转炉除尘设计毕业论文.doc

目 录前言21. 国内外转炉烟气除尘技术的发展和现状31.1湿法系统31.2干法系统52. 新型转炉煤气净化回收72.1双层滤料床过滤除尘器7 2.2转炉煤气净化回收和余热利用新工艺93.结语10参考文献11前 言我国现有600多座转炉，年产钢超过4亿吨，节能减排潜力巨大。目前我国绝大多数转炉的转炉煤气净化采用较为落后的湿法（以下简称老og）除尘，耗水耗电量大，是钢铁工业节能减排的薄弱环节。除了老og除尘之外，近年来我国新建转炉采用了第四代湿法（以下简称新og法），以及引进的千法（以下简称lt法）：使转炉煤气净化技术取得了突破性进展。在转炉煤气净化技术引进的同时，国内多家设计研究单位进行了吸收开发，目前转炉煤气净化的lt法、新og法除引进少量关键技术和部件，大量的设备设计、系统设计立足于国内，甚至新og法基本实现全国产化。对我国转炉炼钢节能减排、实现负能炼钢起到了积极的推动作用。但是我们仍清醒看到，转炉煤气净化发展到今天，这些技术包括引进技术都不同程度的存在一些问题、或有值得改之处，这是我国钢铁工业节能减排要追求和持续研究的新目标和新课题。正是由于目前各种除尘方式的利弊所在，使新建转炉除尘设计选择法还是新og法似乎难以确定。本文就两种除尘方式进行比较，提出自己的建议。1.国内外转炉烟气除尘技术的发展和现状当前,转炉烟气净化及煤气回收技术主要有两大类型:即日本的湿法系统(og法)和德国的干法系统(lt法)。1.1湿法系统图1og法工艺流程og法是以双级文氏管为主,抑制空气从转炉炉口流入,使转炉煤气保持不燃烧状态,经过冷却而回收的方法,因此也叫未燃法,又称湿法。在湿法方面,日本从60年代起开发了og法,这是世界上普遍采用的流程。1962年,日本新日铁公司的转炉首次成功地应用该法对转炉烟气进行除尘并回收,合理地利用废气中的化学能和显能及含铁粉尘。目前己成为世界上最广泛采用的转炉烟气处理方法,在保护环境、回收能源方面发挥了积极作用。og法装置主要由烟气冷却系统、烟气净化系统及附属设备组成(见图1)。在冶炼中生成高一氧化碳浓度且含150200mg/m3粉尘的煤气,温度达1600。在风机吸力作用下,煤气从活动烟罩进入全封闭的回收系统,经汽化冷却烟道后温度降至1000。一级文氏管进行粗除尘和煤气降温、灭火,温度降至75;随之煤气经重力脱水器脱水后再进入二级文氏管进行精除尘和再冷却,温度降至65左右,含尘量降至150mg/m3以下,煤气再度脱水后进入除尘风机。煤气借风机出口正压力、通过三通阀切换,当煤气co30%时,进入煤气柜回收,再供给用户作能源使用。1985年,宝钢一期300t转炉成功引进了日本“og”技术和设备,国内在立足自主开发的基础上对这项技术进行了消化吸收,使“og”法技术在国内得到了较快的发展而占据主要地位,并取得了成熟的经验。其核心是二级可调文氏管喉口。但这种流程也有缺点,如设备单元多、系统阻力损失大、rd喉口易堵塞等。武钢三炼钢250t转炉og系统,引进了西班牙tr公司技术,该系统是将两级文氏管及脱水器串联重组安装在一个塔体内,烟气自上而下运行,总阻力损失仅为18kpa,且流程系统紧凑、简洁、易于维护管理。1998年,作为环保示范项目,日本政府在马钢三炼钢厂70t转炉扩容改造项目中向马钢无偿提供了一套新型“og”法除尘技术和设备。这项技术对传统的“og”法进行了技术改进,将二文rd可调喉口改为重铊式,即环缝洗涤器(简称rsw),还用饱和器代替了一文喉口。烟气首先进入饱和器,然后经过二文rsw和下部弯头脱水器到风机系统,被称新型“og”法。该技术流程简洁、单元设备少、阻损小。二文采用rsw技术,除尘效率高,易于控制,且不易堵塞。除尘效果保证值50mg/m3。目前在柳钢转炉、太钢转炉、济钢转炉上采用,取得初步经验。og法具有技术成熟、可靠性好、一次投资少、吨钢煤气回收量高、投资回收期短、设备国产率高及安装工程量少等优势。og法除尘系统虽然日趋完善,但是仍存在一些问题,如:供排水系统和净化设备的积灰堵塞问题,部分设备受含尘污水的冲刷磨损问题,污泥的脱水处理问题以及由上述问题引起的维修工作量增加问题。此外,由于og法属“高压流程”,系统阻力损失大,除尘供水量大,风机、水泵的耗电量大,因而增加了运行费用。1.2干法系统图 2lt法流程lt称为干式净化回收法,又称干法。60年代后期,西德鲁奇公司开发了lt法,至80年代技术上已日趋完善。目前,lt法已有逐渐取代og法的趋势。lt法工艺流程如下:转炉烟气出炉口后,通过活动烟罩、固定烟罩进入汽化冷却烟道。炉气出口温度为1700,汽化冷却烟道出口为8001000。蒸发冷却器有两个作用,一是将烟气温度降至180200;二是对烟气进行增湿调质,以降低烟尘的比电阻,确保电除尘器的除尘效果。