Manganese-silicon alloy powder recycling process and system thereof

Abstract

The invention discloses a manganese-silicon alloy powder recycling process and system, and aims to realize efficient recycling and reutilization of manganese-silicon alloy powder. The process comprises the steps that manganese-silicon alloy powder and silicon-iron powder are mixed according to a preset proportion and added into a direct-current electric arc furnace to be smelted, the mixture is melted through electric arc heat and resistance heat, and the effects of desulfurization and uniform components are achieved; voltage and current parameters are controlled, the height of the charge level in the furnace is kept unchanged by continuously adding the mixture, and stable smelting is ensured; and after smelting is completed, deslagging and discharging of the liquid ferromanganese alloy are conducted, then cooling, crushing and screening are conducted, and a qualified ferromanganese alloy finished product is obtained. The system comprises a mixing device, a direct-current electric arc furnace, a tapping device, a cooling system and a crushing and screening device, and automatic control and efficient product recovery in the smelting process are achieved. The method has the beneficial effects that the resource utilization rate is increased, the smelting process is optimized, and the method has the characteristics of high efficiency, environmental protection and low cost.

Description

Technical Field

[0001] The invention relates to the field of smelting, and in particular to a manganese silicon alloy powder recycling process and a system thereof. Background Art

[0002] In the production process of silico-manganese alloy, the ore and auxiliary materials are first put into the submerged arc furnace for smelting, and then the liquid iron is cast. After the silico-manganese alloy is cooled and solidified, it is crushed into 50mm x50mm blocks according to customer needs, and packaged before shipment. In this crushing process, a certain amount of silico-manganese alloy powder is inevitably produced. It is estimated that the output of these powders accounts for about 14% of the total output of silico-manganese alloy, and its sales price is only 80% of the finished silico-manganese alloy.

[0003] Due to the large production capacity of manganese silicon alloy and the relatively small market demand for manganese silicon alloy powder, coupled with its low price, the market sales of manganese silicon alloy powder are not ideal. In the industry, the common practice is to use these powders as base materials in the alloy casting process to reduce waste. However, some companies have tried to use medium frequency furnaces to remelt the powder, but this process requires the powder to have a higher grade. Therefore, manganese silicon alloy manufacturers often have to store a large amount of manganese silicon alloy powder. Summary of the invention

[0004] In order to solve the above technical problems, the present invention provides a manganese silicon alloy powder recycling process and system.

[0005] The present invention is achieved through the following technical solutions: A manganese-silicon alloy powder recycling process of the present invention comprises the following steps: S1: Put the manganese silicon alloy powder and ferrosilicon powder into the mixing bin and mix them evenly; due to the different physical properties of manganese silicon alloy powder and ferrosilicon powder, there may be different particle sizes or density differences, so the two raw materials must be fully mixed during the mixing process to avoid segregation or local uneven composition during the smelting process. At the same time, in order to ensure the mixing effect, the mixing time and stirring speed can be properly controlled during mixing, and the uniformity of the mixture can be monitored through the control system. If necessary, multiple tests can be performed to ensure that the mixing effect meets the expected standards.

[0006] S2: Add the mixture into a DC arc furnace, use a rectifier transformer and a rectifier power supply cabinet to convert AC power into DC power, and introduce the current into the furnace through electrodes; compared with traditional AC arc furnaces, DC arc furnaces can provide a more stable arc, effectively reduce arc drift and energy loss, and improve smelting efficiency.

[0007] S3: The mixture is continuously melted by arc heat and resistance heat reaction, and the molten pool is stirred by arc to achieve the effect of desulfurization and uniform composition; the addition of ferrosilicon powder can help the desulfurization reaction at high temperature and promote the purification of manganese silicon alloy components.

[0008] S4: During the smelting process, the voltage level and current intensity of the electrode are controlled according to the set process parameters. Different voltage and current values ​​are used in different smelting periods, and it is ensured that the arc is not exposed from beginning to end; the arc is not exposed in order to avoid heat loss and the generation of oxides in the air.

[0009] S5: Continue to add new mixture to keep the height of the material surface in the furnace constant, the electrode is in a flat cone shape, and the gas escapes evenly from the material surface; S6: When the mixture is completely melted, slag is first discharged, and then the furnace eye is opened by the furnace eye opening machine to release the liquid manganese iron alloy; the purpose of slag discharge is to remove non-metallic impurities in the furnace and ensure the purity of the liquid alloy. When slag discharge, attention should be paid to controlling the time and temperature of slag discharge to avoid slag discharge too early or too late. In addition, the process of furnace eye opening should be coordinated with the pressure and temperature in the furnace to avoid splashing or gas bursting when the furnace is opened. The fluidity and temperature of the liquid manganese iron alloy should be kept in a suitable range to ensure the smooth progress of the casting process.

[0010] S7: The liquid ferromanganese alloy taken out of the furnace is lifted into a casting mold by a crane, crushed, screened, packaged and stored after cooling, to obtain a finished ferromanganese alloy.

[0011] Furthermore, the mass ratio of the above-mentioned manganese silicon alloy powder to ferrosilicon powder is 85-95:1. A reasonable mass ratio is an important factor in ensuring that the final alloy composition meets expectations. In order to improve the accuracy of the ratio, high-precision metering equipment can be used, and these equipment can be calibrated regularly to ensure long-term stable measurement accuracy.

