Green and energy-saving novel manganese-silicon alloy production method
By controlling the ratio of the primary combustion auxiliary materials into the furnace and the smelting conditions, setting up a slag-iron separator and sedation package, the problems of cumbersome pre-furnace operation and low recovery rate of manganese silicon alloys are solved, and efficient and low-cost manganese silicon alloy production are achieved.
Patent Information
- Application Number
- CN202510100369.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-22
- Publication Date
- 2025-04-25
AI Technical Summary
In the existing manganese silicon alloy production process, the front-end operation is complicated, the working intensity is high, and there is a large safety risk. The recovery rate of manganese element is low and the smelting power consumption is high.
By controlling the ratio of silica to manganese elements in the furnace raw combustion auxiliary materials, adjust the content of manganese elements in the furnace raw combustion auxiliary materials, control the smelting time and temperature, and set up a slag-iron separator and calming package to achieve efficient recovery of manganese silicon alloy and low slag-iron ratio production.
It effectively reduces the pre-furnace operation steps, reduces safety risks, improves the recovery rate of manganese elements, reduces smelting electricity consumption and ore consumption, and reduces production costs.
Smart Images
Figure CN119876609A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of smelting, and in particular to a green and energy-saving new manganese-silicon alloy production method. Background Art
[0002] Submerged arc furnace produces manganese silicon alloy. Its main raw materials are various manganese ores and manganese-rich slag, which are reasonably matched. An appropriate amount of silica is added to provide the silicon content in the alloy. A small amount of dolomite is added as a flux. Coke is used as a reducing agent. A redox reaction occurs in the submerged arc furnace to obtain a manganese silicon alloy containing manganese, silicon, iron and other elements. Conventional silicon manganese alloy production usually takes 4 hours to produce one furnace. Each work shift needs to produce two furnaces of iron. The molten iron is packaged in front of the furnace. The molten iron treatment requires a series of processes, including transportation, slag removal, casting, demoulding, ladle cleaning and maintenance, ingot mold maintenance, etc. There are many furnace equipment and facilities involved, the operation is cumbersome, the work intensity is high, and the lifting of molten iron poses a great safety risk. At the same time, the process has a short smelting cycle, the reduction of elements such as manganese and silicon is not sufficient, the slag and iron calming and separation time of the molten iron ladle method in front of the furnace is insufficient, the manganese recovery rate is low, and the smelting power consumption is high.
[0003] The conventional operation process for producing manganese silicon alloy has the following disadvantages: 1. In the production of manganese silicon alloy by ore-fired furnace, each work shift produces two furnaces of iron, and the smelting operation procedures in front of the furnace are complicated, with heavy workload, long working hours and high labor intensity. 2. After the iron is produced in front of the furnace, a crane is needed to lift the molten iron for slag removal and pouring. Many equipment are required, including molten iron ladle, frame, pouring crane, hoisting equipment, rails, winches in front of and behind the furnace, ingot molds, etc. The equipment maintenance workload is large and the cost is high. 3. As the main equipment in front of the furnace, the pouring crane needs to lift the molten metal for slag removal and pouring operations, which poses serious safety hazards. 4. When the manganese silicon alloy production furnace taps iron, the slag iron has a short calming time in the molten iron ladle, the slag iron separation is insufficient, and part of the molten iron is discharged from the slag outlet with the slag, resulting in metal loss. The recovery rate of manganese element in the conventional process is about 86%, the unit smelting power consumption is high, the manganese recovery rate is low, and the production efficiency is low, resulting in high production costs; in order to recycle the manganese silicon alloy in the slag pool, the company needs to invest manpower and equipment to perform gravity screening to recover the alloy, resulting in increased corporate costs. 5. The conventional operation process produces manganese silicon alloy with a slag iron ratio of more than 0.85, a large amount of slag, and requires a large amount of electricity, resulting in a waste of electricity.
[0004] In summary, the prior art has the following problems: when taking out of the furnace, the operation in front of the furnace is cumbersome and labor-intensive, and there is a great safety risk in the lifting of molten iron. Summary of the invention
[0005] The purpose of the present invention is to solve the problem of how to reduce the operation procedures in front of the furnace and reduce the safety risks when taking out of the furnace.
