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某公司增建不锈钢炉外精炼项目节能报告

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2019-04-29
简介
**有限公司增建不锈钢炉外精炼项目节能评估报告建设单位名称:**有限公司评估单位名称:**有限公司**年**月**有限公司增建不锈钢炉外精炼项目节能评估报告目录前言·····································································································31、评估的目的和意义··············································································32、评估过程··························································································41、评估依据····························································································51.1评估范围和内容································

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**有限公司增建不锈钢炉外精炼项目节能评估报告建设单位名称:**有限公司评估单位名称:**有限公司**年**月**有限公司增建不锈钢炉外精炼项目节能评估报告目录前言·····································································································31、评估的目的和意义··············································································32、评估过程··························································································41、评估依据····························································································51.1评估范围和内容················································································51.2评估依据·························································································52、项目概况····························································································82.1建设单位基本情况·············································································82.2项目基本情况···················································································82.3工艺流程及流程图·············································································92.5工程方案·······················································································232.6给排水··························································································242.7供电及电力负荷计算········································································302.8燃气······························································································312.9热力······························································································332.10压缩空气······················································································352.11氮气····························································································352.12氩气····························································································362.13氧气····························································································362.14投资估算与资金筹措·······································································373、能源供应情况分析评估·········································································433.1项目所在地能源供应条件及消费情况···················································433.2项目能源消费对当地能源消费的影响···················································453.3本章评估小结·················································································454、项目建设方案节能评估·········································································474.1项目选址、总平面布置对能源消费的影响·············································474.2项目工艺流程、技术方案对能源消费的影响··········································474.3主要工序能耗指标和能效水平····························································484.4主要耗能设备及其能耗指标和能效水平················································53**有限公司增建不锈钢炉外精炼项目节能评估报告4.5辅助生产和附属生产设施及其能耗指标和能效水平·································604.6本章评估小结·················································································645、项目能源消耗及能效水平评估·······························································655.1项目能源消费种类、来源及消费量分析评估··········································655.2项目能源消耗计算···········································································675.3能效水平分析评估···········································································675.4本章评估小结·················································································746、节能措施评估·····················································································766.1节能措施·······················································································766.2本章评估小结·················································································877、结论·································································································88**有限公司增建不锈钢炉外精炼项目节能评估报告3前言**有限公司生产设施有:550m3高炉两座、1080m3高炉三座、60t转炉一座、70t转炉一座、75t转炉三座、150t转炉一座、1250mm热轧带钢生产线一条、1500mm热轧带钢生产线一条,以及配套公辅设施和余压发电和煤气回收发电等设施。**有限公司坚持以科技创新为先导,以技术改造为手段,以结构调整为主线,不断完善和提高产品深加工能力,提升企业的综合竞争能力。经过详细地市场调研并结合企业自身优势和海外资源优势,拟建设年产不锈钢炉外精炼技术改造项目,满足国内市场的需求。