[0012] Furthermore, the process parameters set above are as follows: smelting start-up stage: in the first 10 minutes of the initial stage of smelting, the electrode voltage is set in the range of 20 to 30 volts, and the current intensity is set in the range of 100 to 300 amperes to ensure that the temperature in the smelting furnace gradually rises to 500 to 800 degrees Celsius and prevent the arc from being formed and exposed prematurely; mid-smelting stage: when the smelting enters 10 to 30 minutes, the electrode voltage is adjusted to the range of 30 to 50 volts, and the current intensity is increased to the range of 500 to 1500 amperes. At this time, the temperature in the furnace gradually rises to 800 to 1500 degrees Celsius. The stability of the arc is maintained by gradually increasing the current intensity to promote the melting of the smelting material; late smelting stage: after the smelting time exceeds 30 minutes, the electrode voltage is adjusted to the range of 40 to 60 volts, and the current intensity is increased to the range of 1500 to 5000 amperes, so that the temperature in the furnace is maintained at 1500 to 1800 degrees Celsius to ensure that the smelting material is completely melted. This process plays a decisive role in the temperature control of the smelting furnace. The setting of voltage and current should fully consider the characteristics of the smelting materials and the target temperature range. In the smelting startup stage, the temperature should be avoided from rising too fast to prevent the arc from getting out of control; in the middle and late stages, the temperature should be steadily increased and the current intensity should be gradually increased to ensure that the material is fully melted.

[0013] Furthermore, the cooling step after smelting is performed by controlling the flow rate and temperature of cooling water, specifically, the flow rate of cooling water is maintained at 5 to 10 liters / minute, and the temperature of cooling water is controlled between 10 and 20 degrees Celsius to ensure slow cooling of the smelted material and avoid cracks or other defects. The control of cooling rate has a direct impact on the microstructure of the alloy, so by adjusting the temperature and flow rate of cooling water, stress concentration, cracks or other metallurgical defects caused by rapid cooling can be avoided.

[0014] A manganese-silicon alloy powder recycling system, comprising: 1. A mixing device, used to mix the manganese silicon alloy powder and the ferrosilicon powder evenly according to a predetermined mass ratio; 2. DC electric arc furnace, the DC electric arc furnace is a four-electrode periodic automatic commutation DC electric arc furnace; 3. The iron-discharging device, including the furnace eye opening machine and the crane, is used to open the furnace eye after the smelting is completed, release the liquid manganese iron alloy, and lift the liquid manganese iron alloy to the casting mold for casting; 4. Cooling system, used to cool the liquid ferromanganese alloy by controlling the flow rate and temperature of cooling water to ensure that the product cools slowly to avoid cracks or other defects; 5. Crushing and screening device, used to crush and screen the cooled ferromanganese alloy, and pack the qualified ferromanganese alloy powder into storage.

[0015] Furthermore, the above-mentioned mixing device includes several silos, conveying pipelines, a mixing tank, a stirring device and a control system; the above-mentioned silos are used to store different types of raw materials, and the above-mentioned silos are connected to the mixing tank through conveying pipelines; the above-mentioned stirring device is arranged in the mixing tank, and has the function of adjusting the stirring speed to adapt to different formula requirements and ensure that the raw materials are mixed evenly; the above-mentioned control system is used to monitor the raw material storage situation of each silo in real time, and control the opening and closing of the conveying pipeline, so as to realize the automation of the mixing process.

[0016] Furthermore, the DC electric arc furnace comprises a furnace body, an electrode system and a water cooling system; the furnace body is the electric heating reaction place of the electric furnace, the outer shell of the furnace body is welded from steel plates, a plurality of thermocouples are installed on the furnace body for temperature monitoring, a furnace bottom air cooling pipe is arranged at the bottom of the furnace body, a slag and iron outlet is arranged in the middle of the furnace body, and a chute is arranged on the slag and iron outlet; the electrode system comprises four electrodes, the electrodes adopt water-cooling protective sleeves, and are provided with electrode sealing guide devices, the electrodes are position-adjusted by a lifting device, and the lifting device comprises a column, a guide wheel and a hydraulic system; the water cooling system is used to cool the short smoke hood, the electrode system and the furnace outlet; the lifting device of the electrode system comprises a column, a rope pulley frame, a counterweight, a conductive cross arm, an electrode clamp, a clamping butterfly spring and a hydraulic cylinder; the conductive cross arm is made of copper-steel composite material, with water cooling inside, the electrode clamp is made of red copper forgings, and the butterfly spring for clamping the electrode is designed with high elasticity to ensure large clamping force, small contact resistance, and the electrode position is smooth. The electrode lifting device realizes automatic adjustment or manual control; the electrode sealing guide device adopts a water-cooling structure, and the guide sleeve has a hard and soft double-layer sealing design to ensure good insulation and sealing between the electrode and the furnace cover. The guide wheel is used to fix the electrode position and adjust the electrode distribution circle diameter during the electrode lifting process; the short smoke hood is fixedly connected to the upper part of the furnace body, and the position of the short smoke hood is located above the electrode and surrounds the electrode distribution area. A preset vertical distance is maintained between the short smoke hood and the electrode to ensure that the electrode does not interfere with the smoke hood when it is lifted or lowered; the short smoke hood of the furnace body is a 12-sided water-cooled structure, which consists of a skeleton, 12 edge cover plates and an anti-magnetic central furnace cover plate. The lower surface of the short smoke hood is sprayed with heat-resistant concrete. The short smoke hood is provided with an operating door, a smoke exhaust port and a flue. The flue is connected to a dust removal device to purify the flue gas generated in the furnace and discharge it into the atmosphere; the outer wall of the short smoke hood is provided with an annular water-cooling pipe, which is connected to a water cooling system to evenly cool the short smoke hood.

