Process and system for recycling crushed manganese of electrolytic manganese

Abstract

The invention discloses an electrolytic manganese crushed manganese recycling process and a system thereof, and aims to recycle crushed manganese in an efficient and environment-friendly manner. The process comprises the following steps: mixing crushed manganese, scrap iron and a desulfurizing agent, adding into a direct-current electric arc furnace, smelting by utilizing direct current, and realizing desulfurization and uniform components by controlling electrode voltage and current intensity. In the smelting process, sampling analysis is conducted regularly, smelting parameters are adjusted according to results, and product quality is ensured. And after smelting is finished, cooling is conducted by controlling the flow speed and temperature of cooling water, and cracks or other defects are avoided. The system comprises a mixing device, a direct-current electric arc furnace, a tapping device and a cooling system, the direct-current electric arc furnace is a four-electrode cycle automatic reversing direct-current electric arc furnace and is provided with a water cooling system and an electrode sealing guide device, and the stability and safety of the smelting process are ensured. In addition, the system further comprises a collecting tank used for recycling dust, and environmental pollution is effectively reduced.

Description

Technical Field

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

[0002] In the production process of electrolytic manganese, the extraction of metallic manganese is a complex and delicate process. From the acid leaching of manganese ore to the electrolytic precipitation in the electrolytic cell, each link has a crucial impact on the quality of the final product. In this process, a certain amount of electrolytic manganese fragments will inevitably be produced. These manganese fragments are mainly produced by the passivation liquid contamination, transportation, aeration and other links after the cathode plate is discharged from the tank, resulting in the partial shedding of electrolytic manganese on the cathode plate. Although the manganese content of these electrolytic manganese fragments is similar to that of qualified manganese flakes, the content of other elements does not meet the standard requirements due to the incorporation of impurities.

[0003] During the cleaning process of the diaphragm frame, a small amount of manganese fragments adhering to the diaphragm bag will be collected. The manganese content of this part of manganese fragments is low and it is difficult to use directly. According to statistics, the output of electrolytic manganese fragments accounts for about 3.5% of the total output of electrolytic manganese, and its sales price is only 55% of the finished electrolytic manganese.

[0004] Due to the large production capacity of electrolytic manganese and the relatively small market demand for electrolytic manganese fragments, coupled with the low price, the market sales of electrolytic manganese fragments are not ideal. At present, some units have tried to use medium frequency furnaces for remelting, but this process requires the manganese fragments to have a higher grade. Medium frequency furnaces have limitations in the removal of impurity elements, especially the inability to effectively desulfurize, which limits the reuse of electrolytic manganese fragments. Summary of the invention

[0005] In order to solve the above technical problems, the present invention provides a process and system for recycling electrolytic manganese and manganese fragments.

[0006] The present invention is achieved through the following technical solutions: A process for recycling electrolytic manganese fragments of the present invention comprises the following steps: S1: Put crushed manganese, scrap iron and desulfurizer into the mixing bin and mix them evenly; the desulfurizer is active lime; due to the different physical properties of crushed manganese, scrap iron and desulfurizer, there may be different particle sizes or density differences, so the 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.

[0007] 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.

[0008] S3: The mixture is continuously melted by exothermic reaction of arc heat and resistance heat, and the molten pool is stirred by arc to achieve the effect of desulfurization and uniform composition; the addition of desulfurizer can help the desulfurization reaction at high temperature and promote the purification of metallic manganese components.

[0009] 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.

[0010] 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 metal; the purpose of slag discharge is to remove non-metallic impurities in the furnace and ensure the purity of the liquid manganese metal. 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 explosion when opening the furnace. The fluidity and temperature of liquid manganese metal should be kept in a suitable range to ensure the smooth progress of the casting process.

[0011] S7: The liquid manganese metal out of the furnace is lifted into a casting mold by a crane, crushed, screened, packaged and stored after cooling, to obtain finished manganese metal.

