冷却内衬操作与维护手册.doc

1、TABLE OF CONTENTS 目录 1.GENERAL BACKGROUND背景概述背景概述 2.DESIGN AND INSTALLATION设计和安装设计和安装 3.DRYING AND HEATING-UP干燥和升温干燥和升温 4.WATER COOLING水冷却水冷却 5.TAPPING PRACTICE排放实践排放实践 6.FURNACE SHUTDOWNS停炉停炉 7.TYPICAL SOUTH AFRICAN START-UP SCHEDULE 南非典型开炉程序南非典型开炉程序 8.HEATING, BAKING AND PRODUCTION WITH ELECTRODE

2、POWER 电极电源升温和烘焙 9.DISCLAIMER免责申明免责申明 Attachments to this document: 相关附件相关附件 Appendix A:Bill of Materials 附件附件A：材料清单：材料清单 Appendix B:Certificate of Registration (ISO) 附件附件B：注册执照：注册执照 Appendix C:Full Size (30x90cm) Installation Drawings 附件附件C：全尺寸：全尺寸(30x90cm)安装图纸安装图纸 Appendix D:Material Safety Data Sh

3、eets (MSDS) 材料安全数据清单材料安全数据清单 Appendix E:Product Definitions 附件附件E：产品定义：产品定义 Appendix F:Product Use Instructions 附件附件F：产品使用说明：产品使用说明 Appendix G:Quality Certificate 附件附件G：质量证明：质量证明 Appendix H:Technical Data Sheets 附件附件H：技术数据清单：技术数据清单 Appendix I:Completion Certificate 附件附件I：竣工证明：竣工证明 1.GENERAL BACKGROU

4、ND背景概述背景概述 1.1CYMCO decided to install the latest freeze lining technology for its 67,5MVA SiMn ferroalloy furnace in Jianshui. 云南冶金集团决定在建水安装 67,5MVA硅锰合金炉子冷却内衬最新冷却内衬技术 1.2This document provides details regarding the installation, operation and maintenance (IOM) of that lining. 此文件提供了该内衬的安装、操作和维护详情 1

5、.3By following the guidelines set out in this IOM manual, the lining will give many years of trouble-free service. 按照操作维护手册指南进行炉子设置，该炉衬将会有许多年的安全工作时间 1.4The content of this document includes :此文件内容包括 1.4.1Bill of materials, Appendix A,材料清单，附件A 1.4.2Certificate of ISO registration, Appendix B,注册执照，附件B

6、 1.4.3Drawings, Appendix C,图纸，附件C 1.4.4Material safety data sheets (MSDS), Appendix D,材料安全数据清单，附件D 1.4.5Product definitions, Appendix E,产品定义，附件E 1.4.6Product use instructions, Appendix F,产品使用说明，附件F 1.4.7Quality certificates, Appendix G,质量证明，附件G 1.4.8Technical data sheets, Appendix H,技术数据清单，附件H 1.4.9

7、Completion certificate, Appendix I,竣工证，附件I 2.DESIGN AND INSTALLATION设计和安装设计和安装 2.1The lining drawing RR-P3N-4031A R1 titled “General Arrangement - Carbon refractory “ in Appendix C depicts the configuration of the entire lining and tap holes. 图纸RR-P3N-4031A R1标题总体布局标题总体布局- 碳耐火材料，见附件碳耐火材料，见附件C，给出了整个内

8、衬和排放口的结构，给出了整个内衬和排放口的结构 2.2Metix supplied only high quality carbon refractory materials (see Appendix G) manufactured by Graftech in the USA and South Africa, including, 迈提克斯公司仅仅提供由南非和美国优卡公司制造的高质量碳耐火材料（见附件G） 2.2.1NMA and NMD carbon blocks, see data sheets in Appendix H, 高导热碳砖和半石墨碳砖，见附件H数据清单 2.2.2Gra