[0017] Furthermore, the DC arc furnace is powered by a three-phase rectifier transformer, and the furnace supplies power to the electrodes through a short-circuit system. The short-circuit system includes conductive copper tubes, water-cooled cables and copper tile water-cooling devices. The electrode power supply path in the short-circuit system is a water-cooled secondary bus system.

[0018] Furthermore, the hydraulic system is used to provide power for electrode lifting, pressing and releasing, electrode clamping device and other smelting operations. The hydraulic system includes a motor, a pump, an electrode lifting valve station, a pressure ring valve station, a butterfly spring gate valve station and a hydraulic gate valve control valve station.

[0019] Furthermore, a collecting trough for recovering dust is provided at the lower part of the furnace body of the electric arc furnace. The position of the collecting trough is vertically aligned with the lower edge of the short smoke hood. The short smoke hood surrounds the upper part of the entire furnace body. The collecting trough and the lower edge of the short smoke hood are connected by an annular water cooling structure to ensure that the high-temperature flue gas does not leak out, while collecting the dust discharged through the electrode gap.

[0020] Among them: the mixing device is used to mix the manganese silicon alloy powder and the ferrosilicon powder evenly according to a predetermined mass ratio; the mixing device includes several silos, conveying pipelines, mixing tanks and stirring devices. Each silo can store manganese silicon alloy powder, ferrosilicon powder and other raw materials respectively, and the conveying pipelines transmit different raw materials to the mixing tank. An efficient stirring device is installed in the mixing tank, which can adjust the stirring speed according to the set process parameters to ensure uniform mixing and avoid agglomeration. After stirring, the mixture will be automatically sent to the next process through the control system. The whole process is fully automated, which greatly reduces the errors in manual operation. The storage of raw materials in the silo can be monitored in real time by the control system to ensure the continuity of the production process and prevent raw material shortages.

[0021] The DC arc furnace can flexibly adjust the electrode position according to the temperature changes in the molten pool or the smelting stage to ensure the stability of the arc. The core technology of the arc furnace lies in its periodic automatic reversing function, which can evenly distribute the current on each electrode, reduce the consumption of the electrode, and improve the energy utilization efficiency. In addition, the furnace body of the arc furnace is lined with high-strength refractory materials, which can withstand high temperature environments and extend the service life of the furnace body. The upper part of the furnace body is provided with an iron outlet and a slag outlet, and the overall cooling of the furnace body is maintained through a water cooling system to avoid overheating damage.

[0022] The iron tapping device is used to open the furnace eye after smelting is completed, release the liquid ferromanganese alloy, and lift the liquid ferromanganese alloy to the casting mold for casting; the furnace eye opening machine is controlled by a hydraulic system, which can accurately open the furnace eye to ensure that the liquid ferromanganese alloy is discharged smoothly and guide it into the casting mold through the guide pipe. The crane system is used to lift the casting pot filled with liquid ferromanganese alloy to different casting positions. The crane is equipped with a precise positioning system, which can flexibly adjust the casting angle and height according to needs to ensure that the liquid alloy is evenly distributed in the mold and reduce casting defects.

[0023] The cooling system uses water cooling technology to precisely control the cooling process of the casting mold and the ferromanganese alloy. The water flow and temperature can be adjusted to ensure that the alloy does not cool suddenly during the cooling process, thereby avoiding cracks or microstructural defects. The entire cooling process is monitored by an automated control system, which adjusts the water cooling parameters in real time to achieve the best cooling effect.

[0024] After cooling, the ferromanganese alloy is sent to the crushing device, where it is crushed into particles or powders that meet the specifications through mechanical force. Then, the powder is screened by the screening device to ensure that the qualified ferromanganese alloy powder enters the packaging process. The screening process can automatically adjust the size of the sieve holes according to the preset standards to meet the needs of products of different specifications. The packaging process is completed by automated equipment to ensure that the powder is sealed and packaged, and the product identification and batch information are attached to facilitate subsequent storage and transportation management.

[0025] The automated control system is used to coordinate the operation of each device in the system, monitor and adjust key parameters in real time, and ensure the efficiency and stability of the entire recycling process. The control system has data acquisition and analysis functions, and can automatically adjust the power of the electric arc furnace, the water flow rate of the cooling system, and the raw material supply rate of the silo according to the different stages of the smelting process. Operators can complete the monitoring and adjustment of the entire process through the human-machine interface, reducing dependence on experience and technology and improving the stability and consistency of the process. The control system also has a fault alarm function. Once an abnormal situation is detected, the system will immediately make adjustments or stop running to prevent the expansion of losses.

[0026] The beneficial effects of the present invention are: Efficient recycling of resources: The present invention effectively recycles the manganese silicon alloy powder produced in the smelting process through precise raw material mixing and smelting process, thus avoiding the waste of raw materials, improving the utilization rate of resources, and greatly reducing production costs.

[0027] Improved smelting efficiency: By adopting a four-electrode periodic automatic commutation DC arc furnace and accurately controlling the temperature, pressure and current intensity during the smelting process, the full melting of the mixture and the stability of the smelting process are ensured, which significantly improves the smelting efficiency and reduces energy consumption.

