AMH QTCN NU LUYN KIM LOI & HP KIM L 80 TN

TRNG I HC BCH KHOA TP. HCM

KHOA CNG NGH VT LIU

AMH QTCN NU LUYN KIM LOI & HP KIM

Mc lc Mc lc... Li ni u.. Chng 1 : Lch s l h quang . Chng 2 : Tnh hnh trong nc .. Chng 3 : Tng quan v l h quang ... Chng 4 : Thit k kch thc l .. Chng 5 : Tnh ton phi liu .. Chng 6 : To x ...

Chng 7 :Qu trnh nu luyn .. Chng 8: Kt cu thng rt..

LI NI U
Ngy nay cng vi s i ln ca t nc, ngnh cng nghip ng vai trht sc quan trng p ng cc yu cu cho ngnh kinh t quc dn: ckh, xy dng, ha hc do ngnh cng ngh vt liu cng pht trinnhanh chng p ng cc yu cu pht trin chung ca t nc. Trong ngnh luyn kim c v nh xng sng ca quc gia. m trchvai tr quan trng ny, mi ngi k s vt liu tng lai nht thit phi hiuv nm r bn cht ca qu trnh luyn kim, cc thit b l, thnh phnnguyn vt liu, thnh phn xV bit vn dng nhng kin thc hc vothc tin, gp phn vo s pht trin ngnh luyn kim ni ring cng nhngnh cng nghip nc nh ni chung. n mn hc l mt phn thit yu ca chng trnh gio dc ca i hc Bch khoa Tp H Ch Minh, l c hi sinh vin bc u p dng vo thc t cc kin thc hc c cng nh l mt c hi tt sinh vin gt hi c cc k nng mi, kin thc thc t mi. Thc hin n mn hc chnh l c lm quen cch thc hin lun vn tt nghip sau ny. D sao th vi t cch l mt sinh vin v cng ch ln u thc hin nn khng th trnh khi cc sai st, nhng cng l mt qu trnh di tm ti v c gng, em rt mong c thy ch bo nhiu hn. n ny c thc hin di s ch dn tn tnh ca thy Thng. Em xin cm n thy rt nhiu v knh chc thy nhiu sc khe tip tc s nghip cao c ny.

Chng 1: LCH S L H QUANG

L h quang c pht trin bi Paul Hroult ngi Php v ng dng trongthng mi bi ngi M nm 1900. Ban u ch yu dung nu thp dng c v thp l xo. Sau chin tranh th gii ln II, nhu cu v thp hp kim cht lng tng cao: thp khng g, chng mi mn c hc, va p, thp c tnh n hi cao m l Besmer, l Mactin, l thi khng kh khng p ng c. V vy phi chuyn sang dung l in nh l h quang, l cm ng, l in x, l plasma

L h quang in c s dng rng ri nu cc loi thp cacbon cht lng, thp hp kim thp , trung bnh v cao vi sn lng ln. Sn lng l h quang chimn 80 90% tng sn lng thp l in, 33,1% tng lng thp (nm 2005). Dung lng l ban u ch vi n vi chc tn, ngy nay ngi ta s dng ph bin cc loi l 100 400 tn/ m. u im ca l h quang l c th dng nguyn liu t st thp ph liu. iu ny gip tit kim nguyn liu, nng lng nn t hiu qu cao v kinh t v mi trng. L h quang c ci tin lin tc v cng ngh: p dng cc bin php cng hanh phng php thi oxy, than, s dng ch in siu cng sut, s dng l hquang 1 chiu siu cng sut, nung liu trc khi nu chy hay s dng l h quangthn ct ( SF) Kt qu l: -Tiu tn in nng gim dn t khong 630 kWh/tn xung di 350 kWh/tn. -Thi gian nu gim t 180 pht xung c th cn 45 pht. -V hng lot ci tin khc nh c kh ha, vi tnh ha, dng nc lm ngui tng v np l, to x bt, kt cu l theo kiu tho y lch tm (EBT), ophi gip tng tui th l v cht lng thp.

Chng 2: TNH HNH TRONG NC

Ch tiu kinh t k thut trong sn xut thp l h quang trong nc rt thp v tiu hao vt t cao ( bng ch tiu ca th gii nm 1970), nng sut lao ng thp do: -Cht lng thp ph khng tt, t trng ng thp nn phi np liu nhiu ln,lng x tng, hiu sut thu hi thp thp, thi gian nu luyn tng. -Ngun cung cp st thp khng nn khng pht huy ht cng sut ca l. -Dung lng l qu nh, nhiu l, b tr ri rc nhiu nh my. -L din hay gp s c do l c, thit b khng ng b.

Bin php khc phc:

-Gia cng ph, ct thp ph tng t trng ng, lm sch thp ph. -Thi oxy v phun than bt gim thi gian nu. -u t l thng LD gim thi gian tinh luyn. -Dung gang lng t l cao b vo phn thiu ca thp ph nn tng cng sut l. -u t h thng lc bi, gim nhim mi trng. -Quy hoch li cc nh my, tp trung li, b cc l nh,ci to cc l trung bnhthnh ln, u t xy mi cc l c ln v hin i 100 400 tn. -p dng cc bin php c kh v t ng ha cao vo khu cht liu, v l, co x tng nng sut v an ton lao ng, gim thi gian nu luyn. -Thu ht cc d n u t nc ngoi vo lnh vc luyn thp theo cng ngh tin tin hc tp cng ngh v k thut

Chng 3: TNG QUAN V L H QUANG

I/ Cu to l :
- V l: Bn trong v c xy hoc m vt liu cn nhit v gch chu la. V l l in h quang gm c v ngoi bng thp chu nhit, c dy 10mm n50mm. V l cn c cc gn tng bn v c cc vnh ai d gi nguyn hnh dngca v l. Vnh ai pha trn lm thnh dng rnh, cha ct to kht khi yy l lm dng chm cu bo m cho v y l c bn ti a v lp lt ctrng lng nh nht. V y l lm bng thp khng c t tnh c th lp tcc thit b khuy trn bng in t. - Thn l : hnh tr, y cong hoc y phng, hay than dng hnh cn y cong.