[0012] Further, after the above mixture is completely melted, sampling and analysis are performed, including the following steps: S1: Regular sampling: During the smelting process, molten metal samples are taken from the molten pool through a sampling device every 1-1.5 hours; S2: Cooling the sample: Cooling and solidifying the taken molten metal sample for subsequent analysis; S3: Composition analysis: Use a spectrometer, chemical analysis or X-ray fluorescence (XRF) to detect the content of manganese, sulfur, iron and impurities in the sample; S4: Modulate smelting parameters: Based on the analysis results, evaluate whether the chemical composition of the sample meets the predetermined standards; if composition deviation is found, adjust the voltage and current in the arc furnace or increase the desulfurizer or crushed manganese to ensure product quality.

[0013] 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.

[0014] Furthermore, the cooling step after smelting is carried out 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 metal, 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.

[0015] A system for recycling electrolytic manganese and manganese fragments, comprising: 1. Mixing device, used to mix crushed manganese, scrap iron and desulfurizer 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 smelting is completed, release the liquid manganese metal, and lift the liquid manganese metal to the casting mold for casting; 4. Cooling system, used to cool the liquid manganese metal by controlling the flow rate and temperature of cooling water to ensure that the product cools slowly to avoid cracks or other defects; 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 crushed manganese, scrap iron and desulfurizer evenly according to a predetermined mass ratio; the mixing device includes several silos, conveying pipelines, mixing tanks and stirring devices. Each silo can store raw materials such as crushed manganese, scrap iron and desulfurizer respectively, and the conveying pipeline transmits different raw materials to the mixing tank. The mixing tank is equipped with a high-efficiency stirring device, 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 manganese metal, and lift the liquid manganese metal 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 manganese metal 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 manganese metal 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 manganese metal 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 manganese metal. The water flow and temperature can be adjusted to ensure that the manganese metal 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 is completed, the packaging process is completed by automated equipment, and product identification and batch information are added 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 fragments produced in the smelting process through precise raw material mixing and smelting processes, thereby 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 metallic manganese 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; Figure 2 : Schematic diagram of electromagnetic stirring of materials in the DC furnace of the present invention; Figure 3 : Schematic diagram of the arc angle of the DC furnace 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 process for recycling electrolytic manganese fragments comprises the following steps: S1: Put crushed manganese, scrap iron and desulfurizer into the mixing bin and mix them evenly; the desulfurizer is active lime; due to the different physical properties of crushed manganese, scrap iron and desulfurizer, there may be different particle sizes or density differences, so the 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 exothermic reaction of arc heat and resistance heat, and the molten pool is stirred by arc to achieve the effect of desulfurization and uniform composition; the addition of desulfurizer can help the desulfurization reaction at high temperature and promote the purification of metallic manganese 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 metal; the purpose of slag discharge is to remove non-metallic impurities in the furnace and ensure the purity of the liquid manganese metal. 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 explosion when opening the furnace. The fluidity and temperature of liquid manganese metal should be kept in a suitable range to ensure the smooth progress of the casting process.

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

[0039] Further, after the above mixture is completely melted, sampling and analysis are performed, including the following steps: S1: Regular sampling: During the smelting process, molten metal samples are taken from the molten pool through a sampling device every 1-1.5 hours; S2: Cooling the sample: Cooling and solidifying the taken molten metal sample for subsequent analysis; S3: Composition analysis: Use a spectrometer, chemical analysis or X-ray fluorescence (XRF) to detect the content of manganese, sulfur, iron and impurities in the sample; S4: Modulate smelting parameters: Based on the analysis results, evaluate whether the chemical composition of the sample meets the predetermined standards; if composition deviation is found, adjust the voltage and current in the arc furnace or increase the desulfurizer or crushed manganese to ensure product quality.

[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 carried out by controlling the flow rate and temperature of the 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 to avoid cracks or other defects. The control of the cooling rate has a direct impact on the microstructure of the metal, so by adjusting the temperature and flow rate of the cooling water, stress concentration, cracks or other metallurgical defects caused by rapid cooling can be avoided. In summary, the implementation steps are as follows: Raw material mixing: Put crushed manganese, scrap iron and desulfurizer into the mixing bin, and use the stirring device to 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.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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 metal. The liquid manganese metal is lifted into the casting mold by a crane.

[0047] Cooling: Liquid manganese metal is fed into 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. After cooling, the finished manganese metal is obtained.