[0028] Improved product quality: During the smelting process, arc stirring and gas escape management ensure the uniformity of the composition in the molten pool, reduce the mixing of impurities, and produce manganese iron alloy products with higher purity and better performance, thereby improving the quality of the finished product.

[0029] Automatic control: The present invention greatly reduces the complexity of manual operation and human errors through automated mixing, conveying, cooling and other systems, improves the continuity and consistency of the production process, and makes the entire production process more stable and controllable.

[0030] Improved environmental performance: The system is equipped with a dust collection device to effectively recycle the dust generated during the smelting process, reducing environmental pollution. In addition, strict gas escape management measures are taken during the smelting process to effectively control waste gas emissions and meet environmental protection requirements.

[0031] Enhanced equipment safety: The water cooling system cools the electrodes and key parts of the furnace, effectively preventing overheating and damage to the equipment, extending the service life of the equipment, and improving the safety and operational reliability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 : Schematic diagram of the process flow of the present invention; DETAILED DESCRIPTION

[0033] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments: Example 1: Figure 1 As shown, a manganese silicon alloy powder recycling process comprises the following steps: S1: Put the manganese silicon alloy powder and ferrosilicon powder into the mixing bin and mix them evenly; due to the different physical properties of manganese silicon alloy powder and ferrosilicon powder, there may be different particle sizes or density differences, so the two raw materials must be fully mixed during the mixing process to avoid segregation or local uneven composition during the smelting process. At the same time, in order to ensure the mixing effect, the mixing time and stirring speed can be properly controlled during mixing, and the uniformity of the mixture can be monitored through the control system. If necessary, multiple tests can be performed to ensure that the mixing effect meets the expected standards.

[0034] S2: Add the mixture into a DC arc furnace, use a rectifier transformer and a rectifier power supply cabinet to convert AC power into DC power, and introduce the current into the furnace through electrodes; compared with traditional AC arc furnaces, DC arc furnaces can provide a more stable arc, effectively reduce arc drift and energy loss, and improve smelting efficiency.

[0035] S3: The mixture is continuously melted by arc heat and resistance heat reaction, and the molten pool is stirred by arc to achieve the effect of desulfurization and uniform composition; the addition of ferrosilicon powder can help the desulfurization reaction at high temperature and promote the purification of manganese silicon alloy components.

[0036] S4: During the smelting process, the voltage level and current intensity of the electrode are controlled according to the set process parameters. Different voltage and current values ​​are used in different smelting periods, and it is ensured that the arc is not exposed from beginning to end; the arc is not exposed in order to avoid heat loss and the generation of oxides in the air.

[0037] S5: Continue to add new mixture to keep the height of the material surface in the furnace constant, the electrode is in a flat cone shape, and the gas escapes evenly from the material surface; S6: When the mixture is completely melted, slag is first discharged, and then the furnace eye is opened by the furnace eye opening machine to release the liquid manganese iron alloy; the purpose of slag discharge is to remove non-metallic impurities in the furnace and ensure the purity of the liquid alloy. When slag discharge, attention should be paid to controlling the time and temperature of slag discharge to avoid slag discharge too early or too late. In addition, the process of furnace eye opening should be coordinated with the pressure and temperature in the furnace to avoid splashing or gas bursting when the furnace is opened. The fluidity and temperature of the liquid manganese iron alloy should be kept in a suitable range to ensure the smooth progress of the casting process.

[0038] S7: The liquid ferromanganese alloy taken out of the furnace is lifted into a casting mold by a crane, crushed, screened, packaged and stored after cooling, to obtain a finished ferromanganese alloy.

[0039] Furthermore, the mass ratio of the above-mentioned manganese silicon alloy powder to ferrosilicon powder is 85-95:1. A reasonable mass ratio is an important factor in ensuring that the final alloy composition meets expectations. In order to improve the accuracy of the ratio, high-precision metering equipment can be used, and these equipment can be calibrated regularly to ensure long-term stable measurement accuracy.

[0040] Furthermore, the process parameters set above are as follows: smelting start-up stage: in the first 10 minutes of the initial stage of smelting, the electrode voltage is set in the range of 20 to 30 volts, and the current intensity is set in the range of 100 to 300 amperes to ensure that the temperature in the smelting furnace gradually rises to 500 to 800 degrees Celsius and prevent the arc from being formed and exposed prematurely; mid-smelting stage: when the smelting enters 10 to 30 minutes, the electrode voltage is adjusted to the range of 30 to 50 volts, and the current intensity is increased to the range of 500 to 1500 amperes. At this time, the temperature in the furnace gradually rises to 800 to 1500 degrees Celsius. The stability of the arc is maintained by gradually increasing the current intensity to promote the melting of the smelting material; late smelting stage: after the smelting time exceeds 30 minutes, the electrode voltage is adjusted to the range of 40 to 60 volts, and the current intensity is increased to the range of 1500 to 5000 amperes, so that the temperature in the furnace is maintained at 1500 to 1800 degrees Celsius to ensure that the smelting material is completely melted. This process plays a decisive role in the temperature control of the smelting furnace. The setting of voltage and current should fully consider the characteristics of the smelting materials and the target temperature range. In the smelting startup stage, the temperature should be avoided from rising too fast to prevent the arc from getting out of control; in the middle and late stages, the temperature should be steadily increased and the current intensity should be gradually increased to ensure that the material is fully melted.