Trn thn l c np y kn c nh hoc di chuyn c khi cht liu vo l theo phong php t trn xung. - Np l : khng c v bc kim loi, nhng m bo cng v bn, ngi ta lm mt vnh ai kim loi m kn chn vm np.

II/ Vt liu xy l :
-L h quang baz thng c xy bng gch manhezit ( MgO), cromit - manhezit (Cr2O3- MgO), manhezit-cromit ( MgO - Cr2O3), cng c khi dng alumin cao xy np l. Ngoi ra cn s dng gch samt cn nhit v gi nhit -Gch manhezit c dng xy phn trn ca tng l v phn y l, thnh phn ha hc : MgO = 86%, CaO = 2%, FeO = 5%, Al2O3 = 1.5%, MnO = 0.8%, v SiO2 = 4%. Gch manhezit c chu la cao 1700 n 1800oC, nhit bt u bin mm 1500oC, v dn nhit li cao, nhng gch ny li c tnh bn nhit km hay b nt v khi nhit thay i t ngt, do ngi ta khng s dng xy np l v chn tng l. -Gch crom-manhezit c thnh phn ha hc : Cr2O3 = 20% n 30%, MgO = 40 n 45%. Loi gch ny c chu la cao, dn nhit tt, v chu c s thay i nhit t ngt, do ngi ta dng xy chn tng l, ch tho thp.
.

-Gch manhezit-cromit c thnh phn ha hc MgO = 65 n 70%, Cr2O3 = 8n 18%. Loi gch ny c ng dng ph bin xy np l. -Gch samt, l loi gch c tnh cht trung tnh, thnh phn ha hc gm : Al2O3 = 20 n 30%, SiO2 = 55 n 60%. Thng dng loi gch ny xy lp cn nhit ngoi cng y, mng rt thp v ni lt thp.

III/ B phn c kh ca l :
-V l: thng c hn bng thp tm vi chiu dy t 16 -50(mm) ty vodung tch ca l, thng th ngi ta chn chiu dy lp v bng 1/200 ng knhl . V phi c bn c th chu c trng lng kim loi v lp lt, ng thi phi chu c p sut ca lp lt khi b gin n nhit. Do v l c hnh dng chm cu c c bn ti a v lp lt nh nht.

-Vng m in cc : c loi t ng trn np l, c loi dng ng xon rut g , c loi kiu i trng , nhim v ca cc vng m ny to s kht cht gia cc in cc v np l trnh hin tng in cc b gy dn n vic tiu hao in cc v gi thnh thp. B phn cp in cc : thng lm bng thp ng thau hoc ng thanh. B phn cp in cc dng dn in n in cc v gi in cc mt cao nht nh . Ngi ta thng gim in tr tip xc gia u cp v in cc nhm gim mt mt in nng. V lm vic trong mi trng khc nghip nn b phn cp in cc phi c bn cao v mt mt nhit l nh nht.
-B phn cp in cc : thng lm bng thp ng thau hoc ng thanh. Bphn cp in cc dng dn in n in cc v gi in cc mt caonht nh . Ngi ta thng gim in tr tip xc gia u cp v in cc nhmgim mt mt in nng. V lm vic trong mi trng khc nghip nn b phncp in cc phi c bn cao v mt mt nhit l nh nht.

-B phn c kh nng h in cc : nm trong mi in cc, mi b phn gm 1 ng c in, khi ng c quay th u dy cp ko b phn in cc ln xung, u dy cp kia ni vi i trng . i trng c dng cn bng t 70 -80% trng lng ca in cc , dm ngang , ct chng v cp mm , do b phn nng h in cc i hi cng sut nh . Thng c hai loi b phn nng h in cc : loi tr thng ng c nh c xe trt trn n, loi c ct trt vo nhau -B phn c kh nghing l : phi m bo vic nghing l phi m , khng va p, c th nghing 450 rt kim loi vo thng , rt v nghing 10- 150 v pha ca npliu tho x. C th iu khin tc nghing mt cch d dng, gim bt vic di chuyn, thng rt nhiu ln trong qu trnh rt. Pha t v tr an ton, khng b kim loi phun bn. C hai loi c cu nghing l chnh : b phn nghing l t bn hng v b phn nghing l t di y. Vi l h quang 50tn, ta dng b phn nghing l di y. B phn ny c cc u im sau : nghing l vng chc, m, u v t ng hon ton, khng nh hng n khu vc lm vic ca cng nhn khi nghing khng lm lch tm l. Bn cnh , cng c cc nhc im nh : hay b ri x, kim loi lng ln ng c, thng xuyn m bo m sch s v kh ro khu vc t b phn c kh nghing l th n mi c th hot ng tt, trc khi l chy cn c ngi kim tra in cn thn. B phn np liu : c hai phng php np liu : dng my np liu v dngthng np liu. Vi l h quang 100 tn, ta khng s dng dng my np liu m dng thng np liu. y l phng php ch yu c dng trong cc lo hin i. Liu c np vo l t mt thng

liu pha trn ca l. Hin nay tt c cc l h quang hin i u c thit k theo kiu np liu t trn, phng php ny honton chnh xc Ngoi cc b phn c kh ch yu ni trn, trong l h quang cn c cc b phnph khc nh c cu nng np l, c cu quay np l, c cu quay thn l v bphn lc sch kh l. Trong cc l bnh thng, in cc s to nn 3 hsu trn mt liu trong qu.trnh nu chy, cn phn liu xa in cc th chy chm hn. Do cng ha qu trnh nu chy liu rn v trnh cho y l khng b qu nhit bi h quang th ngi ta c b phn quay thn l.