9、phite tiles, see CJR data sheet in Appendix H, 石墨砖，见附件I CJR数据清单 2.2.3Tap hole blocks, see grade D data sheet in Appendix H, 排放口砖，见附件H D等级数据清单 2.2.4Carbon cement, see Graftech C34 data sheet in Appendix H, and 碳粘合剂，见附件H 优卡C-34数据清单 2.2.5Carbon ramming material, see Graftech RP20 data sheet in Appendix

10、 H. 碳捣打糊材料，见附件H优卡RP20数据清单 2.3Other materials sourced by CYMCO from local Chinese manufacturers, include, 由云南冶金集团从当地制造商获取的其他材料，包括 2.3.1Hearth ramming material,炉膛捣打材料 2.3.2Carbon blocks,碳砖 2.3.3Hearth insulation refractories,炉膛绝缘耐火材料 2.3.4Sidewall protection refractory,侧壁保护耐火材料 2.3.5Castable to rim of

11、 furnace shell,炉壳边缘浇注料 2.3.6Castable on roof panels,炉盖板浇注料 2.3.7Expansion materials.膨胀材料 2.4All the materials were installed under the supervision of Graftechs site engineer, Mr. Gert de Jager during May 2011. 所有材料均于2011年5月在优卡现场工程师 Mr. Gert de Jager 的监理下砌筑 3.DRYING AND HEATING-UP 干燥和升温干燥和升温 3.1Prope

12、r, controlled drying is required before furnace start-up. 在开炉前需要完全干燥 3.2The key factor to concentrate on during this process is the slow removal of all the water associated with the ceramic mortars, castables, bricks and “gunnited” materials (castable refractory blown-on by compressed air), accordin

13、g to the respective suppliers dry-out schedules. 在此程序中最关见的因素是根据各自供应商的干燥程序将泥浆、浇注料、砖和“喷涂”材料 （浇注耐火材料用压缩空气吹干）中的水排出， 3.3If the heating rate is too fast, steam formed during the process does not have time to escape through the available pores. Pressure builds up and the materials crack or “spall” (curved

14、fragments separate from the refractorys surface). 如果升温速率过快，此期间产生的蒸汽不能从气孔中排出，压力增加，材料破裂或“剥落” ，（碎片从耐火材料表面分离） 3.4However, 90% of Graftech lining is already “baked out” (bricks and blocks).The remaining 10% does not contain “free” or “crystal” water. Only approximately 25% of this “green“ un-baked materi

15、al mass comprises of carbonaceous volatiles (= 10% x 25% = 2,5% of the Graftech material). 然而，90%的优卡内衬已经烘焙（碳砖和炭块）。剩余的10%不包括“自由”和“结晶”水 。仅仅25%的“绿色”未烘焙材料构成了含碳挥发物（= 10% x 25% = 优卡材料的2,5%） 3.5Graftech C34 Cement contains Furfuryl Alcohol and will set-up over time at temperatures below 100C. The best stre

16、ngth is achieved when completely carbonized at 850C (later on in the heating-up schedule after all H2O has been removed). 优卡C34粘合剂包含糠醇，在温度低于100C时供给。当到850C完全炭化达到最好强度。（ 在所有水排出后的升温进程中） 3.6RP20 Ram containing Coal Tar Binder starts carbonizing around 250-300C (also later on in the heating-up schedule af

17、ter all H2O has been removed). RP20捣打料包含煤焦油粘结剂，其大约在250- 300C开始碳化（在所有水排出后的升温进程中） 3.7Also worth mentioning is the large mass of Carbon Ramming (on top of the carbon blocks), that must be cured to its manufacturers schedule without going so fast as to crack it or too slow at high temperature to or oxid

18、ise it. 值得提到的是大块碳捣打糊（碳砖顶部），必须按照制造商程序进行处理，不要过快以免破 裂，也不要过慢否则会氧化 3.8The other part of heating up relates to baking of green Soderberg paste electrodes. Increasing furnace power needs to be at a slow and controlled rate because there is a lot of tar and volatiles that must be driven out of the electrode

