu cc vng khc nhau th khc nhau.

2.3 Vi cc loi nguyn liu khc nhau c ht khc nhau th s chuyn ng cng khc nhau.

- Ht nh vt ht ln.

- Ht qung giu vt ht qung ngho.

Qung vt koke (v vy m than koke c dn ra bin nhiu hn).

- Ht vn c kch thc 6mm b bc theo kh ln trn ct liu ti khong khng gian di y cn ln mt phn liu vn. (kch thc 3mm tip tc bc theo kh l ra khi l cao, phn cn li lng xung mt liu v c phn b vo trung gian hay bng l).

2.4 Nguyn liu chy lng s tri tut xung nhanh hn nguyn liu rn.

3- Tc chuyn ng ca liu trong l.

Tnh trung bnh cho tng loi nguyn liu:

- Mc tanh

6,07 8,33

TB 7,2h

- Gang c

6,46 8,88

TB 7,7h

- Fe Si

8,33 11,18

TB 9,8h

- Fe Mn

8,30 12,96

TB 10,XIV- Kch thc ca cc on l cao 55m3:

Dung tch np liu thc t ca cc on l cao l:

C l: (/4 x 1,92 x 0,4 = 1,13 (m3)(tr ng liu);

Thn l: (/12 x(2,92 + 1,92 + 2,9 x 1,9) x 6,5 = 29,85 (m3);

Hng l: (/4 x 2,92 x 0,9 = 5,94 (m3);

Bng l: (/12 x (2,12 + 2,92 +2,1 x 2,9) x 2,3 = 11,4(m3);

Ni l: (/4 x 2,12 x 1,5 = 5,19 (m3);

Cng: 53,51m3.

TTTn giCt caoKch thc (mm)

ng knhChiu cao

1y l283923001730

2Lp gang cht4569231

3Ni l4800d trong=24001700

4Hng l6500d1= 2400

d2= 30502097

5Bng l8597d= 30501000

6Thn l9600d1= 3050

d2= 10005647

7C l15250d= 10001488

8nh l phn cha liu16735d= 18701303

*nh km mt ct l cao v l gi nng.

XV- Quy trnh k thut:1- An ton in

2- Qui trnh thao tc k thut ca trng ca

3- Quy trnh thao tc gi nng

4- Quy trnh thao tc trc l

5- Quy trnh vn hnh ng c in 6- Quy trnh nghin bn7- Quy trnh k thut vn hnh qut gi 8- Quy trnh vn hnh np liu 9- Quy trnh k thut luyn gang Np liu

Xe kp

L cao

Lc

Th

LcBTV

Lc

BX

3 L gi nng

Q.Gi

Gang lng i c lin tc, i luyn thp

X ht, x bng, x kh

Trm qut gi

chuyn gang

EMBED Equation.DSMT4












H5 ni l

H4 hng l

H3 bng l


H2 thn l

H1 C l











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