然后进入圆形静电除尘器,烟气轴向进入其中,并通过气流分布板均匀分布在横截面上,烟气得到净化。静电除尘器一般设有三到四个电场,采用专门的变电系统供电,在电除尘器下部的集灰,用扇形刮灰器刮到位于其下部的链式输送机中,送入中间料仓,然后通过气力输送系统再将干灰送到压块系统的集尘料仓中。除尘效率高达99%,烟气经过电除尘器后进入除尘风机。煤气借风机出口正压力、通过三通阀切换,进行回收或放散。回收柜前设置二次冷却塔使煤气温度降至50左右。流程如图2。1995年宝山钢铁公司三期工程的转炉煤气净化系统为全套引进的德国lt技术,总投资4060多万美元,处理风量175000m3/h,原始含尘浓度70g/m3,出口含尘浓度10mg/m3。lt法目前在德国、法国、奥地利、澳大利亚等国有较为广泛的应用。相比较而言,lt法具有以下优点:用电场除尘,除尘效率高达99%;省去庞大的循环水系统;回收的粉尘压块可返回转炉代替铁矿石利用;系统阻力损失小。lt法虽然比og法有许多优势,但是,经过国内几十年的运行,lt法的问题也逐渐凸显出来。主要问题有:(1)国内尚不掌握此项技术,需引进国外技术和设备,投资造价高;(2)自动控制连锁多,要求自动化程度高,故障率高,维修时间长;(3)由于蒸发冷却使煤气中含有较高的水分,易形成结露,影响极间距和运行电压,还影响输灰系统设备运行寿命;(4)系统泄爆频繁,影响电除尘器内部件的寿命和除尘效果;出口粉尘浓度不能稳定在设计的10mg/m3;(5)烟气8001000以下余热未回收,除尘后高温煤气热能浪费。2.新型转炉煤气净化回收2.1双层滤料床过滤除尘器图3双层颗粒床除尘原理杨国华研究发明了双层滤料床(图3),该过滤床由上粗下细、上轻下重的双层滤料组成(下层滤料选用石英砂,粒径为0151mm,堆积密度约1300kg/m3;上层滤料选用普通膨胀珍珠岩颗粒,粒径为25mm,是下层滤料砂的45倍,堆积密度约70kg/m3,为下层滤料砂的近1/20)。过滤时,含尘气体自上而下穿过滤层,先经过粗颗粒的上层滤料层,进行第一级过滤,称为粗除尘,截留气体中的绝大部分粉尘,膨胀珍珠岩层为深层过滤,双层滤料过滤床容尘量将远远超过单层沙床;再经过细粒径的下层滤料层,进行第二级过滤,称为精除尘,截获漏过上滤层的微细粉尘,细沙层为表面过滤,是双层滤料床高过滤效率的主要贡献者。其除尘效率高达99199%,容尘量也达到28163kg/m2。反吹清灰时,反吹气自下而上通过滤层,由于上层滤料颗粒密度小于下层滤料正常流化时所形成的流化床床层密度,且有足够的密度差,因此,流化时,上层滤料颗粒始终悬浮于下层滤料层之上,形成不相混分层流化床。清灰结束后,上下两层滤料界面清晰,互不相混,双层滤料层结构保持不变。该项技术是对不等密度双组份颗粒流化床技术的创新性应用,已取得国家专利。该项技术对粉尘的过滤效率高,容尘量大,而且对细小颗粒的过滤效率也比较好,对粉尘的成分不敏感。双层滤料除尘器耐高温而且系统阻力损失小。2.2转炉煤气的净化回收和余热利用新工艺图4转炉煤气净化回收及余热利用系统整个新工艺系统可分为过滤除尘系统、余热利用系统和煤气回收系统三部分(如图4)。除尘器内壳体采用耐1000高温的耐热钢材料制成。从汽化冷却烟道引来的高温烟气,进入颗粒床过滤器,在颗粒床过滤器内,含尘烟气从上往下经过双层颗粒床除尘器得到净化,经由洁净气出口管排出,进入余热回收装置。清灰时高压空气自下而上穿过双层颗粒床,颗粒床流化而使粉尘脱落,脱落的粉尘被氮气吹扫带出。在整个系统开始运行、运行间隙及运行结束时,对煤气除尘和余热回收系统进行氮气吹扫。反吹阀门的开关由专门的plc控制,反吹阀门与相应的洁净煤气出口阀自动控制连锁,当某一床层的反吹阀门打开的同时,相应的洁净煤气出口阀门关闭,高压氮气反吹气流对床层进行反吹。气流自下而上穿过双层颗粒床,颗粒床流化而使粉尘脱落。脱落的粉尘由于重力作用自然沉降到除尘器底部。反吹次序、反吹时间和反吹间隔时间由plc自动控制。转炉烟气中,绝大部分是co。co是有毒、易燃易爆气体。为人员和设备的安全考虑,系统运行前和结束后要进行n2吹扫,在卸灰机构和浓度测试点设n2封和n2吹扫设施。3.结语围绕新型双层滤料除尘器,近年来做了不少从理论到现场试验的工作,其中在江阴鑫裕213t熔铝炉的除尘器运行良好,江阴海虹615t熔铝炉的除尘器也已经投入使用。实测数据显示,新型除尘器过滤效率高、容尘量大、压降小,而且所需原料耐高温、价格低廉,为双层滤料除尘器能够全干法处理炼钢转炉烟气,提供了理论和实践经验。新工艺除尘后可以采用余热利用系统回收8001000烟气的余热,实现全干法除尘,节约水资源,提高余热回收率,可解决当前炼钢转炉烟气除尘面临的难题。参考文献 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