19、 paste mass at a fairly slow rate so as not to crack or lose an electrode tip. 其他行馆升温部分为索德伯格电极糊，增加炉子电源需要缓慢的速率且易控，因为在缓慢速 率下，要从电极糊排出许多焦油和挥发物，以免不会断裂 3.9To summarize, the Graftech carbonaceous lining (freeze lining) needs very little attention during start-up if the operators follow the suggested schedu

20、les for the other materials (White Ceramics, Carbon Rammed hearth and/or Soderberg Electrodes), as the freeze lining material is mostly protected by these other materials and as the heat soaks through to the Graftech materials, it has a gradual enough curing rate. 总的来说，如果按照推荐的程序开炉，优卡含碳内衬（冷却内衬）在开炉过程中

21、，对 其他材料（白色耐火材料、炉膛谈捣打糊、索德伯格电极）几乎不需要注意，因为冷 却内衬材料大部分由这些材料保护，因为温度通过优卡材料渗透，并有逐渐固化速率 4.WATER COOLING水冷却水冷却 4.1There must be a uniform and continuous film of water on the steel shell. Evidence of dry spots should be investigated for root cause (i.e. clogged headers, etc.) 钢结构炉壳上必须有均匀的、持续的水。应追究干燥点的起源（堵塞的喷嘴等

22、） 4.2The steel shell should remain free of any build-ups such as algae, lime or oxidation. A practice of abrasively cleaning the shell during the planned outages, or on some other common basis, should be implemented. 钢结构炉壳上应避免任何藻类、石灰或氧化物。在计划中断时必须对炉壳或其他常见基础设 施进行打磨清扫 4.3Inlet water temperatures should

23、 be maintained below 350C. 进水温度应保持在350C以下 4.4Water quality is dependent on regional and seasonal conditions and it is suggested that some data be collected to establish baselines for specific facilities. If required, the water should be treated chemically or purified to maintain good quality water s

24、uitable for providing efficient cooling to the furnace shell and refractories. 水的质量取决于区域和季节性条件，建议搜集一些数据来作为专门设施的基准线。如有需要 ，水应进行化学处理或净化以供给高质量的水以提供炉壳和耐火材料高效的冷却。 4.5Back-up or redundant cooling system components should be in place and maintained for functionality. 备用或冗余的冷却系统应放置并维护 4.6During initial furna

25、ce start-up some operators leave the water cooling turned off and then regularly monitor the steel shell temperatures with calibrated infrared thermal imaging equipment until the shell surface reaches approximately 500C. This practice will assist in the drying and baking of the cement and ramming ma

26、terials. 在炉子启动初始阶段，一些操作人员保持水冷却关闭，并用校准红外热成像设备定期检测钢 结构炉壳温度，直到炉壳表面温度达到 500C。这将对粘合剂和捣打材料的干燥和烘焙有所帮助。 4.7It is a requirement for a freeze lining to have water cooling on it at all times during operation to ensure it is achieving the correct “frozen material” build-up inside the furnace, which is necessary

27、 to protect the carbonaceous refractories. 冷却内衬运行期间，需要随时供给水冷确保炉子内部产生对含碳耐火材料起到保护作用的“ 凝固材料”。 4.8Short periods of water being switched off on selected panels for maintenance purposes while the furnace electrical power is on, is acceptable. It is required to switch on the water again immediately after c

28、ompleting the work. 当炉子通电时，为了维修钢板导致的短期断水是可以接受的。当完成维修后，需要立刻通水 。 4.9If the shell water cooling systems requires maintenance, it is recommended to plan such work to coincide with other scheduled maintenance to be done on the furnace (when the power will be switched off). 如果需要维修炉壳水冷系统，建议与炉子上其他预定的维修相符（电源

