I. Overview
Henan Taihang Quanli (Group) Co., Ltd. is a high-tech enterprise specializing in the research and development of electric furnace energy-saving technologies and preheat and transport of scrap steel complete sets of equipment. The DP-type preheating and transportation complete sets of equipment developed by our company have adopted the recovery and utilization of waste heat from electric furnaces and preheating of scraps. Transmission, high-temperature smoke purification and a series of high-tech and methods, the use of electric furnace waste heat to preheat scrap, effectively solve the EAF high energy consumption, low production efficiency, serious environmental pollution and other issues.
In recent years, our company has successively developed and produced DP30, DP50, DP70, DP90, DP100, DP150 for Wugang, Longnan Special Steel, Xining Special Steel, Hubei Huaxin Special Steel, Wuhu Xinxing Cast Pipe, Hebei Taiyu Heavy Industry and other units. Six types of scrap preheating conveying equipment have achieved remarkable economic and social benefits after being used. Compared with similar foreign products, it has the advantages of high preheating temperature of scrap, good system sealing, high degree of automation, stable operation, and obvious energy saving effect.
The development and development of the DP series of preheating and transportation complete sets of scrap equipment fills the domestic gap and can replace the import. It has become the first choice equipment for technical transformation and industrial upgrading of iron and steel enterprises in China, achieving green production, energy efficiency and efficiency improvement for electric steelmaking enterprises. Product quality and catching up with the world's advanced level have a very important role and significance.
Second, DP-type scrap preheating transmission complete sets of equipment technical indicators
The feeding method of the electric furnace using the DP-type scrap preheating conveying equipment was changed from the traditional spinning furnace lid basket feeding method to the scrap steel preheating continuous feeding method, and the electric furnace realized a “four consecutive†fully-enclosed and efficient smelting, in which energy was saved and reduced. Pai, increase production and other aspects have obvious results, with the following characteristics:
(1) Increase the steel output by more than 10%;
(2) The smelting cycle is shortened by 10-15 minutes;
(3) Electricity per ton of steel 80-100KW.h;
(4) The electrode consumption is reduced by 0.5-0.8%; the refractory consumption is reduced by 5%; the amount of CO2 released by the ton steel is reduced by 20-30%; the dust content at the production site is less than 10mg/M3;
(5) Dioxin and CO emissions have reached developed country emission standards; dust content has been reduced from 17Kg/t to 11Kg/t.
(6) The preheat temperature of scrap steel is above 4500C.
(7) The service life of the trolley cooling tank is more than 6 months.
(8) vibrator service life of more than 20,000 hours.
(7) Scrap conveying capacity 100-500t/h.
III. Process characteristics of DP type preheated conveying complete sets of scrap equipment
1) Energy conservation: Compared with conventional electric furnaces, the energy saving of continuous feed electric furnace comes from scrap preheating, and the lid of the electric furnace does not need to be opened to avoid the heat radiation loss caused by exposure of the bath, and the electric furnace is continuously working in the refined state. The arc is always covered, making the heat transfer efficiency from the arc to the molten pool higher, reducing the heat loss of the arc to the lining, furnace lid and water wall, making the smelting cycle shorten from 60-90 minutes to 40-75 minutes in the traditional electric furnace. Matched with the caster, and the power consumption costs are also reduced to a minimum. Due to the continuous operation of the electric furnace, the power supply curve is stable, which can reduce power consumption by at least 5%.
2) Reduction of electrode consumption: As the smelting current is reduced, the head loss of the electrode is reduced; the atmosphere in the furnace is a reducing atmosphere, the consumption of the electrode surface is reduced, and the breaking rate of the electrode is reduced.
3) Increased the yield of scrap steel to molten steel: Continuous addition of electric furnace smelting operation reduces the content of iron oxide in the slag and metal loss during slag discharge, and can increase the metal yield by 1.5-2%.
4) Reduction of soot treatment volume: When the flue gas passes through the preheating section, part of the dust can be deposited into the scrap steel and be reused for re-melting, so that the amount of ton steel dust produced can be reduced to 11kg, and the amount of the same electric furnace dust charged at the top is about It is 17kg to 20kg.
5) Improved energy utilization: In the operation of continuous charging electric furnace, enough CO generated after oxygen and carbon are injected into the furnace can be used to maintain a certain foam slag height, realize submerged arc operation, and improve energy utilization.
6) Full utilization of waste heat: The scrap steel can be preheated to more than 450°C on the transfer section. The waste heat from the rear can be generated by the waste heat boiler to generate electricity or heat, and the flue gas from the boiler can basically enter the bag filter directly. Dust removal. The conventional electric furnace system flue gas needs to go through water-cooled pipelines, mechanical coolers and other equipment. It consumes a lot of energy to cool down before it can pass the flue gas to the dust collector, and the energy carried by the flue gas is completely wasted.
7) Ensure that CO can effectively control system air leakage in the case of full combustion within the pipeline, so that the flue gas entering the dust removal system is reduced to the minimum, reducing the various costs incurred when the dust collector is increased, and the system investment can be reduced. Effectively reduce.
8) Baghouse dust collector has low power consumption: Because the feeding does not need to open the furnace lid, the bag system of the continuous charging furnace process is significantly reduced compared with the traditional top charging furnace. Therefore, the fan power is reduced by 30%.
9) To achieve clean production and other benefits: The furnace lid is closed during the feeding of the transfer equipment, and the entire preheated smelting system maintains negative pressure, so the environment is clean. Continuous feed electric furnaces operate in a continuous melt-refining manner and low phosphorous and sulfur levels are also expected.