项目建成投产后,产品结构得到调整,产品档次得到提升,极大提高企业核心竞争能力。1、评估的目的和意义由于我国正处于工业化和城镇化加快发展阶段,能源消耗强度较高,消费规模不断扩大,特别是高投入、高消费、高污染的粗放型经济增长方式,加剧了能源供求矛盾和环境污染状况。能源问题已经成为制约经济和社会发展的重要因素。节能是缓解能源约束,减轻环境压力,保障经济安全,实现全面建设小康社会目标和可持续发展的必然选择,体现了科学发展观的本质要求,是一项长期的战略任务,必须摆在更加突出的战略位置。节能评估通过对项目生产工艺、生产设备的审查,限制了工艺技术水平低、能效水平差的设备采用,引导企业积极采用国家鼓励的先进工艺技术和节能设备,促进项目装备水平的大幅提高;通过对产品单耗指标的核定,促进企业积极采取各种切实可行的节能措施,使产品单耗指标严格控制在单位产品能耗限额范围内,从而避免了能源的大量浪费,有效地降低了企业的生产成本。节能评估对于严格限制不符合国家产业政策、节能政策项目的准入,抑制高能耗、高污染行业的盲目扩张具有重要意义,对调整优化产业结构具有指导作用。**有限公司增建不锈钢炉外精炼项目节能评估报告42、评估过程根据《固定资产投资项目节能评估工作指南》和《固定资产投资项目节能评估和审查暂行办法》中的有关要求,**有限公司委托**有限公司承担本项目的节能评估工作。**有限公司接受委托后,项目编制技术人员经过现场勘察、调查和测试,收集项目的基本情况及用能方面的相关资料,确定评估依据,选择评估方法,对项目的用能状况进行全面分析,形成评估结论,根据《固定资产投资项目节能评估工作指南》编制节能评估文件。**有限公司增建不锈钢炉外精炼项目节能评估报告51、评估依据1.1评估范围和内容本报告为**有限公司增建不锈钢炉外精炼项目节能评估报告,报告中对项目所在地的能源供应情况、建设方案、工艺设备选择、项目采取的节能措施、项目能源消耗及能效水平等进行了评估,并对项目节能方面存在的问题提出了合理建议及结论,为决策机构提供可靠依据。1.2评估依据1.2.1法律、法规《中华人民共和国节约能源法》(中华人民共和国主席令第七十七号)《中华人民共和国清洁生产促进法》(中华人民共和国主席令第七十二号)《中华人民共和国循环经济促进法》《中华人民共和国电力法》《中华人民共和国建筑法》《中华人民共和国计量法》《国家鼓励发展的资源节约综合利用和环境保护技术》(国家发改委第65号令)《中华人民共和国强制检定的工作计量器具检定管理办法》《**省节约能源条例》《固定资产投资项目节能评估和审查暂行办法》(国家发展和改革委员会令第6号)《关于转发〈国家发展和改革委员会关于加强固定资产投资项目节能评估和审查工作的通知〉的通知》(**发改投资[2007]152号)1.2.2规划、行业准入条件及产业政策《钢铁产业发展政策》(国家发展改革委2005年第35号令)**有限公司增建不锈钢炉外精炼项目节能评估报告6《钢铁产业调整和振兴规划》(国务院2009年)《关于印发节能减排综合性工作方案的通知》(国发[2007]15号)《节能中长期专项规划》(发改环资[2004]2505号)《产业结构调整指导目录(2011年本)》(国家发展和改革委员会令第9号)《铁合金行业准入条件》(2009年)1.2.3用能标准、节能规范及产品推荐目录《钢铁企业主工序单位产品能源消耗限额》(DB13/1207-2010)《钢铁企业设计节能技术规定》(YB9051-1998)《铁合金单位产品能源消耗限额》(GB21341-2008)《钢铁企业节水设计规范》(GB50506-2009)《钢铁企业节能设计规范》(GB50632-2010)《钢铁企业能源计量器具配备和管理要求》(GB/T21368-2008)《工业企业能源管理导则》GB/T15587-2008《工业设备及管道绝热工程设计规范》GB50246-1997《工业设备及管道绝热工程质量检验评定标准》GB50185-1993《评价企业合理用电技术导则》GB/T3485-1998《评价企业合理用热技术导则》GB/T3486-1993《中小型三相异步电动机能效限定值及节能评价值》GB/T18613-2006《三相配电变压器能效限定值及节能评价值》GB/T20052-2006《综合能耗计算通则》GB/T2589-2008《公共建筑节能设计标准》DB13(J)81-2009《外墙外保温工程技术规程》JGJ144-2004《采暖通风与空气调节设计规范》GB50019-2003《建筑照明设计标准》GB50034-2004**有限公司增建不锈钢炉外精炼项目节能评估报告7《建筑采光设计标准》GB/T50033-2003《**省用水定额(试行)》《国家重点节能技术推广目录》(第一批)(2008年5月)《国家重点节能技术推广目录》(第二批)(2009年12月)《节能机电设备(产品)推广目录》(第一批)《节能机电设备(产品)推广目录》(第二批)(2010年8月)《节能降耗电子信息技术、产品与应用方案推荐目录》(第一批)1.2.4国家明令淘汰的用能产品、设备和生产工艺目录根据《产业结构调整指导目录(2011年本)》,本项目不涉及国家明令淘汰的用能产品生产,项目生产工艺及设备选取严格遵守《产业结构调整指导目录(2011年本)》规定,严禁购置或采用目录中限制和淘汰的设备和生产工艺。本项目不存在《高耗能落后机电设备(产品)淘汰目录》(第一批)中规定的设备和产品。1.2.5其它资料《**有限公司增建不锈钢炉外精炼可行性研究报告》。