[0041] Furthermore, the cooling step after smelting is performed by controlling the flow rate and temperature of cooling water, specifically, the flow rate of cooling water is maintained at 5 to 10 liters / minute, and the temperature of cooling water is controlled between 10 and 20 degrees Celsius to ensure slow cooling of the smelted material and avoid cracks or other defects. The control of cooling rate has a direct impact on the microstructure of the alloy, so by adjusting the temperature and flow rate of cooling water, stress concentration, cracks or other metallurgical defects caused by rapid cooling can be avoided.

[0042] To sum up, the implementation steps are as follows: Raw material mixing: Put manganese silicon alloy powder and ferrosilicon powder into the mixing bin at a mass ratio of 85-95:1, and use a stirring device to fully mix the two in the mixing tank. The raw materials in the mixing bin are sent to the mixing tank in sequence through the conveying pipeline, and the stirring speed of the stirring device is adjusted according to the predetermined formula to ensure the uniformity of the raw material mixing.

[0043] Smelting process: The mixture is added to the DC arc furnace through a conveying device. The DC arc furnace adopts a four-electrode periodic automatic reversing design. The rectifier transformer and rectifier power supply cabinet convert AC power into DC power, and the current is introduced into the furnace through the electrodes. Smelting is divided into three stages: Smelting start-up phase: Within the first 10 minutes, the electrode voltage is set at 20 to 30 volts, the current intensity is set at 100 to 300 amperes, and the furnace temperature is gradually increased to 500 to 800 degrees Celsius to avoid premature arc formation and exposure.

[0044] Mid-smelting stage: 10 to 30 minutes into the process, adjust the electrode voltage to 30 to 50 volts, increase the current intensity to 500 to 1500 amperes, and gradually increase the temperature in the furnace to 800 to 1500 degrees Celsius to stabilize the arc and promote material melting.

[0045] Late smelting stage: After more than 30 minutes, the electrode voltage is set at 40 to 60 volts, the current intensity is increased to 1500 to 5000 amperes, and the temperature in the furnace is maintained at 1500 to 1800 degrees Celsius to ensure complete melting of the material.

[0046] Gas Escape and Molten Pool Management: As smelting progresses, new mixture is continuously added to the furnace to keep the height of the material surface in the furnace constant. A flat cone shape is formed around the electrode to ensure uniform gas escape. At the same time, the arc stirring action makes the composition in the molten pool uniform, achieving the effect of desulfurization. The arc is never exposed to ensure the stability of the smelting process.

[0047] Melting and tapping: When the mixture is completely melted, the slag removal operation is carried out first. The furnace eye is opened by the furnace eye opening machine to release the liquid manganese iron alloy. The liquid manganese iron alloy is lifted into the casting mold by a crane.

[0048] Cooling and crushing: The liquid ferromanganese alloy is sent to the cooling system. The cooling system controls the water flow rate to 5 to 10 liters / minute and the water temperature to 10 to 20 degrees Celsius to ensure that the material is cooled slowly to avoid cracks. The cooled ferromanganese alloy is crushed, screened, packaged and stored to obtain the finished ferromanganese alloy.

[0049] Embodiment 2: A manganese-silicon alloy powder recycling system, comprising: 1. A mixing device, used to mix the manganese silicon alloy powder and the ferrosilicon powder evenly according to a predetermined mass ratio; 2. DC electric arc furnace, the DC electric arc furnace is a four-electrode periodic automatic commutation DC electric arc furnace; 3. The iron-discharging device, including the furnace eye opening machine and the crane, is used to open the furnace eye after the smelting is completed, release the liquid manganese iron alloy, and lift the liquid manganese iron alloy to the casting mold for casting; 4. Cooling system, used to cool the liquid ferromanganese alloy by controlling the flow rate and temperature of cooling water to ensure that the product cools slowly to avoid cracks or other defects; 5. Crushing and screening device, used to crush and screen the cooled ferromanganese alloy, and pack the qualified ferromanganese alloy powder into storage.

[0050] Furthermore, the above-mentioned mixing device includes several silos, conveying pipelines, a mixing tank, a stirring device and a control system; the above-mentioned silos are used to store different types of raw materials, and the above-mentioned silos are connected to the mixing tank through conveying pipelines; the above-mentioned stirring device is arranged in the mixing tank, and has the function of adjusting the stirring speed to adapt to different formula requirements and ensure that the raw materials are mixed evenly; the above-mentioned control system is used to monitor the raw material storage situation of each silo in real time, and control the opening and closing of the conveying pipeline, so as to realize the automation of the mixing process.