Fourth, economic analysis
With the improvement of China's industrialization level, the amount of scrap steel will increase year by year, and the amount of scrap steel will increase year by year. New type of steel preheating complete sets of equipment will be widely used in domestic steel companies, resulting in greater social and environmental protection. And economic benefits.
V. User benefits
1) Reduce power consumption. The consumption of electricity per ton of steel is reduced by 80-100 Kw.h, according to the current industrial electricity consumption of 0.5 Kw/h. The cost per ton of steel decreased by 50 yuan, and the annual production of steel by 100 tons of electric furnace was calculated at 1.25 million tons. The total cost was reduced by 62.5 million yuan.
2) The scrap steel is preheated in the conveying process and passed the furnace gas above 1100 degrees, which increases the material temperature and shortens the smelting time. One day, 3 more steels can be produced, with an increase of 300 tons per day, an increase of 9,000 tons per month, and an annual output of 100,000 tons.
3) The company saves 0.5-0.8 kilograms of electrode per ton of steel, and the annual output of steel is 500,000 tons. The company saves about 2,500-4,000 tons of electrodes per year, and saves 4,000-64 million yuan annually.
Sixth, the basic situation of the company
Henan Taihang Quanli (Group) Co., Ltd. (hereafter referred to as "the company") formerly known as the Henan Hebi General Machinery Plant of the Ministry of Machinery Industry, was transformed into Henan Taihang Quanli (Group) Co., Ltd. in 2004 and is specialized in vibration machinery. The provincial-level high-tech enterprises in the development, production, and sales of environmental protection equipment and EAF steelmaking related technologies and equipment are the only company in the country currently specialized in EAF heat recovery, scrap preheating, high-temperature flue gas purification technology and EAF steelmaking Complete equipment development and application technology research base, by the end of 2007 by Henan Province identified as the province's implementation of energy-saving emission reduction project demonstration enterprises, Hebi City was identified as the city's circular economy construction key demonstration enterprises, and was listed as a key support to be listed companies.
The company is located at No.1 Beizhan Road, Hebi City, Henan Province, covering an area of ​​87,000 square meters. The company's registered capital is 79.55 million yuan. The legal representative is Comrade Huang Quanli, an expert with outstanding contributions from the country. Now the company has total assets of 145 million yuan, 4500 yuan of fixed assets, 460 employees, including nearly 100 types of engineering and technical personnel; has 13 production plants, more than 300 sets of various types of machining, testing and testing equipment (sets) . The company has won the National First Science and Technology Conference Award and the advanced unit of national scientific and technological progress, the provincial contract and keeping promises unit, the advanced unit of patent work and other honorary titles.
The company is an enterprise technology center in Henan Province and a demonstration enterprise for energy saving and emission reduction projects in the province. Taihangquanli Group Design Institute has three research labs, namely, the electric furnace energy-saving and environmental protection technology research room, the information and automation research room, and the mechanical vibration engineering research room. The Technical Center successively cooperated with domestic research institutes to undertake more than 10 national, provincial and ministerial-level scientific research projects; 4 national-level new products and 16 national patents.
The company's main products include preheating and conveying equipment for electric furnace steel scrap, environmental protection dust removal equipment, vibration machinery, etc. More than 1,000 specifications of 45 series have been formed, and a series of new products and new technologies such as DP series scrap preheating transportation complete sets of equipment have reached the domestic level. Leading and international advanced level, product market competitiveness, high product coverage, is widely used in metallurgy, coal, mining and other industries, operations in more than 30 provinces, municipalities and autonomous regions, and exported to Middle East countries and regions .
The company has strong technical force, and has 63 outstanding scientific and technological talents in market research, development, product design, process research, molds and tooling manufacturing, including 2 nationally outstanding contribution experts, 12 senior engineers, and a strong technology development team. , Can provide users with short-circuit green steel making engineering design, equipment manufacturing and general contracting services.
The technology center has more than 100 sets of equipment and instruments for design and development, testing and testing. It has realized design automation. The design has adopted international advanced I-DEAS 3D CAD/CAE design software and self-developed Mechanical parameter calculation software can complete conventional parameter calculation, 3D modeling, finite element analysis and 2D engineering drawing. With various advanced and complete testing methods, it has a physical and chemical analysis laboratory, and has established the largest industrial experimental device for bulk material transport and vibration mechanical materials in the same industry in China. The processing capacity can reach 2000t/h, which can fully meet the requirements of the company. The detection needs of various types of large-scale equipment manufactured to ensure the technical performance and quality of large-scale equipment.
The company's high-tech and high-tech products have been continuously introduced, and the technological development results have appeared in an endless stream. Large-scale thermal mineral vibrating screens, oval-thickness vibrating screens, large-scale powerful vibrating screens, preheated conveying complete sets of scrap equipment, and super-large plane vibrating screens (5500×8000 mm) have been developed successively. ), large-scale ore transfer equipment and other new products, some of the product technology to achieve the leading domestic and international advanced level, for China's metallurgical industry, scientific and technological progress and technological innovation, steel enterprises to achieve energy conservation and consumption reduction made a contribution.
Henan Taihang Quanli (Group) Co., Ltd. researches and develops DP series of preheating and transportation complete sets of scrap equipment, which can effectively solve the serious problems of high energy consumption, low efficiency and serious pollution of the EAF steelmaking, and can be used as a substitute for imports. It is a steel company in China. The first-selected equipment for technological transformation and industrial upgrading is of great significance for the EAF steelmaking enterprises to achieve green production, energy conservation and efficiency enhancement, improve product quality, and surpass the world advanced level.