**有限公司增建不锈钢炉外精炼项目节能评估报告82、项目概况2.1建设单位基本情况建设单位:**有限公司企业性质:有限公司企业运营总体情况:易企询https://www.eqxun.com/2.2项目基本情况项目名称::**有限公司增建不锈钢炉外精炼项目建设地点:**有限公司厂区南侧项目性质:新建建设规模:**有限公司利用现有的一台60t转炉和一台70t转炉,实施增建不锈钢炉外精炼项目,增建镍铁合金矿热炉12台、铬铁合金矿热炉4台、增建2台90tAOD炉、2台90tLF炉、1台90tVOD炉、1台板坯连铸机和1台圆坯连铸,生产不锈钢连铸坯104万吨。项目所需铁水由公司内现有高炉提供,以内部结算价购买,故高炉不在本项目建设范围内。**有限公司增建不锈钢炉外精炼项目节能评估报告9产品方案及生产规模:生产的钢坯为:奥氏体不锈钢、铁素体不锈钢、双相不锈钢钢坯。其中奥氏体不锈钢46.87×104t,铁素体不锈钢46.87×104t,双相不锈钢10.5×104t,合计104.24×104t。表2-1产品方案表序号产品名称代号钢种产量备注1奥氏体不锈钢30400Cr19Ni1046.87×104t2铁素体不锈钢41012Cr1346.87×104t3双相不锈钢2205022Cr23NiMo3N10.5×104t2.3工艺流程及流程图图2-1全厂生产工艺流程图**有限公司增建不锈钢炉外精炼项目节能评估报告102.3.1原料各散状料和铁合金料均为合格料,由炼钢车间外部经汽车运至辅原料和铁合金地下受料槽受卸,然后经带式输送机运往车间主厂房加料跨对应的高位料仓贮存。在冶炼需要时,各种辅原料、铁合金料经投料系统进行计量并依次投入到冶炼炉中。2.3.2铁合金水熔炼每两台矿热炉组成一个矿热炉车间,每个车间配一座干燥窑及一座回转窑,分别负责原料的干燥及焙烧还原,回转窑前设筛分、破碎设施及配料。表2-2矿热炉主要参数表序号名称单位数量备注1炉膛直径mm82002炉膛深度mm30003电极直径mm13504电极极心圆直径mm3300-3500可调5电极工作行程mm12006电极检修行程mm15007烟罩高度mm13008出铁口个数个29电极升降速度m/min0.52.3.2.1镍铁合金熔炼红土镍矿(含Ni约2%)运入原料厂后,经配入还原剂后送入回转窑。回转窑的工作区可以分为三段,即干燥段、加热段、焙烧段。在回转窑中,红土镍矿焙烧脱水,重量减少30%左右。同时,氧化镍和部分铁被炉料中的还原剂还原。在回转窑出料端设有密封的出料装置,镍渣以600~900℃的温度在隔热状态下被送入到矿热炉。经矿热炉冶炼即可得到**有限公司增建不锈钢炉外精炼项目节能评估报告11粗制镍铁。图2-2镍铁合金生产工艺流程图本项目新建36MVA镍铁合金矿热炉12台,每两台矿热炉组成一个镍铁合金车间,每个车间配备一座干燥回转窑和一座焙烧回转窑,因此镍铁合金冶炼需要6座干燥回转窑和6座焙烧回转窑。2.3.2.2铬铁合金熔炼高碳铬铁是以铬铁矿为原料,入炉矿品位40%,以硅石作为造渣熔剂,用炭质还原剂(焦碳)在电加热的矿热还原炉内进行碳还原的产品,是连续熔炼和间断出炉的电热法工艺。铬铁矿(或烧结矿)与焦炭的合格料,硅石合格料分别由皮带机送至配料站配料,配好的混合料经皮带机送至炉顶料仓,混合料经料管连续加入炉内。按2小时间隔,用开铁口机打开出铁口,液态高碳铬铁流入铁水包,炉渣经铁水包流入渣包,然后铁水包送炼钢车间;靠近铁水包的渣包运至干渣场冷却,冷却后经破碎、跳汰回收渣中跑铁。**有限公司增建不锈钢炉外精炼项目节能评估报告12图2-3铬铁合金生产工艺流程图本项目新建36MVA铬铁合金矿热炉4台,每两台矿热炉组成一个铬铁合金车间,每个车间配备一座干燥回转窑和一座焙烧回转窑,因此铬铁合金冶炼需要2座干燥回转窑和2座焙烧回转窑。2.3.2.3回转窑热源及矿热炉应用途径根据矿热炉参数,本项目镍铁合金矿热炉所用原料经过预还原,因此煤气产生量以及煤气热值均较有所降低;铬铁合金矿热炉由于是冷料入炉,因此煤气产生量以及煤气热值均较高,详见下表。**有限公司增建不锈钢炉外精炼项目节能评估报告13表2-3矿热炉煤气参数设备名称煤气产生量(Nm3/h)煤气温度(℃)成分(%,V/V)COCO2N2H2OH2CH4O2镍铁合金矿热炉18000.004705522.57860.51铬铁合金矿热炉8400.00450759.555410.5根据矿热炉煤气参数可知,镍铁合金矿热炉煤气的热值约为6948.15kJ/Nm3,铬铁合金矿热炉煤气的热值约为9474.75kJ/Nm3,混合后煤气平均热值为8422kJ/Nm3。本项目拟利用矿热炉煤气作为干燥回转窑和焙烧回转窑的燃料,不足部分使用转炉煤气。干燥回转窑年处理红土镍矿(含水率约30%)398.40万吨,设计热耗为102.75×103kJ/t矿,回转窑热效率为85%,干燥矿年耗热量为4.82×1011kJ。焙烧回转窑年处理红土镍矿(干基)264.00万吨,设计热耗为997.69×103kJ/t矿,回转窑热效率为85%,焙烧矿年耗热量为3.10×1012kJ。综上所述,回转窑年耗热量为3.582×1012kJ,本项目矿热炉煤气产生量为26400.00Nm3/h,煤气热值平均为8422kJ/Nm3,矿热炉年运行7200h。8422×26400×7200≈1.60×1012kJ/a<3.582×1012kJ/a因此,本项目矿热炉煤气不能够满足本项目回转窑用气需要,不足部分采用下一工序的转炉煤气以及**焦化有限公司的焦炉煤气作为补充燃料。