Chng 4: THIT K KCH THC L

1. Xc nh th tch ni l : Mt tn thp chim 1 th tch l 0,145m3 (th tch ring ca thp l Vokl = 0,145m3/tn) Mt tn x chim th tch l 0,333 m3 (th tch ring ca x l Vox 0,33 m3/tn) V l h quang dng x baz v c dng gang trong phi liu nn chn g x = 0,15 g KL Nn th tch l: V = Vkl + Vx = gkl . Vokl + gx . Vox V = 80.0,145 + 80.0,15.0,33 = 15,56 ( m3) 2. Chiu su v ng knh ni l: Khi tnh ton cn cc iu kin sau : Hnh dng ni l : cu cn

Mc x lc oxi ho trng vi mc ca s cht liu v c D/H = 5 vi D, H l ng knh v chiu su ca ni l Chiu cao phn l l hnh cu : h1 = 0,2 H Th tch ni l
V=h23R2+Rr+r2+h1r22+h126

Vi R = D/2, r = (D 2h3) = 1,7 H, nn ta c: V = 12,1 H3= 15,56(m3) Chiu su ca ni l: H = (15,56 / 12,1)1/3 = 1,087 (m) = 1087 (mm) ng knh ca ni l: D = 5H = 5435(mm) Bn knh ni l: R = D/2 =2718 (mm) Kch thc phn cong hnh cu y l: d = 3,4H = 3696(mm) Chiu cao phn l l hnh cu : h 1 = 0,2 H = 217 mm Chiu cao h2 : h 2 = 0,8 H = 870 (mm)

3. Kch thc khng gian nu luyn : Chn tng ca l thng lm cao hn mc ca np liu t 100 200mm xkhng tip xc vi lp gch xy ca tng l. ng knh ca khng gian nu chyc tnh mc ny. Ta c: DKG = D + 200 = 5435 + 200 = 5635 (mm) Chiu cao t ngng ca s n ming trn l : H1= (0,4 0,45 ) DKG Khi xc nh chiu cao ca khng gian nu chy H1 t ngng ca liu n chnnp l cn ch cc c im sau : chiu cao tng l H1 m tng th tui th np ltng theo do xa ngn la h quang, ng thi nu luyn c liu nh, th nhng bmt mt mc nhit ca l s tng ln. Tuy nhin ngi ta thng cho np l xa b mtkim loi v s gim c thi gian dng l tu sa v ci thin c mt s ch tiukinh t k thut H1 = 0,45 DKG = 2536 (mm) nghing ca tng l ; x=H1-10010=2536-10010=243,6(mm) ng knh khng gian nu luyn D1= DKG + 2x=5635+2.243,6=6122(mm) Chiu cao vng np l :
h3=DKG8=704(mm)

Chiu cao tng cng t mt kim loi n np l l H2 : H2 = H1 + H3 = 2536 + 704 = 3249 (mm) ng knh np l: D1 = 10 H3 = 10 . 704 = 7040 (mm) ng knh y ni l: d = D 2h2 = 3,4 H = 3,4 . 1087 = 3696 (mm) ng knh trong DT = DKG+ 2.tng= 5635 + 2. 600 = 6835(mm) Chiu dy lp thp thp = (1/200 1/250).DT = 27,34 34,17 ta chn thp = 30(mm) ng knh ngoi DN = DT + 2. thp = 6835 + 2.30 = 6895 (mm) Chiu rng ca l: bc = (0,2-0,3)DKG = 1408(mm)

Chiu cao ca l: hc = (0,7-0,8)bc = 1056 (mm) dy np l :np l=340(mm) dy tng l tng l=520-620 (mm) dy y l : y l= 850 (mm)

Chng 5: TNH TON PHI LIU

Nu Luyn Thp 14CrMnSi Thnh phn mc thp: Mc C Cr Mn Si P S Cu Ni

14CrMnSi

0,11-0,16 0,14

0,5-0,8 0,65

0,9-1,2 1,05

0,4-0,7 0,55

<0,03

<0,03

0,3

0,3

Thnh phn nguyn liu: Thnh phn Loi liu C Cr Mn Si P S Cu Ni

Gang

3,0-3,4 (3,2)

0,4-0,6 (0,5)

1,8-2,2 (2)

0,4-0,6 (0,5)

0,1-0,2 (0,15)

BCT38

0,14-0,22 (0,18)

0,4-0,65 (0,5)

0,12-0,30 (0,21)

0,04

0,05

FeSi75

0,03

0,7

75

0,05

0,4

FeMn75

75

0,038

0,03

FeCr65 FeNi98 ASTM B111, B171

0,6 -

65 -

0,07 -

0,04 -

98

1.25

0.4

88.35

10

Chy hao cc nguyn t trong l in h quang luyn thp ( bng 2) : Thi k nu chy Fe Mn Si Cr P S 2 - 5% 50 - 70% 50 - 75% 5 - 10% 20 - 40% Thi k oxy ha 8 - 10% 10 - 15% 50 - 80% 10 - 20% 15 - 20% 30 - 40% Thi k honnguyn 15 - 20% 2 - 5% 70 - 80% -

Thp vn: 95% Gang: 5% -Tnh lng Fero mangan: [Mn]liu=(0,5.95+0,5.5).10-2 =0,5% Lng Mn thiu: GMn =( [Mn]trong mc [Mn]liu.(100-60)(100-12,5).10-4).100 = (1,05-0,5.0,35).100=0,875kg Lng Ferro mangan cn dng: GFeMn75 = 0,8750,75.0,85=1,37kg Chn 1,2kg (cn dng 960 kg trong m 80 Tn)

