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轉爐吹煉過程噴濺機理及預報模型研究進展

Research progress of converter splash mechanism and prediction model technology

  • 摘要: 轉爐作為一個高溫高壓、多元多相的反應容器,容易發生噴濺或溢渣事故. 良好的熔池攪拌可以增大渣–金反應面積,提高煉鋼效率;異常的熔池攪拌則會造成金屬損失,毀壞爐體及其附屬設備,甚至威脅到爐前工作人員的人身安全. 本文總結了前人對噴濺機理及影響因素的研究結果,轉爐噴濺按產生的原因可以分為爆發性噴濺、泡沫性噴濺、金屬性噴濺和其他噴濺,其中爆發性噴濺的危害最大,泡沫性噴濺的發生頻率最高. 噴濺事故的產生總體可以歸結為爐內激烈化學反應產生氣泡驅動的高溫熔體噴濺和頂底復吹為熔池提供的流動能量所產生的噴濺,且一次噴濺事故的發生常常是多種因素耦合引發,從單方面分析噴濺事故原因過于片面,研究出一套適用于轉爐噴濺的安全評價模型是當務之急. 并對現有的噴濺預報模型進行了綜述,總結了爐氣分析法、音頻分析法、圖像分析法的預測原理及部分應用結果,指出現有預測模型沒有得到廣泛應用的原因,未來噴濺預測模型會朝著更加智能化、精細化的方向發展.

     

    Abstract: As a high-temperature, high-pressure, multi-phase reaction vessel, the converter is vulnerable to splashing or slag overflow. Good molten pool surge can expand the slag–gold reaction area and enhance steelmaking efficiency. Abnormal molten pool surge can cause metal loss, damage the furnace body and its auxiliary equipment, and even threaten the personal safety of workers working in front of the furnace. This paper summarizes the previous research findings on splashing mechanisms and influencing factors. According to the occurrence principle, converter splashes can be classified into explosive splashes, foam splashes, metallic splashes, and other splashes, among which explosive splashes are the most dangerous and foam splashes occur most frequently. The occurrence of splashing accidents can be generally attributed to the high-temperature melt splashing caused by bubbles produced during the vigorous chemical reaction in the furnace and the splashing produced by the flow energy generated during the top–bottom combined blowing of the molten pool. The influencing factors of splashing are discussed based on six aspects: loading system, slag making system, oxygen supply system, bottom blowing system, temperature system, and safety system, and the foam of slag, oxygen lance blowing parameters, and bottom blowing parameters are thoroughly examined. It is observed that the occurrence of a splashing accident is frequently caused by the coupling of multiple factors. It is mainly one-sided, and hence the cause of the splashing accident cannot be unilaterally analyzed. Currently, no methods are present that can effectively quantify the effect of each factor on the splashing. Thus, developing a set of safety evaluation models suitable for converter splashing is imperative. Furthermore, the author summarizes the existing splash prediction models, examines the benefits and drawbacks of some splash prediction models, and summarizes the prediction principles and some application outcomes of the furnace gas analysis, audio analysis, and image analysis methods. Although preliminary progress has been made in the study of prediction models, there are still challenges that need to be overcome. It is pointed out that the reason why the existing prediction models have not been widely used is due to the low prediction accuracy, short prediction time, high cost, and low practicability. Several researchers have used a combination of several models to predict splash in converter. The findings reveal that various models can learn from each other, and the prediction accuracy of the comprehensive model is higher than that of the single model. Furthermore, the splash prediction model will become more intelligent and refined in the future.

     

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