29、关闭） 4.10Thermocouples installed in the lining should be checked regularly and replaced as soon as possible once it became faulty during operation. 安装在内衬上的热电偶需定期检查，在运行期间，热电偶一旦失效马上更换， 5.TAPPING PRACTICE放排放排 5.1A good quality tap hole clay is recommended which contains both refractory clay as well as c

30、arbonaceous particles, together with a tar bonding liquid (water based clays should not be used). This type of clay will provide a balance between closing the tap hole properly and being able to open it with relative ease for the next tap, but also assist to provide some building up of the tap hole

31、“trumpet” whenever excessive wear caused by excessive oxygen lancing is noticed (see item 5.2 below). 一个高质量的排放口粘土包括含有沥青液体的耐火粘土和碳粒子（不使用睡醒粘土），这种 类型的粘土将在关闭排放口和打开下一次排放的排放口之间提供一个平衡，也为当过度耗氧 切口造成的过度磨损发出的“喇叭声”提供了一些物质 5.2During initial furnace start-up some operators specially prepare the metal tap holes by

32、plugging the inside and outside third with quality tap hole clay but they use coke particles for the remaining centre-third. This configuration facilitates the drilling process for the first-drilled tap. Subsequent closing is done 100% tap hole clay from hot face to cold face. 在炉子启动初始阶段，操作人员特地用排放口粘土

33、堵塞三分之一出铁口的内、外部，但是， 他们用焦炭粒子堵塞剩余中心的三分之一。该结构对第一次排放口开口起到促进作用。随后 ，从热面到冷面关闭排放口粘土 5.3When drilling tap holes, it is a good practice to record and log the drilled length. As the “trumpet” throat becomes bigger the drilling distance will become smaller. This log (or journal) will give the operator an early i

34、ndication of potential maintenance needs (i.e. to rebuild tap hole length with additional reconstructive clays). 在进行排放口开口时，最好对打钻的长度进行进行记录，当“喇叭声”变的更大时，开口距 离将变的更小。这运行记录将提供操作员需要进行潜在维修的指示。（即：用粘土对排放口 长度重建） 5.4Drilling depths should be as deep as possible (until red hot tap hole clay is being drilled into

35、). The drill can then be retracted and the last bit of tap hole opening can be performed with a poking iron. If this is not successful, a limited amount of oxygen lancing at this stage would be required for the final opening. This procedure will create a balance of not damaging the tips of the drill

36、 bit while preserving the tap hole length to a maximum. 开口深度要尽可能深（直到红热排放口粘土钻的里面），钻杆可以伸缩，排放口开口的最后 一点可以用戳铁一起完成。如果不成功，需要用有限量的氧气喷枪来完成最终开口。此程序 在保留排放口长度最大值的同时不会损坏钻杆尖端 5.5In general O2 lancing is detrimental to the life of carbonaceous and graphite tap hole components and must be minimized. The number of O

37、2 lance pipe lengths used should be recorded for each tap (record should include quantities as well as frequency) 一般情况下，氧气喷枪对排放口含碳的石墨砖有害，必须将其危害最小化。氧气喷枪管长度 应记录在每一个上面（记录包括数量和频率） 5.6Approximate calculations from recorded tap hole lengths can also be used to verify that a sufficient quantity of clay has

38、 been used to close the tap hole. 记录的排放口长度近似计算可用于检测粘土数量是否充足 5.7After tapping the furnace, it is recommended that minimal (or zero) metal or slag is left to freeze in the tap hole (particularly metal). This will assist with easier drilling when the tap hole is opened again. 在炉子开口以后，建议在出排放口预留最小限度的铁或渣。

39、当排放放口再次打开时，更容易 打钻（开口） 5.8When excessive tap hole wear is experienced, the use of tap hole clay with higher carbon content is recommended to assist with the gradual repair and build-up of the tap hole to its original diameter. 当排放口过度磨损，建议在排放口使用较高含碳量的粘土来逐步修和重建排放口原始尺寸。 5.9The front face of the tap hole