-Tnh lng Ferro Silic: [Si]liu = (0,21.95+0,2.5).10-2 =0,2% Lng Si thiu : GSi =( [Si]trong mc [Si]liu.(100-62,5)(100-65)(100-17,5).10-6).100 = (0,5 0,2.0,11).100=0,478 kg Lng Ferro Silic cn dng: GFeSi75 = 0,4780,75.0,75=0,85kg Chn 0,75 kg (cn dng 600 kg trong m 80 Tn ) -Tnh lng Ferro Crom: [Cr]liu = 0% Lng Cr thiu: GCr =( [Cr]trong mc [Cr]liu.(100-7,5)(100-15)(100-3,5).10-6).100 = 0,65.100 =0,65kg Lng Ferro Crom cn dng: GFeMn75 = 0,650,75.0,75=1,16kg (cn dng 928 kg trong m 80 Tn)

-Tnh lng Ferro Niken: [Ni]liu = 0% Lng Ni thiu: GNi = [Ni]trong mc = 0,3.100 =0,3kg Lng Ferro Niken cn dng: GFeNi98 = 0,30,98.0,99=0,31kg (cn dng 248 kg trong m 80 Tn) - Tnh lng Cu cn cho vo: [Cu]liu = 0% Lng Cu thiu: GCu = [Cu]trong mc = 0,3 .100 =0,3kg Lng Cu (ASTM B111, B171) cn dng:

GCu = 0,30,88.0,96=0,36kg (cn dng 288 kg trong m 80 Tn) ***Kim tra li thnh phn cc nguyn t trong mc: [C] = (3,2.5+0,18.95+0,6.1,16+1,25.0,36).0,85.10-2 =0,29% %C cn tnh cho m l: %Cmac + 0,35% = 0,14 +0,35=0,49% Lng C cn thiu 0,49-0,29 = 0,2% Vy b sung CGraphit =0,20,98.0,7=0,29kg (cn dng 232 kg trong m 80 Tn) [Si] = (2.5+0,21.95+75.0,75+2.1,2 )0,75.10-2=0,66% [Mn] = (0,5.5 +0,5.95 + 0,7.0.75+75.1,2+0,36.0,4).0,7.10-2 = 0,985% [Cr] = (0,03.0,75 + 65.1,16).0,95.10-2 = 0,71% [Ni] = (0,31.98 + 10.0,35).0,99. 10-2 = 0,335 % [Cu] = (88,35.0,36).0,99.10-2 =0,31 % Vy Si,Mn,Cr,Ni,Cu nm trong gii hn mc thp

Chng 6: TO X
+ L h quang to x bazo kh S v P tt. + Thng dng vi (CaO) v dolomite (MgO), hunh thch (CaF2), qung st, samot,gch manhezit ca tng l b bo mn, Na2O. + Cht to x vo ngay trong liu. + Co x v to x nhiu ln ( khong 3 4 ln). Bng thnh phn tr dung: Vt liu Vi Hunh thch Manhezit Tro dcc Gch inat Samot SiO2 2,3 3,6 3 46 94 62 Fe2O3 2,2 1,5 2 18 1,1 2 Al2O3 0,8 0,2 1 26 1,6 35 CaO 91,3 1 10 2,5 0,7 MgO 3,3 92 0,8 0,3 MnO 1 CaF2 94,2 S 0,1 P CaC03 0,5 FeO -

Qung st Vy cn Than cc

3,8 1,75 51

81,2 35,57 7

1,2 0,62 35

0,2 1,4 5

0,2 0,62 -

0,7 1,43 -

0,1 -

12,6 56,8 -

a. Thi k oxy ha to x oxy ha kh P, tp cht: 2[P] +5(FeO) = (P2O5) + 5[Fe] 4(CaO) + (P2O5) = (4CaO.P2O5) Nn 2[P] + 4(CaO) + 5(FeO) = (4CaO.P2O5) + 5[Fe] Nn cn to nhiu x cha nhiu FeO v CaO. iu kin kh P tt: + % (FeO) cao, thi oxy (cho qung st vo). + baz cao B = (CaO + FeO)/ SiO2 = (2 3) + Dng h x: CaO SiO2 FeO MgO (tng ng l 35 45%; 20%; 15 20%;10%). Cho thm CaF2 tng chy long, SiO2 c trong x do chy hao Si trongkim loi lng v trong nguyn liu to x. + nht thp = 2 6 . + Cn to x sm ngay t u. Trc khi cho liu vo ta ri 1 lp vi (1,5 2 tn) + Co x v to x nhiu ln (khong 3 4 ln) . b. Thi k hon nguyn to x hon nguyn: (CaO) + [S] = (CaS) +[O]Ks = 0,04 [S] = S1/(1 + Ls . gx/100) Vi S1 : hm lng S c trong liu kim loi. gx : lng x tnh bng % lng liu np vo l Ls = (S) / [S] : h s phn b ca lu hunh. CaO l thuc kh S ch yu. Kh nng kh ca MnO v MgO km hn nhiu.Nn cn lng CaO trong x cao. Ngoi ra hm lng (FeO) nh hng mnh n [S],cn to x c hm lng (FeO) cng nh cng tt (< 1%). Ta phi co ht x oxy ha to x mi. iu kin kh S tt : + baz cao B = (CaO + FeO) / SiO2 = 3 4 . + (FeO) t 0,1% n 1% . + X c dy tt, khong 2 3% lng kim loi. + Co x v to x nhiu ln v nguyn liu cha nhiu lu hunh ( do nhiu gang) c. iu chnh x: + chy long : iu chnh lng Samt hay CaF2 + kim : tng kim bng cch tng lng CaF2, qung st.

