1、HIsmelt熔融还原技术熔融还原技术Smelt Reduction Technology-HIsmelt 汇报人：贾利军汇报人：贾利军Presentor:Jia Lijun-汇报内容Content1 HIsmelt技术简介技术简介HIsmelt introduction2 HIsmelt工艺技术优势工艺技术优势Technical advantage of HIsmelt3 生产情况介绍生产情况介绍Plant operation experience4 工艺流程的优化工艺流程的优化Optimization of process5 结论结论 Conclusion-1.1 1.1 引言引言 Bac
2、kgroundBackground 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，是解决我国焦煤资源贫乏和环保问题的先进炼
3、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 Australia had run fours y
4、ears 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 focusing on the research of i
5、nnovative 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.-1.2 HIsmelt工艺描述工艺描述 HIsmelt Process Description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
6、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-u 煤中碳素溶于铁水,矿石溶于渣中 carbon in the coal dissolve in the bath,u 含铁原料被还原成液态铁水；Iron-bearing material is reduced to liquid ironu 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 form slagu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 energyu渣与铁水液体把能
7、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 2221COOCOOHOH22221 COFeCOFe32332SRV 熔融还原炉中发生的反应为熔融还原炉中发生的反应为：Reaction in the SRV:COFeCFeO-1.3 HIsmelt工艺流程工艺流程 HIsmelt process flowIron oredolomitedryerPre-reduction kilnCycloneBag houseDust injectionC
8、oal millCoal limeGranulated slagCoal millOre injectioncoal injectionlimel injectionIron recoverySlag granulationLadle carSteel millPig casterKnock out vesselConvective coolerWaste gasFGDCyclone de-dustingStovesboilerFGDSuck fanOxygen plantElectrical blowerscrubberHot gas generator for the coal millG
9、enerator-2HIsmelt工艺技术优势工艺技术优势 Advantages of HIsmeltu 投资成本低：与传统的炼铁技术相比，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:q HIsmelt不需要焦炉和烧结厂或球团厂，因此建设成本降低；HIsmelt eliminates coke oven,sinter plant and pellet plantq 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
10、比较简单，HIsmelt shares many common equipment used in blast furnace,such as hot blast stoves,generator etc.q 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 materials selection and no blending facility is needed.-2 HIsmelt工艺技术优势工艺技术优势 Advantages of HIsmeltu操作成本低：操作成本低：Lowe
11、r operational costLower operational costq 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.-u更大的原料灵活性更大的原料灵活性Great flexibility in raw material：q 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
12、can not be used by the blast furnace sinter plant.-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 no silicon;so less slag is needed in the steel mill and thus reducing steel mill cost铁水成分铁水成分 ChemistryHIsmeltBFC4.00.15%4.5%Si0.01%0.50.3%Mn0.02%0.40.2%P0.020.01%0.09
13、0.02%S0.10.05%0.040.02%温度 Temperature/1430-145014501500Himselt工艺与高炉生产铁水成分对比HIsmelt Hot Metal vs.BF Hot Metalu铁水质量好铁水质量好 Superior hot metal quality-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,phenols or tars due to the revolutionary process and elimina
14、tion of coking oven and sintering process.u 更绿色环保的炼铁技术更绿色环保的炼铁技术 Less Environmental Impact-3 生产情况介绍生产情况介绍 Production Experience3.1 奎纳纳情况概览奎纳纳情况概览 Kwinana summaryq 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 ramp-up period beginning in November 2005:50%by 2006,80%by 2007,85%by 2
15、008q 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 removedq 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 closed due to sluggish market demand caused by global economic crisis from e
16、nd of 2008-3.2 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的煤耗 Coal Rate of HIsmelt-4 工艺流程的优化工艺流程的优化 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 experi
17、ence,SDM,Rio Tinto and the end user decided to modify some of the process and equipment to reduce cost and waste.-4.1 新新矿粉预热系统矿粉预热系统 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-特点特点 Advantage:q改进后的工艺既能实现矿粉的加热、预还原的目的，且
18、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.It is a mature,stable and efficient solution.q 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 utilizat
19、ion rate.-4.2 矿粉喷吹系统矿粉喷吹系统Modification of Iron Ore Injection Systemq考虑新的矿粉预热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
20、iron bearing dust and carbon bearing dust,which will help reduce waste and improve raw material utilization rate.-4.3 铁、渣系统的改进铁、渣系统的改进Modification of the slag and metal handling systemu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。
21、End tapped metal recovery:about 300t hot metal will 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.-u 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
22、带的铁，能提高HIsmelt工艺铁水收得率，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
23、 the slag:-4.4 煤气煤气余热回收余热回收系统系统 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 recovered t
24、o 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.-4.5 锅炉及动力系统锅炉及动力系统 Modification of the Boiler and Power systemq 原鼓风发电机组利旧 Old TAB will be re-usedq 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 generatorq 增设一台电动鼓风机备用。Add a back
25、 up electrical blowerq 制氧驱动方式改为电动。Oxygen plant is driven by electricityq 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.-q特点：各系统相互独立，互不影响。特点：各系统相互独立，互
26、不影响。Characteristic:the function of each equipment is not solely reliant on the upstream equipment,which provides redundancy.-5 总总 结结 Conclusionq 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 commer
27、cialized 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.-q 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
28、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,therefore more competent.-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.-
