It is assumed that the raw material sintering plant has 8 belt sintering machines (1×174 m2, 1×150 m2, 5×360 m2, 1×400 m2), with an annual output of 21.98 million tons of sinter.
Measures to increase the output of sinter:
1. Adopt the new technology of sintered material layer air humidification
In the case of a certain sintering area and sintering load, the effective way to improve productivity is to increase the vertical sintering speed, thereby increasing the speed and output of the sintering machine.
The vertical sintering speed depends on the air infiltration speed of the sintering material layer. Increasing the air infiltration rate helps the combustion of carbon in the mixture on the sintering machine, thereby accelerating the sintering speed. Improving heat conduction and generating more heat from the crushed coke in the material layer are the prerequisites for increasing the sintering speed. Chinese steel mills use steam injection on the sintering material layer to make the air infiltrated into the material layer more humid, increase the air infiltration rate in the material layer, increase the heat transfer rate, and achieve the purpose of increasing the vertical sintering speed.
The raw material sintering plant successively sprayed steam on the material surface of each sintering machine in mid-June 2013. By spraying steam on the material surface, the speed and loading capacity of the sintering machine were increased to a certain extent, and the output of sintering ore increased accordingly.
2. Increase the ratio of quicklime to strengthen sintering
Quicklime as a binder can strengthen sintering production, achieve the effect of increasing production and energy saving, and improve the quality of sintered ore. Properly increasing the ratio of quicklime during the sintering process can effectively improve the granulation effect of the mixture in the secondary mixing process and increase the temperature of the sintering mixture; increasing the ratio of quicklime can reduce the amount of limestone added, thereby reducing the limestone at high temperature. The lower decomposition endothermics and reduces the solid fuel consumption.
Through sintering cup experiment and production practice, Chinese steel mills, for every increase of 1.0% quicklime, the particle size of the +3 mm mixture increases by 6.8%, and the material temperature rises by 1.8℃; when the ratio of quicklime increases from 3.0% to 4.5%, the sintering machine is used The coefficient has a large increase. After it continues to increase to 4.5%, the growth rate slows down, and there is a downward trend; as the proportion of quicklime increases, the drum strength first rises and then decreases, and the high point occurs when the proportion of quicklime is 4%~ 4.5%; the proportion of quicklime increased from 3% to 4.5%, the utilization factor increased by 3.6%, the solid fuel consumption was reduced by 1.25 kg/t, the average particle size of sintered ore increased by 2.63 mm, and the amount of 5-40 mm in the finished ore increased by 1.8 %. At the same time, the quicklime ratio is increased, the granulation effect of the mixture and the pelletizing effect are obviously improved, and the white spots of the high alkalinity sinter are also avoided.
3. Strictly control the moisture of the mixture
Moisture plays an important role in the mixture. Too high or too low moisture will reduce the air permeability of sintering; moisture will evaporate and condense during the sintering process, which will make the material layer too wet and increase the air draft resistance. Proper moisture can improve the granulation of the mixture and increase the air permeability of the material layer. Through a series of exploration and practice, under the current raw material conditions (65% Australian powder + 20% Pakistan powder + 5% refined powder + other 10%), it is advisable to control the moisture content of each sintering unit mixture at 6.5%-7.5%, and Strictly control in accordance with this standard.
4. Preheat the mixture
In order to increase the temperature of the mixed material and reduce the “over-humidity” phenomenon produced during the sintering process, on the one hand, the ratio of quicklime is increased, on the other hand, hot water is passed through the first mixing, steam is passed through the second mixing, and the mixed silo is introduced Steam is used to preheat the mixture to make the temperature of the mixture reach above 60°C, thereby increasing the temperature of the mixture, reducing the over-humidity phenomenon at the bottom of the sintered material layer, and reducing the resistance of the material layer.
5. Strengthen granulation and improve the air permeability of the mixture
In order to improve the air permeability of the mixture, the sintering plant optimizes the ore blending structure, on the one hand, to increase the blending ratio of large-particle ore such as Yangdi powder, and on the other hand, it tries to add some pellets (green pellets) to the mixture of 8# sinter , The ratio is about 5%, which can improve the permeability of the material layer, reduce the negative pressure of sintering, and increase the output of sintered ore.
6. Improve solid fuel particle size
The particle size of the solid fuel used in sintering is related to the characteristics of the mixture and has a great influence on the sintering production process. The reasonable particle size range of general solid fuel is 0.5-3mm. If the particle size is too large, the sintering speed becomes slower, the sintering zone becomes wider, the air permeability of the material layer becomes worse during the sintering process, the vertical sintering speed decreases, and the utilization factor of the sintering machine decreases. If the particle size is too small, the sintering speed will become faster, the liquid phase reaction will not proceed completely, the strength of the sinter will become poor, the amount of returned ore will increase, the yield will decrease, and the utilization factor of the sintering machine will also decrease.
In order to ensure the particle size of solid fuel, on the one hand, the maintenance, maintenance, and turning of the crushing equipment should be done to ensure that the roller skin has a normal working surface, and at the same time, the normal supply of roller skin spare parts should be supervised; third, it is strictly required that each shift is not started. Less than 6 hours; through these measures, the qualified rate of coke powder particle size is guaranteed, and the particle size of <3mm reaches 78.2%, which has played a certain role in stabilizing sintering production and increasing the output of sintering ore.
7. Pay close attention to equipment management to reduce thermal shutdown
Pay attention to the maintenance and management of key sintering equipment to reduce the monthly repair time of sintering machines. By strengthening the tracking of the maintenance process of each machine to improve the quality of maintenance, especially the maintenance of sintering machine trolleys, grate bars and key equipment for single-line production, the frequency of sintering machine maintenance has been changed from the original monthly maintenance Overhaul twice every three months, and the length of overhaul remains the same.
Reduce thermal downtime. Through the analysis of the time and frequency of thermal shutdown of each sintering machine, common problems are identified, and rectification measures are formulated; the sense of responsibility is strengthened, equipment failures are assigned to personnel, and thermal shutdowns caused by equipment failures are reduced. At present, the thermal shutdown time of each unit is controlled within 300 min/month.
By optimizing the structure and quality of raw materials and fuels, strengthening production process control, applying new sintering technologies and carrying out various research activities, Chinese steel mills have increased the output of sinter from 21.98 million tons in 2012 to 26.52 million tons in 2013, which is an increase for blast furnaces. The proportion of sintered ore into the furnace has created favorable conditions for further reducing production costs.
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If you are looking for dependable volume manufacturing metal parts supplier with High pressure die casting service who offers you competitive price, good service and quality for aluminium die casting, zinc, or magnesium die casting, then BE-CU Prototype are surely a partner you are looking for to fulfill all your die casting needs. With quality service and state of art technology, BE-CU indeed claim in providing quality pressure die casting including aluminum/zamak/magnesium alloy castings to our customers all over the world.
To work with us,be-cu don’t just stop at taking your order and delivering your die casting products. be-cu are there for you at every step right from your preferred selection of aluminum die casting, Zamak die casting (Zamak 2, Zamak 3, Zamak 5, Zamak 8) or magnesium die casting products and services to post-order phase. In brief, once you become our customer, be-cu are with you every step on the way.