+ Co x v to x mi. X to ra c th lm vt liu xi dng nh Clinker, xi mng Portlang, gch d. Ch : Si trong gang nhiu th cn lm lng cht lm ngui v tr dung tng nn x tngnn SiO2 trong x tng nn Oxit st mt (trong x) tng nn gim sut thu hi vgim bn p lt. - Hm lng Si cao s lm xu n s kh P v S nhng khong s dng gang c Siqu thp s lm kh hn trong s hnh thnh x. - Hm lng Si thp th s ha tan vi vo x thp lm ko di thi k khng x vou lc nu d gy chy ng gi.Hm lng Si trong gang ti u l 0,3 0,5% -Hm lng Mn nn chn theo phi liu. Tng Mn th d kh S v to x. - S trong gang mong mun ti u l 0,04 0,05% khng vt qu 0,07%P khng vt qu 0,15%.Vi s dng trong to x, cn dng vi mi nung, thnh phn ng nht, kch thc 60 100 mm. Lng m S 0,1 0,2% , Si 0,2 0,5%, gim lng vi mt mt. - Hunh thch, boxit dng lm x long: + Boxit: 35 37% Al2O3 ; 10 15% SiO2; 12 15% Fe2O3 v ch s dng khikhng c hunh thch + Hunh thch: SiO2 5% ; 1 3% CaO ; cn li l CaF2

Chng 7: QU TRNH NU LUYN

Gm cc giai on: + V l. + Cht liu. + Nu chy. + Qu trnh oxy ha . + Qu trnh hon nguyn v hp kim ha.

1. V l:
a. Yu cu khi v l : Khi l mi xy th kch thc v hnh dng ph hp thc t, nhng trong qu trnhnu luyn th lp lt ca l b n mn ca x lng v kim loi lng do c nhit vhot tnh cao. Ngoi ra, y l cn b ph hng khi np liu dng cc ln hoc y lb qu nung khi in cc qu gn y trong khi lng kim loi lng cn qu t khng bo v y l. V vytrc khi nu luyn cn phi lm sch ni l v v l cnthn. Cn ch mt s c im sau :

Trc khi v l cn co sch x v thp cn ng li trong l. Nu x trn ln vovt liu v l s lm gim chu la ca y l Khi l h th kim loi lng v x ng rn rt nhanh nn cn phi lm sch l cngnhanh cng tt, tranh th v l lc nhit cn cao (khong 700-900oC). V l ng ch, nhng ni no b bo mn su th va v va nn cht. Lp vkhng c qu dy, ti a l 30mm.Sau khi v xong, dng xng san bng lp v, lm cho y l c hnh dng nh c. b. Nguyn vt liu dng v l: - Bt manhezit cha 90% MgO, c ht 0.8-1.5mm dng v l v chn tng cc ch h hng nh. - Khi cn v nhng ch h hng ln th dng hn hp bt manhezut v 5-10%nha nghoc thy tinh lng. Ngi ta cng c th dng bt manhezit vi ncthy tinh. c. Dng c v l : - Vi l 100 tn, ngi ta v l bng my dng kh nn, a quay nn cc vtliu v l vo ch cn v. Ngoi ra cn c th dng xng v l nhng khng cng u, cng nhn vt v.

2. Cht liu :
a. Yu cu: - Liu phi c cht sao cho nu chy liu nhanh nht, thi gian nu chy vcht liu chim 50% thi gian nu luyn ca m thp. - Liu c xp st chc, m bo cht c nhiu v truyn nhit tt. - Cc loi liu kh chy, cc to nn cht vo vng di in cc. - Sau khi v l xong, cht liu vo l ngay, ban u cho 1500 2000 kg vi voy l to x sm v trnh liu va p mnh vo l khi th liu t trn xung. b. Phn b liu : - T l ti u gia kch thc cc cc liu nh sau : 15% liu nh, 45% liu trungbinh, 40% liu ln. - Th t np liu nh sau: + Trc ht ph di y l bng mt na lng liu nh bo v y l khib hng khi cc cc liu ln ri xung. + K l mt lp cc, tip theo l mt lp liu ln, ch t ngay di incc, trn lpliu ny v st tng bn l liu c kch thc trung bnh. + Cui cng ngi ta np phn liu nh cn li vi gang vn di cng. Vicch np nh

th ny, liu s rt st, dn in ca liu tt hn, rt ngn thi giannu chy. - Vn in cc, cht to x cng c cht cng vi liu. Cht liu vo l : cht liu t trn xung, y l phng php cht liu tt, bo mnng sut cao, thit b cht liu n gin. -Khi np liu m ra, cn trc a thng cht liu vo l v y thng c mra, liu trong thng ri xung y l.

3. Nu chy:
Giai on ny bt u khi cht liu xong n khi chy lng hon ton. Theo quytrnh cngngh c giai on si th giai on nu chy chim 50% m nu. y lgiai on quyt nh nng sut l v tiu hao in nng. a. Trnh t nung chy liu : Sau khi nung chy liu, in cc c h xung v ngi ta thng in vo l. Hquang pht ra c nhit rt cao(3000-4000o) v lm chy liu. Qu trnh nungchy liu gm 4 thi k : -Thi k 1: khong 10-15 pht sau khi thng in vo l. H quang pht ra s bc x mt phn ln mt liu, phn ln bc x ln nh l, tng l. Trong thi kny khng nn s dng cng sut in ln v tia h quang khng n nh, d gy hhng tng v nh l. -Thi k 2 : khong 15-20p sau khi thng in vo l. Mt s liu rn di chnin ccchy lng v t xung y l, li trn b mt in cc nhng ci h. in cc cm su xung h, tia h quang pht ra trc tip vo liu, ct liu tut dn, nhit t mi pha truyn vo liu. -Thi k 3 : sau khi thong in vo l c 1h15 pht n 1h30 pht th cc hpht trin c b rng ln b su, mc kim loi lng tng nhanh, h quang pht rac liu che kn. Lc ny nn a vo cng sut in ti a rt ngn thi giannu chy. Thi k ny, h quang pht ra ting ku m, la v khi nu bc ln nhiutrn nh l. -Thi k 4 : trong thi k ny, kim loi lng chim n hoc hon ton,ch cn mt t cc liu nm st tng hoc bn hng l. Thi k ny cn y nhngcc liu ny vo b kim loi lng. in cc cch xa mt kim loi, h quang pht ram, la v khi trng xut hin nhng ngn la khng cao nh thi k 3.Trong giai on ny to x sm rt quan trng ,gip pht h quang n nh , tngnhit kim loi, gim chy hao, hp ph kh vo kim loilng,v to iu kinkh P. tranh th kh P ta cho qung st v vi. Tng lng vi ln,v tng lngqung st (FeO) = 15 20 % th kh P t hiu qu nht. Cui giai on ly mu phn tch hm lng C, P, S