[0006] To this end, an embodiment of the present invention provides a green and energy-saving new manganese silicon alloy production method (an energy-saving manganese silicon alloy production method), the method comprising the following steps:
[0007] Step 1: Control the ratio of silicon dioxide to manganese in the raw fuel and auxiliary materials entering the furnace;
[0008] Step 2: Adjust the manganese content in the raw fuel and auxiliary materials entering the furnace to ≥32%;
[0009] Step 3: Control the smelting time and increase the smelting temperature to enrich the Al2O3 content in the slag to 22% to 26% and the manganese content in the slag to 5% to 7%;
[0010] Step 4: a slag-iron separator is arranged in front of the furnace, and the molten iron and slag are directly drained into the slag-iron separator through a chute when the molten iron and slag are discharged from the furnace.
[0011] A calming bag is arranged at the overflow port of the slag-iron separator, and the manganese-silicon alloy is subjected to secondary precipitation in the calming bag to form return slag, which is then fed into the furnace after being cooled and crushed.
[0012] In step 1, the ratio of silicon dioxide to manganese in the raw fuel and auxiliary materials entering the furnace is controlled to be 0.73-0.76.
[0013] In step three, the smelting time is controlled to be 8 hours.
[0014] In step three, the smelting temperature is increased to 1550°C to 1650°C.
[0015] In step three, the manganese content in the slag is controlled to be 6%.
[0016] In step three, the slag basicity is controlled to be 0.65-0.75, and the slag-iron ratio of the slag is controlled to be 0.4-0.6.
[0017] Adjust and control the height difference between the iron flow outlet and the iron discharge outlet at the lower end of the slag dam of the slag-iron separator to be 10 to 15 cm.
[0018] In step three, the slag-iron ratio of the slag is controlled to be 0.55.
[0019] The recovery rate of manganese element is controlled to be 89% to 90.12%.
[0020] The beneficial effects are as follows: the present invention sets a slag-iron separator, eliminates the outdated method of tapping iron with a pouring crane ladle, and secondary precipitates the manganese silicon alloy that has not been precipitated due to the excessively fast tapping flow rate through a calming ladle. At the same time, based on the SiO2 / Mn control range of the raw materials entering the furnace, the reducing agent is appropriately increased, the comprehensive effective components of the raw fuel and auxiliary materials entering the furnace are increased, and the slag-iron ratio is reduced; by extending the smelting time, reducing the number of tapping furnaces, and increasing the smelting temperature, the smelting power consumption is effectively reduced, the ore consumption is reduced, and the recovery rate is improved. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Figure 1 It is a flow chart of a green and energy-saving novel manganese silicon alloy production method provided by an embodiment of the present invention;
[0022] Figure 2 It is a production layout diagram of a manganese silicon alloy production method of the prior art;
[0023] Figure 3 It is a flow chart of the prior art method for producing manganese silicon alloy;
[0024] Figure 4 This is a production layout diagram of a first implementation method of a green and energy-saving new manganese silicon alloy production method provided by an embodiment of the present invention;
[0025] Figure 5 It is a flow chart of the first implementation method of the green and energy-saving new manganese silicon alloy production method provided in an embodiment of the present invention. DETAILED DESCRIPTION
[0026] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0027] The technical solution adopted by the present invention is: to propose a new process idea, to eliminate old equipment and safety hazards by adjusting the iron-tapping method in front of the furnace, and to effectively separate and recover the manganese silicon alloy that has not been precipitated due to the excessively fast slag iron flow rate in the iron-tapping process; at the same time, by adjusting the process ingredients, the percentage of comprehensive useful elements entering the furnace is increased, the slag iron ratio is reduced, the smelting time is extended, and the number of iron-tapping furnaces is reduced, so as to achieve safe production, increase output, improve the recovery rate of manganese elements, and reduce consumption, thereby creating economic benefits for the enterprise.