[0051] Furthermore, the DC electric arc furnace comprises a furnace body, an electrode system and a water cooling system; the furnace body is the electric heating reaction place of the electric furnace, the outer shell of the furnace body is welded from steel plates, a plurality of thermocouples are installed on the furnace body for temperature monitoring, a furnace bottom air cooling pipe is arranged at the bottom of the furnace body, a slag and iron outlet is arranged in the middle of the furnace body, and a chute is arranged on the slag and iron outlet; the electrode system comprises four electrodes, the electrodes adopt water-cooling protective sleeves, and are provided with electrode sealing guide devices, the electrodes are position-adjusted by a lifting device, and the lifting device comprises a column, a guide wheel and a hydraulic system; the water cooling system is used to cool the short smoke hood, the electrode system and the furnace outlet; the lifting device of the electrode system comprises a column, a rope pulley frame, a counterweight, a conductive cross arm, an electrode clamp, a clamping butterfly spring and a hydraulic cylinder; the conductive cross arm is made of copper-steel composite material, with water cooling inside, the electrode clamp is made of red copper forgings, and the butterfly spring for clamping the electrode is designed with high elasticity to ensure large clamping force, small contact resistance, and the electrode position is smooth. The electrode lifting device realizes automatic adjustment or manual control; the electrode sealing guide device adopts a water-cooling structure, and the guide sleeve has a hard and soft double-layer sealing design to ensure good insulation and sealing between the electrode and the furnace cover. The guide wheel is used to fix the electrode position and adjust the electrode distribution circle diameter during the electrode lifting process; the short smoke hood is fixedly connected to the upper part of the furnace body, and the position of the short smoke hood is located above the electrode and surrounds the electrode distribution area. A preset vertical distance is maintained between the short smoke hood and the electrode to ensure that the electrode does not interfere with the smoke hood when it is lifted or lowered; the short smoke hood of the furnace body is a 12-sided water-cooled structure, which consists of a skeleton, 12 edge cover plates and an anti-magnetic central furnace cover plate. The lower surface of the short smoke hood is sprayed with heat-resistant concrete. The short smoke hood is provided with an operating door, a smoke exhaust port and a flue. The flue is connected to a dust removal device to purify the flue gas generated in the furnace and discharge it into the atmosphere; the outer wall of the short smoke hood is provided with an annular water-cooling pipe, which is connected to a water cooling system to evenly cool the short smoke hood.

[0052] Furthermore, the DC arc furnace is powered by a three-phase rectifier transformer, and the furnace supplies power to the electrodes through a short-circuit system. The short-circuit system includes conductive copper tubes, water-cooled cables and copper tile water-cooling devices. The electrode power supply path in the short-circuit system is a water-cooled secondary bus system.

[0053] Furthermore, the hydraulic system is used to provide power for electrode lifting, pressing and releasing, electrode clamping device and other smelting operations. The hydraulic system includes a motor, a pump, an electrode lifting valve station, a pressure ring valve station, a butterfly spring gate valve station and a hydraulic gate valve control valve station.

[0054] Furthermore, a collecting trough for recovering dust is provided at the lower part of the furnace body of the electric arc furnace. The position of the collecting trough is vertically aligned with the lower edge of the short smoke hood. The short smoke hood surrounds the upper part of the entire furnace body. The collecting trough and the lower edge of the short smoke hood are connected by an annular water cooling structure to ensure that the high-temperature flue gas does not leak out, while collecting the dust discharged through the electrode gap.

[0055] Among them: the mixing device is used to mix the manganese silicon alloy powder and the ferrosilicon powder evenly according to a predetermined mass ratio; the mixing device includes several silos, conveying pipelines, mixing tanks and stirring devices. Each silo can store manganese silicon alloy powder, ferrosilicon powder and other raw materials respectively, and the conveying pipelines transmit different raw materials to the mixing tank. An efficient stirring device is installed in the mixing tank, which can adjust the stirring speed according to the set process parameters to ensure uniform mixing and avoid agglomeration. After stirring, the mixture will be automatically sent to the next process through the control system. The whole process is fully automated, which greatly reduces the errors in manual operation. The storage of raw materials in the silo can be monitored in real time by the control system to ensure the continuity of the production process and prevent raw material shortages.

[0056] The DC arc furnace can flexibly adjust the electrode position according to the temperature changes in the molten pool or the smelting stage to ensure the stability of the arc. The core technology of the arc furnace lies in its periodic automatic reversing function, which can evenly distribute the current on each electrode, reduce the consumption of the electrode, and improve the energy utilization efficiency. In addition, the furnace body of the arc furnace is lined with high-strength refractory materials, which can withstand high temperature environments and extend the service life of the furnace body. The upper part of the furnace body is provided with an iron outlet and a slag outlet, and the overall cooling of the furnace body is maintained through a water cooling system to avoid overheating damage.

[0057] The iron tapping device is used to open the furnace eye after smelting is completed, release the liquid ferromanganese alloy, and lift the liquid ferromanganese alloy to the casting mold for casting; the furnace eye opening machine is controlled by a hydraulic system, which can accurately open the furnace eye to ensure that the liquid ferromanganese alloy is discharged smoothly and guide it into the casting mold through the guide pipe. The crane system is used to lift the casting pot filled with liquid ferromanganese alloy to different casting positions. The crane is equipped with a precise positioning system, which can flexibly adjust the casting angle and height according to needs to ensure that the liquid alloy is evenly distributed in the mold and reduce casting defects.

[0058] The cooling system uses water cooling technology to precisely control the cooling process of the casting mold and the ferromanganese alloy. The water flow and temperature can be adjusted to ensure that the alloy does not cool suddenly during the cooling process, thereby avoiding cracks or microstructural defects. The entire cooling process is monitored by an automated control system, which adjusts the water cooling parameters in real time to achieve the best cooling effect.

[0059] After cooling, the ferromanganese alloy is sent to the crushing device, where it is crushed into particles or powders that meet the specifications through mechanical force. Then, the powder is screened by the screening device to ensure that the qualified ferromanganese alloy powder enters the packaging process. The screening process can automatically adjust the size of the sieve holes according to the preset standards to meet the needs of products of different specifications. The packaging process is completed by automated equipment to ensure that the powder is sealed and packaged, and the product identification and batch information are attached to facilitate subsequent storage and transportation management.