Nu hm lng P cn nhiu th co x v to x mi nhiu ln. H cng sut chuyn sang giai on oxy ha (P = 60 65% Ph quang ) b. Cc bin php rt ngn thi gan nu chy: - Nung liu trc. - S dng ch in cao, hay siu cng sut. - Thi oxy vi p lc 10 20 atm. - Thi du, kh thin nhin. - Dng gang lng t l cao. - Nu phn liu gm cc liu nh th c th s dng mc in th ti a ngay t u

4. Giai on oxy ha :
Giai on ny c nhim v ch yu l: + Kh P, kh N2, kh H2 v tp cht phi kim + Kh C n gii hn cho php ( nh hn 0,03 1% so vi mc thp yu cu). + Nng nhit kim loi. + Nu nguyn liu sch th c th chuyn sang giai on hon nguyn. Vic kh C rt quan trng , l ng lc lm b kim loi si, kh kh, tp chtphi kim, cithin vic trao i cht v nhit trong l, lm ng u thnh phn vnhit . L bin phpchnh tinh luyn oxy ha, quyt nh ln n cht lng v snlng thp . tin hnh oxy ha kim loi ta dng ng thi cc bin php : cho qung st v thi oxy do: Thi oxy th tng nhit nhanh, rt ngn thi gian, tng nng sut l, tit kimin nng,khuy trn kim loi rt tt, kh c cc kh c hi. Nng FeO cng caoth tc kh C cng cao. Ta c th tng nng FeO bng cch dng qung st hocthi oxy vo l. Cc phn ng xy ra: 2 [C] + O2 =2 {O2} Hay: 2 [Fe] + O2 = 2 [FeO] 2 (FeO) C + (FeO) = {CO} + [Fe] Hay:[FeO] + [C] = [Fe] + {CO} Ngc li bin php ch cho qung st: kh P v tp cht tt do hm lng (FeO)cao, nhit tng chm, ko di thi gian. Cc phn ng xy ra: Fe2O3 = 2 FeO + 0,5 O2 [ FeO] + [C] = [Fe] + {CO} P l nguyn t c hi, hm lng P cao trong thp s lm gim dai va p, bn,

 cng v lm tng gin ngui ca thp. Trong kim loi, P b oxy ha theophn ng : 2 [Fe3P] + 5(FeO) = (P2O5) + 11 [Fe] (P2O5) + 3 (FeO) = (3 FeO . P2O5) P2O5 v 3FeO. P2O5 l cc hp cht khng bn, chng d b phn ha nhit cao v P ha tan tr li vo kim loi. V vy ngi ta phi cho thm CaO to hpcht bn vng v i vo x theo phn ng : (3FeO . P2O5) + 4 (CaO) = 4 (CaO.P2O5) + 3(FeO) Ngoi ra, hm lng SiO2 cao cng gy tr ngi cho vic kh P v n c th tcdng vi CaO to 2CaO.SiO2. Kt qu l P i tr vo kim loi lng. Ngoi ra nht thp th qu trnh kh P cng thun li. Do c th kh P cui giai on nu chy v u giai on oxy ha, lc nynhit tng i thp, khong 1500oC Kh kh v cc tp cht phi kim loi : trong giai on si, kim loi c khuytrn, cc bt kh Co l trung tm kt t cc kh khc v cc tp cht phi kim. Kh Cothot ra mang theo n cc kh N2, H2 v cc tp cht khc cng ni ln x. V vy,trong giai on oxy ha, kim loicng si mnh lit, x cng long th cng to iukin kh kh v tp cht nhanh, trit . u tin ta tho x c v to x mi gm: vi, dolomite, SiO2 ,Al2O3. Sau khi xchy long th cho qung st vo. Chia lm 3 t, mi t 1 tn qung st trnhgim nhit t ngt. Ly mu phn tch C, P, S. Nu [P] cn cao th ko di thi gian v thay x. Khi pt c hm lng [P] < 0,015% th thi oxy vi p sut t 10 20 atm t np lxung b kim loi tng tc oxy ha, tng nhit . Chuyn sang giai on honnguyn.