[0048] Embodiment 2: A system for recycling manganese fragments from electrolytic manganese, comprising: A system for recycling electrolytic manganese and manganese fragments, comprising: 1. Mixing device, used to mix crushed manganese, scrap iron and desulfurizer 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 smelting is completed, release the liquid manganese metal, and lift the liquid manganese metal to the casting mold for casting; 4. Cooling system, used to cool the liquid manganese metal by controlling the flow rate and temperature of cooling water to ensure that the product cools slowly to avoid cracks or other defects; 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] Among them: the mixing device is used to mix crushed manganese, scrap iron and desulfurizer evenly according to a predetermined mass ratio; the mixing device includes several silos, conveying pipelines, mixing tanks and stirring devices. Each silo can store raw materials such as crushed manganese, scrap iron and desulfurizer respectively, and the conveying pipeline transmits different raw materials to the mixing tank. The mixing tank is equipped with a high-efficiency stirring device, 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.

[0054] 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.

[0055] The iron tapping device is used to open the furnace eye after smelting is completed, release the liquid manganese metal, and lift the liquid manganese metal 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 manganese metal 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 manganese metal 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 manganese metal is evenly distributed in the mold and reduce casting defects.

[0056] The cooling system uses water cooling technology to precisely control the cooling process of the casting mold and the manganese metal. The water flow and temperature can be adjusted to ensure that the manganese metal 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.

[0057] After cooling is completed, the packaging process is completed by automated equipment, and product identification and batch information are added to facilitate subsequent storage and transportation management.

[0058] 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.

[0059] 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.

[0060] Mixing device: The mixing device consists of several silos, conveying pipelines, mixing tanks, stirring devices and control systems. The silos are used to store crushed manganese, scrap iron and desulfurizer, and the raw materials are automatically delivered to the mixing tank according to the set proportion 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.

[0061] 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.

[0062] Iron-tapping device: The iron-tapping device includes a furnace eye opening machine and a crane. The furnace eye opening machine is used to open the furnace eye and release liquid manganese metal, and the crane transports the liquid manganese metal to the casting mold for casting.

[0063] Cooling system: The cooling system cools the liquid manganese metal by adjusting the water flow rate and water temperature. The cooling system ensures that the material cools slowly to avoid cracks or other defects.

[0064] 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.

[0065] 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 fragments from electrolytic manganese, characterized in that: The following steps are involved: Put crushed manganese, scrap iron and desulfurizer into a mixing bin and mix them evenly; the desulfurizer is active lime; 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 metal; The liquid manganese metal out of the furnace is lifted by a crane into a casting mold for casting, cooled, packaged and stored to obtain finished manganese ingots.

2. The process for recycling manganese fragments from electrolytic manganese according to claim 1, characterized in that: After the mixture is completely melted, sampling and analysis are performed, including the following steps: Regular sampling: During the smelting process, molten metal samples are taken from the molten pool every 1-1.5 hours through a sampling device; Cooling samples: Cooling and solidifying the taken molten metal samples for subsequent analysis; Component analysis: Use a spectrometer, chemical analysis or X-ray fluorescence (XRF) to detect the manganese, sulfur, iron and impurity content in the sample; Modulate smelting parameters: Based on the analysis results, evaluate whether the chemical composition of the sample meets the predetermined standards; if composition deviation is found, adjust the voltage and current in the arc furnace or add desulfurizer or crushed manganese to ensure product quality.

3. The process for recycling manganese fragments from electrolytic manganese according to 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. The process for recycling manganese fragments from electrolytic manganese according to 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. The electrolytic manganese scrap manganese recycling system according to any one of claims 1 to 4, characterized in that: The system comprises: A mixing device, used to mix crushed manganese, scrap iron and desulfurizing agent uniformly 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 manganese iron alloy by controlling the flow rate and temperature of the cooling water to ensure that the product is cooled slowly to avoid cracks or other defects.

6. The electrolytic manganese scrap manganese recycling system according to 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. The electrolytic manganese scrap manganese recycling system according to 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. The electrolytic manganese scrap manganese recycling system according to 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. The electrolytic manganese scrap manganese recycling system according to 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. The electrolytic manganese scrap manganese recycling system according to 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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