[0060] The automated control system is used to coordinate the operation of each device in the system, monitor and adjust key parameters in real time, and ensure the efficiency and stability of the entire recycling process. The control system has data acquisition and analysis functions, and can automatically adjust the power of the electric arc furnace, the water flow rate of the cooling system, and the raw material supply rate of the silo according to the different stages of the smelting process. Operators can complete the monitoring and adjustment of the entire process through the human-machine interface, reducing dependence on experience and technology and improving the stability and consistency of the process. The control system also has a fault alarm function. Once an abnormal situation is detected, the system will immediately make adjustments or stop running to prevent the expansion of losses.

[0061] In summary, the system includes a mixing device, a DC arc furnace, an iron-discharging device, a cooling system, and a crushing and screening device.

[0062] Mixing device: The mixing device consists of several silos, conveying pipelines, mixing tanks, stirring devices and control systems. The silos are used to store manganese silicon alloy powder and ferrosilicon powder, and the raw materials are automatically delivered to the mixing tank according to the set ratio through the conveying pipeline. The stirring device in the mixing tank can adjust the stirring speed to ensure that the raw materials are mixed evenly. The control system can monitor the storage status of the raw materials in each silo in real time, and automatically control the opening and closing of the conveying pipeline to realize automatic mixing operation.

[0063] DC arc furnace: The DC arc furnace is a four-electrode periodic automatic reversing DC arc furnace. The furnace body is welded from steel plates and equipped with multiple thermocouples for temperature monitoring. The bottom of the furnace body is equipped with air cooling pipes. The electrode system includes four electrodes, which are protected by water cooling sleeves and adjusted by a hydraulic lifting system to ensure that the electrodes are always in the best position. The water cooling system cools the low smoke hood, electrode system and furnace outlet to ensure efficient operation of the arc furnace and prevent high temperature overheating.

[0064] Iron-discharging device: The iron-discharging device includes a furnace eye opening machine and a crane. The furnace eye opening machine is used to open the furnace eye and release the liquid manganese-iron alloy, and the crane transports the liquid manganese-iron alloy to the casting mold for casting.

[0065] Cooling system: The cooling system cools the liquid ferromanganese alloy by adjusting the water flow rate and water temperature. The cooling system ensures that the material cools slowly to avoid cracks or other defects.

[0066] Crushing and screening device: The cooled ferromanganese alloy is crushed and screened by the crushing and screening device, and the qualified ferromanganese alloy powder is packaged and stored and sold as a finished product.

[0067] Auxiliary equipment: The system is also equipped with a dust collection device to recover the dust discharged through the electrode gap during the smelting process to ensure environmental protection during the production process.

[0068] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A process for recycling manganese silicon alloy powder, characterized in that: The following steps are involved: Put the manganese silicon alloy powder and ferrosilicon powder into a mixing bin and mix them evenly; The mixture is added into a DC arc furnace, and the AC power is converted into DC power by using a rectifier transformer and a rectifier power supply cabinet, and the current is introduced into the furnace through electrodes; The mixture is continuously melted by arc heat and resistance heat reaction, and the molten pool is stirred by arc to achieve the effect of desulfurization and uniform composition. During the smelting process, the voltage level and current intensity of the electrode are controlled according to the set process parameters. Different voltage and current values ​​are used in different smelting periods, and it is ensured that the arc is not exposed from beginning to end; Continuously add new mixture to keep the height of the material surface in the furnace constant, the electrode is in a flat cone shape, and the gas escapes evenly from the material surface; When the mixture is completely melted, the slag is first discharged, and then the furnace eye is opened by the furnace eye opening machine to release the liquid manganese iron alloy; The liquid ferromanganese alloy is lifted into the casting mold by a crane, crushed, screened, packaged and stored after cooling to obtain the finished ferromanganese alloy.

2. A manganese-silicon alloy powder recycling process as claimed in claim 1, characterized in that: The mass ratio of the manganese silicon alloy powder to the ferrosilicon powder is 85-95:

1.

3. A manganese-silicon alloy powder recycling process as claimed in claim 1, characterized in that: The set process parameters are: Smelting start-up stage: In the first 10 minutes of smelting, the electrode voltage is set in the range of 20 to 30 volts and the current intensity is set in the range of 100 to 300 amperes to ensure that the temperature in the smelting furnace gradually rises to 500 to 800 degrees Celsius and prevent the arc from forming and exposing prematurely; Mid-smelting stage: When the smelting enters the 10th to 30th minute, the electrode voltage is adjusted to the range of 30 to 50 volts, and the current intensity is increased to the range of 500 to 1500 amperes. At this time, the temperature in the furnace gradually rises to 800 to 1500 degrees Celsius. The arc stability is maintained by gradually increasing the current intensity to promote the melting of the smelting material. Late stage of smelting: After the smelting time exceeds 30 minutes, the electrode voltage is adjusted to the range of 40 to 60 volts, and the current intensity is increased to the range of 1500 to 5000 amperes, so that the temperature in the furnace is maintained at 1500 to 1800 degrees Celsius to ensure that the smelting material is completely melted.