[0028] In the embodiment of the present invention, Figure 1 , provides a green and energy-saving new manganese silicon alloy production method, the method comprising the following steps:
[0029] Step 1: Control the ratio of silicon dioxide to manganese in the raw fuel and auxiliary materials entering the furnace;
[0030] Step 2: Adjust the manganese content in the raw fuel and auxiliary materials entering the furnace to ≥32%;
[0031] Step 3: Control the smelting time and increase the smelting temperature to enrich the Al2O3 content in the slag to 22% to 26% and the manganese content in the slag to 5% to 7%;
[0032] In step three, the smelting time is controlled to be 8 hours; the smelting temperature is increased to 1550°C to 1650°C, for example, the smelting temperature is 1600°C or 1610°C. The recovery rate of manganese silicon alloy is effectively improved to achieve the purpose of reducing costs and increasing efficiency of enterprises. The manganese content in the slag is controlled to be 6%; the slag basicity is controlled to be 0.65 to 0.75, and the slag-iron ratio of the slag is controlled to be 0.4 to 0.6. Preferably, the slag-iron ratio of the slag is controlled to be 0.55.
[0033] By extending the smelting time and reducing the number of iron-tapping furnaces, as the furnace temperature rises, the Al2O3 content of the slag is enriched to between 23% and 26%, the slag basicity (CaO+MgO) / SiO2 is controlled between 0.65 and 0.75, and the slag-iron ratio is reduced from the original 0.85 to 1.1 to about 0.55, thereby realizing the production of manganese silicon alloy with low slag ratio, achieving the goals of reducing slag volume, increasing output, reducing power consumption and reducing costs.
[0034] Step 4: a slag-iron separator is arranged in front of the furnace, and the molten iron and slag are directly drained into the slag-iron separator through a chute when the molten iron and slag are discharged from the furnace.
[0035] A calming bag is set at the overflow port of the slag-iron separator. The manganese-silicon alloy is precipitated twice in the calming bag to form return slag, which is cooled and crushed before entering the furnace. In order to avoid the backlog of return slag, the amount of return slag produced is used as the return slag consumption for batching calculation. The height difference between the iron flow port and the iron discharge port at the lower end of the slag dam of the slag-iron separator is adjusted to control 10-15cm. Avoid the occurrence of over-slag or iron leakage.
[0036] In step 1, the ratio of silicon dioxide to manganese in the raw fuel and auxiliary materials entering the furnace is controlled to be 0.73-0.76. The recovery rate of manganese and silicon elements is improved. The ratio of SiO2 / Mn (ratio of silicon dioxide to manganese) of the overall raw fuel and auxiliary materials entering the furnace is controlled between 0.73 and 0.76; raw materials with high SiO2 content and high CaO and MgO content are selected; when the comprehensive effective manganese content of the raw fuel and auxiliary materials entering the furnace is ensured to be ≥32%, safe production is achieved, the manganese recovery rate is improved, the silicon utilization rate is improved, the output is increased, the power consumption is reduced, and the cost is reduced.
[0037] The manganese recovery rate is controlled to be 89% to 90.12%. Specifically, the returned slag in the calming bag is crushed and put into the furnace, and the slag-iron ratio is adjusted by the process ingredients to produce manganese silicon alloy. The slag-iron ratio is reduced from the original 0.85 to 1.1 to about 0.55 or 0.55, and the amount of slag is greatly reduced; by extending the smelting time, reducing the number of iron-making furnaces, and increasing the smelting temperature, the manganese recovery rate is increased from the previous 86.58% to 90.12%.
[0038] The present invention provides a slag-iron separator, eliminates the outdated pouring crane ladle tapping method, and secondary precipitates the manganese silicon alloy that has not been precipitated due to the excessively fast tapping flow rate through a calming ladle. At the same time, the range of SiO2 / Mn of the raw materials entering the furnace is controlled, the reducing agent is appropriately increased, the comprehensive effective components of the raw fuel and auxiliary materials entering the furnace are increased, and the slag-iron ratio is reduced; by extending the smelting time, reducing the number of tapping furnaces, and increasing the smelting temperature, the smelting power consumption is effectively reduced, the ore consumption is reduced, and the recovery rate is improved.
[0039] Embodiment 1:
[0040] The green and energy-saving new manganese-silicon alloy production method of the present invention is as follows: Figure 4 , the method comprising:
[0041] This application makes and installs a slag iron separator in the furnace site, sets up a flow channel to directly drain iron and slag to the slag iron separator, and effectively separates the molten iron and slag from the iron tapping method. Figure 2 , Figure 3 Compared with the prior art, the present application realizes technical innovation and improves the safety of operation.