本项目利用现有的一台70t转炉和一台60t转炉对铁合金水进行脱磷脱硅处理,两台转炉煤气产生量合计为8540.28Nm3/h(55Nm3/t半钢),转炉煤气组分如下表所示。**有限公司增建不锈钢炉外精炼项目节能评估报告14表2-4转炉煤气参数COCO2H2N2O2其他51%20%1.5%20%2%5.5%根据转炉煤气参数可知,本项目转炉煤气平均热值为6442.83kJ/Nm3,年运行时间为7200h,该车间年外供转炉煤气为3.96×1011kJ/a。**焦化有限公司现有4×38孔TJL80型侧装捣固焦炉,每小时产生焦炉煤气120921.60m3/h,除回炉自用煤气以及供给**钢铁有限公司的煤气外,还剩余煤气38045.00m3/h,焦炉煤气低位发热量为16956.54kJ/m3(0.5786kgce/m3)。本项目回转窑所需燃料扣除矿热炉煤气后,缺口为1.586×1012kJ/a,上述转炉煤气和焦炉煤气能够满足回转窑燃气需要。2.3.3不锈钢精炼因为生产不锈钢的主原料为高炉铁水、镍铁合金水、铬铁合金水等富含热量的熔融状态的金属原料,所以可以采用“铁水(或铁合金水)预处理+AOD炉+LF炉”的二步法工艺路线组织生产不锈钢,部分超低碳、超低氮钢种可以采用“铁水(或铁合金水)预处理+AOD炉+LF炉+VOD”的三步法工艺路线组织生产。**有限公司增建不锈钢炉外精炼项目节能评估报告15表2-4不锈钢精炼工艺流程图不锈钢精炼的过程是“脱碳保铬”和合金化的过程,其关键点是控制冶炼过程,使脱碳反应有利进行,而且尽可能减少合金元素的氧化,达到收得率高、冶炼时间短、生产效率高、生产成本低的目的。因此要优化入炉原料结构配比、对加料制度、供氧制度、造渣制度、温度控制等进行控制。不锈钢冶炼中,碳和铬元素在熔池中同时存在,而铬是易氧化元素,在脱碳过程中不可避免存在着铬的氧化,氧化的特征表现为两者的竞争氧化,从而必须进行“脱碳保铬”的工艺控制。因此本项目不锈钢精炼采用转炉前期脱硅、脱磷和AOD炉顶底复吹后期还原精炼相结合的工艺过程。工艺过程分述如下:第一步:转炉前期脱硅脱磷本项目转炉前期脱硅是利用氧化剂将铁水中的硅氧化脱除的过程。**有限公司增建不锈钢炉外精炼项目节能评估报告16本项目利用顶吹转炉进行脱硅,氧化剂为气体氧化剂,即氧气。向铁水中吹入氧气时,脱硅反应为:①2Fe+O2=2FeO②[Si]+2FeO=SiO2+2Fe本项目转炉前期脱磷是利用石灰系脱磷熔剂的氧化脱磷工艺。氧化剂为氧气其反应为:2[P]+3CaO+5FeO=3CaOP2O5+5Fe表2-5转炉脱磷处理周期序号工序名称时间(min)备注1兑铁水42加废钢23吹炼7-104取样2生产熟练后,此项可取消5出半钢4-66出渣2∑平均冶炼周期21-26计算取25分钟表2-6转炉脱硅处理周期序号工序名称时间(min)备注1兑铁水42加冷却剂23吹炼9~124取样2生产熟练后,此项可取消5出半钢4-66出渣2∑平均冶炼周期25-28计算取27分钟**有限公司增建不锈钢炉外精炼项目节能评估报告17第二步:AOD顶底复吹1)初期脱碳将脱硅脱磷后的半钢水包送至AOD顶底复吹炉座上,降下顶部氧枪,开枪供氧向熔池内吹氧脱碳,此时炉底风咀也将氮气切换成为氧气。为了控制炉内温度,可加入适量不锈钢废钢。当炉内刚水中碳含量小于2%后,转入氧化脱碳。2)氧化脱碳转入氧化脱碳时,可以提起顶部氧枪,加大底部风咀的供氧强度,随钢水中碳含量的变化,而调整底部风咀的氧气和氩气的比例,并逐步以氩气替代氧气。3)还原精炼当炉内钢水中碳含量降到规定值的时候,底部风咀停止供氧,加入硅铁和石灰,并改为从底部风咀全程供氧,进行强烈搅拌,使已被氧化的铬和锰还原,达到所炼钢种的规定含量。表2-7AOD炉精炼处理周期表序号作业项目作业时间(min)周期时间(min)1加料32分阶段吹炼423测温取样34还原期85测温取样36吹氩均匀化77出钢4合计70**有限公司增建不锈钢炉外精炼项目节能评估报告18第三步:LF精炼炉精炼当AOD炉内钢水液基本达到温度和成分要求后,将钢水倒入钢包中,送至LF炉进行炉外精炼,使钢水的成分、温度以及均匀性达到浇铸要求,即可送至连铸机进行浇铸。表2-8LF炉精炼处理周期序号作业项目作业时间(min)周期时间(min)1钢水罐起重机坐包时间52钢水罐车开入加热工位13下降炉盖、测温、取样334电极旋转到位115加渣料、降电极、第一次加热10106加合金337第二次加热,精炼15158测温、取样339喂线3310提升电极及电极旋转到位2211提升炉盖1112钢水罐车开出1113钢水罐起重机吊包时间5合计5342第四步:VOD炉精炼本项目,部分钢种需经VOD炉精炼后再去浇铸。钢包接通氩气放入真空罐,吹氩、调整流量到20~30L/min(标态),测温1570~1610℃,测自由空间不小于800mm。然后,扣VOD包盖、真空罐盖、抽真空、吹氧。当入罐碳大于0.6%时,为避免发生喷溅,应延长预吹氧时间,晚开5级、4级泵,低真空度小吹氧量将碳去除到0.5%后再进入主吹。**有限公司增建不锈钢炉外精炼项目节能评估报告19停氧条件即吹氧终点判断,应以氧浓度差电势或气体分析仪为主,结合真空度。废气温度变化、累计耗氧量进行综合判断。由于本项目VOD炉冶炼钢种的碳含量小于0.03%,因此需要进行真空脱碳脱氧操作,即停氧后立即打开高真空喷咀,抽真空到极限真空度,同时增大氩气流量(标态)至2~3…
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