4. A manganese-silicon alloy powder recycling process as claimed in claim 1, characterized in that: The cooling step after smelting is carried out by controlling the flow rate and temperature of cooling water. Specifically, the cooling water flow rate is maintained at 5 to 10 liters / minute, and the cooling water temperature is controlled between 10 and 20 degrees Celsius to ensure slow cooling of the smelted material and avoid cracks or other defects.

5. A manganese-silicon alloy powder recycling system according to any one of claims 1 to 4, characterized in that: The system comprises: A mixing device, used to evenly mix the manganese silicon alloy powder and the ferrosilicon powder according to a predetermined mass ratio; A DC electric arc furnace, wherein the DC electric arc furnace is a four-electrode periodic automatic commutation DC electric arc furnace; The iron-discharging device includes a furnace opening machine and a crane, which is used to open the furnace after smelting is completed, release the liquid ferromanganese alloy, and lift the liquid ferromanganese alloy to the casting mold for casting; The cooling system is used to cool the liquid ferromanganese alloy by controlling the flow rate and temperature of the cooling water to ensure that the product cools slowly to avoid cracks or other defects; The crushing and screening device is used to crush and screen the cooled ferromanganese alloy, and pack the qualified ferromanganese alloy powder into the warehouse.

6. A manganese-silicon alloy powder recycling system as claimed in claim 5, characterized in that: The mixing device includes several silos, conveying pipelines, a mixing tank, a stirring device and a control system; the silos are used to store different types of raw materials, and the silos are connected to the mixing tank through conveying pipelines; the stirring device is arranged in the mixing tank and has the function of adjusting the stirring speed to meet different formulation requirements and ensure that the raw materials are mixed evenly; the control system is used to monitor the raw material storage status of each silo in real time, and control the opening and closing of the conveying pipeline, so as to realize the automation of the mixing process.

7. A manganese-silicon alloy powder recycling system as claimed in claim 5, characterized in that: The DC electric arc furnace comprises a furnace body, an electrode system and a water cooling system; the furnace body is the electric heating reaction place of the electric furnace, the furnace body shell is welded by steel plates, a plurality of thermocouples are installed on the furnace body for temperature monitoring, a furnace bottom air cooling pipe is arranged at the bottom of the furnace body, a slag and iron outlet is arranged in the middle of the furnace body, and a chute is arranged on the slag and iron outlet; the electrode system comprises four electrodes, the electrodes adopt water-cooling protective sleeves, and are provided with electrode sealing guide devices, the electrodes are adjusted in position by a lifting device, and the lifting device comprises a column, a guide wheel and a hydraulic system; the water cooling system is used to cool the low smoke hood, the electrode system and the furnace outlet; The lifting device of the electrode system includes a column, a rope pulley frame, a counterweight, a conductive cross arm, an electrode clamp, a clamping butterfly spring and a hydraulic cylinder; the conductive cross arm is made of a copper-steel composite material, and is internally cooled by water; the electrode clamp is made of a copper forging; the butterfly spring for clamping the electrode is designed with high elasticity to ensure a large clamping force and a small contact resistance; the electrode position is automatically adjusted or manually controlled by the electrode lifting device; The electrode sealing guide device adopts a water-cooling structure, and the guide sleeve has a hard and soft double-layer sealing design to ensure good insulation and sealing between the electrode and the furnace cover. The guide wheel is used to fix the electrode position and adjust the electrode distribution circle diameter during the electrode lifting process; The short smoke hood is fixedly connected to the upper part of the furnace body. The short smoke hood is located above the electrode and surrounds the electrode distribution area. A preset vertical distance is maintained between the short smoke hood and the electrode to ensure that the electrode does not interfere with the smoke hood when it is raised or lowered. The short smoke hood of the furnace body is a 12-sided water-cooled structure, which consists of a skeleton, 12 edge cover plates and an anti-magnetic central furnace cover plate. The lower surface of the short smoke hood is sprayed with heat-resistant concrete. The short smoke hood is provided with an operating door, a smoke exhaust port and a flue. The flue is connected to a dust removal device to purify the flue gas generated in the furnace and discharge it into the atmosphere. The outer wall of the short smoke hood is provided with an annular water-cooling pipe, which is connected to the water cooling system to evenly cool the short smoke hood.

8. A manganese-silicon alloy powder recycling system as claimed in claim 7, characterized in that: The DC arc furnace is powered by a three-phase rectifier transformer. The furnace supplies power to the electrodes through a short-circuit system. The short-circuit system includes a conductive copper tube, a water-cooled cable and a copper tile water-cooling device. The electrode power supply path in the short-circuit system is a water-cooled secondary bus system.

9. A manganese-silicon alloy powder recycling system as claimed in claim 7, characterized in that: The hydraulic system is used to provide a power source for electrode lifting, pressing and releasing, electrode clamping device and other smelting operations. The hydraulic system includes a motor, a pump, an electrode lifting valve station, a pressure ring valve station, a butterfly spring gate valve station and a hydraulic gate valve control valve station.

10. A manganese-silicon alloy powder recycling system as claimed in claim 7, characterized in that: A collecting trough for recovering dust is provided at the lower part of the furnace body of the electric arc furnace. The position of the collecting trough is vertically aligned with the lower edge of the short smoke hood. The short smoke hood surrounds the upper part of the entire furnace body. The collecting trough and the lower edge of the short smoke hood are connected by an annular water cooling structure to ensure that high-temperature flue gas does not leak out, while collecting dust discharged through the electrode gap.

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