40、 should be in such a condition that the mud gun spout will fit tightly into or onto it to ensure that maximum tap hole clay can be inserted into the tap hole to form the “mushroom” inside the furnace which is the best way to ensure maximum life expectancy of a tap hole. 排放口前面应保持这样的条件：泥炮开口机喷头应紧固来确保进入

41、到排放口的粘土的最大化 ，这是确保排放口寿命最大化的最好方法 5.10The volume of the tap hole clay used should be monitored and controlled. The amount of tap hole clay used should match the volume of tap hole clay inserted into the tap hole during the closing operation, plus an extra 20 25% to ensure the maintenance and build-up o

42、f the tap hole. Typically a mud gun with a minimum of 40 litre live capacity is recommended. Between 20 an 25 litres to be used for closing a normal tap hole, the balance of the clay being available to be used in case the tap hole did not close on the first try. 要对排放口粘土用量进行监控和控制。在堵眼期间，排放口粘土的数量应与添加到排

43、放口粘 土的数量相配，加上额外的 20 25% 来确保排放口的维修与重建。建议使用40公升容量的泥炮开口机。20到25公升用于关闭正常 排放口，万一排放口在第一次关闭时失败，可对粘土进行平衡化。 5.11The tap hole “Mickey” (Item TH4, Drawing No. RR-P3N-4031 X 4) blocks should be replaced once excessive wear is noticed or the mud gun cannot seal properly against this block anymore. This can be don

44、e during a planned maintenance shutdown of the furnace. It is dangerous to work on a worn tap hole while the furnace is in operation as a spontaneous tapping of the furnace might occur in such times when the tap hole sealing integrity is compromised and can lead to burning injuries being sustained.

45、About 3 hours should be allowed to perform such a task. 一旦过度磨损或泥炮开口机不能密封砖，排放口的“米奇”砖应进行更换，这可在炉子停炉 维修时进行更换。当炉子在运行时，进行排放口米奇砖的更换是很危险的，因为当排放口密 封完全被压缩时，在这情况下可能会发生自发的排放，可能会导致持久性的损坏。此操作大 约需要3小时。 5.12During normal operation the Mickey block typically needs to be replaced every 6-8 months. When regular/excess

46、ive oxygen lancing is performed, this period will be shorter. 正常操作期间，米奇砖需每6- 8个月进行更换。如果氧气喷枪过度或不合格，此时间会缩短。 5.13Typically the tap hole-insert (Item TH3, Drawing No. RR-P3N-4031X4) lasts from 12 to 18 months. This insert can be done at the same time as the Mickey block replacement (during a planned fur

47、nace maintenance shutdown). Eight hours should be allowed to perform such a combined task. 排放口添加（序号TH3，图纸编号 RR-P3N- 4031X4）持续12到18个月。此添加物可与米奇砖的更换同时进行（在计划的停炉维修期间 ）。此工作需要8个小时 5.14It has been found that the tap hole area needs more extensive repair work, every 3 to 5 years. This should be planned and p

48、erformed under the supervision of a technically competent person with in-depth experience of such repair work on freeze linings. 排放口区域需要进行大量的修复工作，没3到5年。这需要在一个有较深冷却内衬维修经验的 人的监理下进行。 6.FURNACE SHUTDOWNS停炉停炉 6.1Whether a lengthy outage of more than one week is planned and is of sufficient length to allo

49、w the lining to cool significantly it is good practice to pump a carbonaceous grout (GrafTechs GR37TM Grout) prior to restart between the steel shell and the graphite tiles to ensure that any lost contact between these areas has been re-established to the cooling system. 是否把一个星期的停电计划在内以及是否有足够的长度来冷却，最好在重启前在炉壳和石墨 砖之间泵入含碳泥浆(优卡GR37TM 泥浆）来检测，以确保此区域间冷却系统的连接不会减少。 6.2For this purpose it would be required to have some grouting holes drilled into the shell which can be fitted with a connection to a high pressure refractory pump to force the material into the areas where such cavities