[0042] like Figure 5 The present application manufactures and installs a calming bag at the overflow port of the slag-iron separator of the manganese-silicon alloy furnace, so that the manganese-silicon alloy that has not been precipitated in time after passing through the slag-iron separator can be secondary precipitated in the calming bag to form return slag with a high manganese content. The return slag is cooled and crushed and then put into the furnace for manganese-silicon alloy production. At the same time, by extending the smelting time, reducing the number of iron-tapping furnaces, and increasing the smelting temperature, the recovery rate of manganese-silicon alloy can be effectively improved, thereby achieving the purpose of reducing costs and increasing efficiency for enterprises.
[0043] The present application realizes an improvement in the recovery rate of manganese and silicon elements by controlling the SiO2 / Mn (ratio of silicon dioxide to manganese elements) of the raw fuel auxiliary materials entering the furnace to 0.73-0.76, for example, 0.75.
[0044] In conjunction with the reference of the SiO2 / Mn parameter control range, the present application adjusts the comprehensive effective manganese content of the raw fuel and auxiliary materials entering the furnace to ≥32%, and at the same time appropriately increases the amount of coke added, prolongs the smelting time, and uses a higher furnace temperature to enrich the Al2O3 content in the slag to between 22% and 26%, for example, 24%, reduces the manganese content in the slag to 6% or about 6%, increases the slag basicity from 0.55 to 0.65 to 0.75, for example, 0.70, and reduces the slag-iron ratio from 0.85 to 0.55 or about 0.55, which can effectively reduce the occurrence of manganese-silicon alloy not precipitating in time and flowing into the water slag pool due to the excessively fast slag-iron flow rate during the iron-tapping process, and the manganese recovery rate is correspondingly increased from 86.58% to 90.12%, achieving the goals of reducing the slag amount, increasing output, reducing power consumption, and reducing costs.
[0045] The process technology of the present application is energy-saving and environmentally friendly, can reasonably utilize limited manganese ore resources, reduce the amount of slag, extend the smelting time, reduce the number of iron-making furnaces, improve the reduction of various elements, increase the recovery rate of the manganese silicon alloy production furnace, reduce the production cost of manganese silicon alloy, and at the same time achieve better economic benefits for the enterprise.
[0046] From January to April 2023, the applicant controlled the ratio of silicon dioxide to manganese in the raw fuel and auxiliary materials entering the furnace to 0.75, adjusted the comprehensive effective manganese content of the raw fuel and auxiliary materials entering the furnace to ≥32%, and appropriately increased the amount of coke added, controlled the smelting time to 8 hours, and used a smelting temperature of 1600°C to enrich the Al2O3 content in the slag to 24%, reduce the manganese content in the slag to 6%, increase the slag basicity to 0.70, and reduce the slag-iron ratio to 0.55; after producing manganese silicon alloy according to this process, the applicant's various technical and economic indicators have been improved. Among them, smelting power consumption was reduced by 75kWh / t compared with last year (September-December 2023), manganese ore was reduced from 2117kg / t to 2063kg / t, a decrease of 54kg / t, the average daily output increased by 2.87 tons, and coke consumption decreased by 23kg / t; the manganese recovery rate increased by 3.54%, and the average recovery rate of metallic manganese of each furnace was stable at more than 90%. The metallic manganese recovery rate of excellent furnaces can reach 94.77%, and the overall production cost of manganese silicon alloy has been greatly reduced.
[0047] Specific technical effects include:
[0048] 1. Significantly improve economic and technical indicators:
[0049] (1) The returned slag in the calming bag is crushed and put into the furnace, and the slag-iron ratio is adjusted by the process ingredients to produce manganese silicon alloy. After implementation, the slag-iron ratio is reduced from the original 0.85-1.1 to about 0.55 or 0.55, and the amount of slag is greatly reduced; by extending the smelting time, reducing the number of iron-making furnaces, and increasing the smelting temperature, the manganese recovery rate is increased from the previous 86.58% to 90.12%.
[0050] (2) After the returned slag in the calming bag is crushed and put into the furnace, and the slag-iron ratio is adjusted through the process ingredients to produce manganese silicon alloy, the consumption of raw materials per ton of iron and manganese ore is reduced, and the consumption of manganese ore is reduced from the original 2117kg / t to 2063kg / t (cumulative from January to April 2023), a decrease of 2.55%.