5. Giai on hon nguyn v hp kim ha:

Giai on hon nguyn l giai on quan trng trong qu trnh luyn thp, n cnh hng quyt nh n cht lng thp nu luyn. a. Nhim v giai on hon nguyn: - Kh oxy ca cc oxyt FeO, MnO, SiO2nhng ch yu l kh oxy ca oxytst v hm lng ca chng ln, s tn ti ca n nh hng rt ln n cht lngca thp. - Kh S n gii hn cho php. - Tinh luyn v hp kim ha thp. - Kh cc kh hidro, nit trong thp. - Khng ch thnh phn v nhit kim loi, v sau tho thp ra c. b. Trnh t tin hnh cc giai on hon nguyn :

- Sau khi co x oxy ha xong, ngi ta gim mc in th s dng. Lc ny kimloi rt nng, nhit bc x ln, cn a cng sut in thp vo l. - m bo hon nguyn tt, ngi ta ln lt cho cht kh oxy yu vo ltrc, sau l loi trung bnh, cui cng l cht kh mnh. Vy, u tin ngi tacho FeMn75 vo trc kh oxy s b, tip theo l FeSi v cui cng l Al kh oxy trit . Trong giai on hon nguyn, vn kh oxy c t ln hngu. - Cc phn ng kh S thc cht xy ra song song vi cc phn ng kh oxy. Saukhi kh oxygn xong th cho cht to x nh vi, hunh thch tng baz vtnh chy long ca x, to iu kin kh S nhanh. Trong giai on ny, vic kh Srt tt, lc ny, cc cht kh cnli nh Mn, CaO,C, CaC2, CaF2s tp trung vocc phn ng kh S. Cc phn ng kh S xy ra nh sau: C + [FeS] + (CaO) = [Fe] + (CaS) + {CO} C + (MnS) + (CaO) = [Mn] + (CaS) + {CO} 3 (FeS) + (CaC2) + 2 (CaO) = 3 [Fe] + 3 (CaS) + 2{CO} 2 (FeS) + 2(CaO) + SiFeSi = 2 [Fe] + 2 (CaS) + (SiO2) 2 (CaF2) + 2(FeS) + SiFeSi = 2[Fe] + 2 (CaS) + (SiF4) - Trong cc phn ng c to ra kh CO kh bay ra khi kim loi. khc phc,ngi ta c th tng cng khuy trn kim loi, m ca l CO thot ra d dng. - baz ca x cng cao v x cng chy long th hiu qu kh S cng cao. - Nhit cng cao th kh S cng tt v kh nng ha tan ca Ca Strong x tngln, qu trnh khuch tn n cc vng phn ng tng ln. - Tng tc khuch tn ca [FeS] vo trong x bng cch tng nhit kim loi. - Nung sy cc loi ferro hp kim v cc cht to x trc khi cho vo l. - Khuy trn kim loi tng kh nng kh S. - Dng x tng hp vi cc thnh phn nh sau: 53% CaO, 43% Al2O3, 3% SiO2,1% FeO lc kim loi. -Va xo trn kim loi bng x tng hp, va thi kh argon vo kim loi lng. c. Hp kim ha: -Cho nguyn t hp kim phi ng thi im, s lng, cc. - cc FeSi75 l 30 35mm, FeMn75 l 55 60 mm. Nung Fero n 700 8000Cri mi cho vo l. -Lng FeSi75 v FeMn75 cho vo giai on ny( tnh phn phi liu).

KT CU THNG RT
1.

V ngoi:
V ca thng rt hn hoc tn bng thp tm, v hn nh hn v tn 15-20%. V hn

va tit kim kim loi, va c th lm tng dung lng thng rt ln 2-3% vi iu kin khng tng kh nng trc ca cu trc. Hin nay cc thng rt hn c dung lng ln nht l 300T. chiu dy ca v, tnh theo lc m tm thp chu ng(bao gm nhit ng lc) khi thng mang ph ti ln nht, chiu dy ca v thng rt loi va v to l 14-28mm .V thng cn khoan nhng l thot hi ng knh 20mm. Tai trc dng nhc thng, hn (hoc tn) vo v ngoi. ng knh tai trc tnh theo lc ct ca gc trc v ph ti ln nht. V tr tai trc thng cao hn trng tm thng (khi ng thp lng) 350-400mm, thng rt n nh bt c iu kin cng tc no. Trn ming thng rt c ming tro x, thng ming ny thp hn mp trn 100200mm, v tr ca n cn trnh tai trc. Dung lng thng cn p ng yu cu l khi thp lng trong thng vt qu 10%, vn c th cha c lng x bng 3% lng thp lng. thng rt p ng c yu cu m rng l, thng dng 1 s bin php sau: cha thng rt thnh hnh bng cch tn thnh loi thng hn, cha thng trn thnh hnh bu dc (li dng tay trc c sn) vch thng xy mng 1 cch thch ng hoc ni cao thng rt

2. Tng thng rt:

Vch thng rt xy bng gch chu la sa mt bn acid hoc baze. Thng dng nht l gch sa mt. Chiu dy cao phn ca vch thng xem bng chiu dy vch thng. Tng gch trong thng khng nn t qu 2 tng, 1 l tng cng tc, 1 l tng bo v. y thng khng t qu 3 tng.

Tui th ca thng xy bng cc gch tnh cht ging nhau nhng hnh dng khc nhau, s rt khc nhau, l v hnh dng v kch thc cc k gch khc nhau m k gch l ch yu nht ca vch thng. Dng gch hnh cong vn nng c th rt ngn thi gian xy, k gch b, kh b tut v co th xy cc thng c ng knh bt k.

Dung lng thng (tn) dy

Phn di Chiu gch xy (mm) Chiu cao (mm)

Phn gia Chiu dy gch xy (mm) Chiu cao (mm)

Phn trn Chiu dy gch xy (mm) Chiu Cao (mm)

Chiu dy y thng (mm)

10 25 50 90 130 200 260

140 180 180 220 220 300 330

685 870 1312 1160 1457 1500 1500

140 140 140 180 225 250

750 600 750 900 1800 1800

125 125 125 125 140 145 170

750 456 510 758 970 950 1050

185 240 230 265 315 390 410

Tui th ca vch thng thng 15-20 ln s dng. Nhn t nh hng n tui th ca thng l: tnh cht ca x ( bazo ca x, lng FeO v MnO ), thnh phn v nhit thp lng, thi gian thp lng v x lu li trong thng, tc ngui v ch nung nng thng, cht lng xy gch v cng tc bo qun,Vch thng rt d bi thp lng v FeO v MnO ca x n mn, v Feo v MnO c th cng gach samot to thnh cht ha hp c im nng chy thp. Nn khi c thp si, tng l b n mn nhiu, khi c thp Mn cao th li cng nghim trng. Thc hnh c nhanh, gim thi gian gi x v thp li trong thng cng c th nng cao tui th ca thng.

Nng cao lng Al2O3 trong gch sa mt, c th nng cao c chu nng ca n. V vy, nu s dng gch aluymin cao, mn chc, c xp <12%, th c th nng cao c tui th ca thng mt cch r rt. nc ngoi nghin cu dng thng gch samt graphit kt qu chng t loi gch hn gch samt v chu nng v tnh chng x. Nhng v khng tm c nguyn liu thch hp, nn cha dng rng ri trong sn xut. Vch thng tnh baze-gch manhzit hoc lmit c u im l chu nng cao, tnh chng x tt, baze ca x khng b h thp, nn c th gim bt c hin tng P v S tr li trong thp. Nhng gch tnh base dn nhit tt, thp lng trong thng tn nhit v h nhit nhanh, d kt bu gn ng x, cn ra bng hunh thch hoc crilit, thp st li trong thng nhiu, tnh chu nng lnh t bin km v t. V vy hin nay khng dng vch thng baze. y thng gn thnh thng mt ci l nht gch rt. Khi c thp lng i qua l ca gch rt (ming rt) chy vo ng rt gia hoc khun c. Tay nt bc gch chu nng c tc dng ng m ming rt v iu tit dng thp. V vy tay nt v gch rt l b phn quan trng ca thng v cng l mt nhn t quan trng nh hng n cht lng ca thi thp. C hai cch lt gch rt: lp trong thng v lp ngoi thnggch rt gm nhiu loi gch samt, samt alumin, samt graphit, manhzit v sa mt lt manhzit.l ba loi gch rt samt lt manhzit khc nhau: Gch rt samt c chu nng thp, chng x km, trong qu trnh c thng b n mn nghim trng nn kh ng kn tay nt. Nhng ng knh gch rt c th dn dn t m rng b khuyt c hin tng p lc thp lng trong thng b gim, lm cho tc rt tng i u n, v u im m loi gch ny vn c s dng. Gch rt manhzit v tnh dn nhit tt, thp lng d b ng li ming rt phi thm thao tc dng oxy t bu. Dng gch rt tm qua du cc hoc hc n c nhng u im sau: +Kh kt bu. +C th trnh c hin tng nt gch. +Chu c va chm ln. Gch rt alumin c chu nng cao, tnh chng x tt v gi c u im ca gch samt l dn nhit km, l nguyn nhn ngy cng dng gch rt alumin cao thay th cho gch sa mt. N bao gm u im ca gch samt lt manhzit v c ca gch manhzit, samt manhzit Chn loi gch lt v u nt no, ch yu phi xt n thnh phn ha hc ca thp lng v thi gian c mi thng. Thi gian rt cng di, an mn cng nhiu, khng nn ng

thi dng ming rt v gch nt bng samt, v im bin mm ca chng rt thp d dnh vo nhau, khi nng tay nt phn hnh cu ca u nt c th b v ra. Khi dng gch nt samt v ming rt manhzit th khuyt im tren gim nhiu. ng knh ming rt to nh xc nh theo tc rt. Cho nn ng knh gch rt c lin quan n loi thp, kch thc thi v phng php c. i vi thp m tnh chy long km ng knh l rt l 60mm ;i vi thp hp kim thp v thp lng cacbon.l 45-60mm; i vi thp si l 30-40mm
3.

Tay nt:
Tay nt gm ba phn :thanh li, gch bc v u nt Thanh li lm bng thp trn, ng knh ca n ph thuc vo cng bn nhit

cao. Hin nay thanh li loi ln cc xng dng c ng knh l 40-50mm Ngoi thanh li phi bc gch bo v cho thanh li khng b thp lng v x n mn. Thng dng gch bc sa mt. bo m ch ni c kn, khe h gia gch bc cn phi xy bng bt va cht lng tt, cn phi chn lc gch bc cht lng hp cch v hnh dng chnh xc. Gch nt lp u ca thanh lilm thnh cng vi ming rt 1 ci van ng m. V vy gch nt l phn quan trng nht ca tay nt. C hai phng php ni gch nt vo thanh li .;dng c hoc cht; mi loi u c u khuyt ring nhng cng xng thng dng loi u. Gch nt c loi lm bng sa mt v samt alumin cao(cha Al2O3 n 42%) v sa mt graphit. Trong gch nt samt v samt alumin cao l c dng rng ri nht. Gch nt samt alumin cao tt hn gch sa mt. Gch samt graphit ch to kh hn, gi thnh cao, ch dng khi c thp c bit. Tay nt lm xong phi sy 2 ngy m mi c dng, khi sy tt nht l treo ln khi b cong Thng tay nt do nhn cng thao tc qua 1 h thng n by.. c xng dng thit b c t ng, 15 l mactanh dng chung 3 my c. Qu trnh c iu khin t xa bng thit b nn dung dch. p lc lm vic c th n 15-60 atm, bo m khi ng nt c 1 lc l 400-2800kg ,khi m tay nt sinh ra 1 lc l 570-2250kg. Thit b rt d khng ch. Phng php c t ng khng ch t xa ci thin 1 cch r rt iu kin lao ng, nng cao nng sut, cn ph bin dn dn.

Ti liu tham kho

1. Bi ging trn lp. 2. Sch K thut l in luyn thp. 3. Sch K thut sn xut kim loi. 4. n cc nm trc. 5. Sch tra cu mc thp.