[0051] (3) After the returned slag in the calming bag is crushed and put into the furnace, and the slag-iron ratio is adjusted by the process ingredients to produce manganese silicon alloy, the amount of slag is reduced, the power and heat loss are reduced, the unit power consumption is significantly reduced, and the smelting power consumption of manganese silicon alloy is reduced by 75kW.h / t, a decrease of 1.83%.
[0052] 2. Reduced the labor intensity of the smelting operators in front of the furnace: the outdated iron-casting method of the furnace pouring crane was eliminated by the iron-casting method of the slag-iron separator; at the same time, the smelting time was extended and the number of iron-casting furnaces was reduced. The iron-casting time was extended from the original 4 hours per furnace to 8 hours per furnace, and the number of iron-casting furnaces per work shift was changed from 2 furnaces to 1 furnace, which effectively reduced the labor intensity of the smelting operators in front of the furnace.
[0053] 3. Reduce the equipment in front of the furnace: reduce the pouring crane, hoisting equipment, ladles, frames, rails, winches in front of and behind the furnace, etc., which reduces the cost of equipment maintenance and use, and prevents the occurrence of abnormal molten metal overflow accidents.
[0054] 4. Promote the advancement of ferroalloy smelting technology and effectively promote energy conservation and emission reduction, reduce the utilization of resources such as ore and flux, reduce the generation of slag, and reduce environmental pressure.
[0055] The above description is only an illustrative embodiment of the present invention and is not intended to limit the scope of the present invention. The components of the present invention can be combined with each other without conflict, and any equivalent changes and modifications made by any technician in the field without departing from the concept and principle of the present invention should fall within the scope of protection of the present invention.
Claims
1. A green and energy-saving new manganese silicon alloy production method, characterized in that: The method comprises the following steps: Step 1: Control the ratio of silicon dioxide to manganese in the raw fuel and auxiliary materials entering the furnace; Step 2: Adjust the manganese content in the raw fuel and auxiliary materials entering the furnace to ≥32%; Step 3: Control the smelting time and increase the smelting temperature to enrich the Al2O3 content in the slag to 22% to 26% and the manganese content in the slag to 5% to 7%; Step 4: a slag-iron separator is arranged in front of the furnace, and the molten iron and slag are directly drained into the slag-iron separator through a chute when the molten iron and slag are discharged from the furnace.
2. The green and energy-saving new manganese silicon alloy production method according to claim 1 is characterized in that: A calming bag is arranged at the overflow port of the slag-iron separator, and the manganese-silicon alloy is subjected to secondary precipitation in the calming bag to form return slag, which is then fed into the furnace after being cooled and crushed.
3. The green and energy-saving new manganese silicon alloy production method according to claim 1 is characterized in that: In step 1, the ratio of silicon dioxide to manganese in the raw fuel and auxiliary materials entering the furnace is controlled to be 0.73-0.
76.
4. The green and energy-saving new manganese silicon alloy production method according to claim 3 is characterized in that: In step three, the smelting time is controlled to be 8 hours.
5. The green and energy-saving new manganese silicon alloy production method according to claim 4 is characterized in that: In step three, the smelting temperature is increased to 1550°C to 1650°C.
6. The green and energy-saving new manganese silicon alloy production method according to claim 1 is characterized in that: In step three, the manganese content in the slag is controlled to be 6%.
7. The green and energy-saving new manganese silicon alloy production method according to claim 6 is characterized in that: In step three, the slag basicity is controlled to be 0.65-0.75, and the slag-iron ratio of the slag is controlled to be 0.4-0.
6.
8. The green and energy-saving new manganese silicon alloy production method according to claim 1 is characterized in that: Adjust and control the height difference between the iron flow outlet and the iron discharge outlet at the lower end of the slag dam of the slag-iron separator to be 10 to 15 cm.
9. The green and energy-saving new manganese silicon alloy production method according to claim 1 is characterized in that: In step three, the slag-iron ratio of the slag is controlled to be 0.
55.
10. The green and energy-saving new manganese silicon alloy production method according to claim 1 is characterized in that: The recovery rate of manganese element is controlled to be 89% to 90.12%.