I. Overview
Before the early 1970s, most of the sintering machines in China were old-fashioned sintering machines with curved curves. The structure was unreasonable, the sealing was not good, and the air leakage rate was as high as 45% to 75%. After the early 1970s, a new batch was built in China. The new sintering machine and the old-fashioned sintering machine have been technically modified to different degrees, so that the air leakage rate is reduced to 40% to 60%. Compared with foreign advanced countries, the leakage of the sintering machine in China is quite serious, and the leakage of the sintering machine in Japan The rate is not more than 30%. The main parts that affect the air leakage of the sintering machine are: (1) the head and tail of the sintering machine bellows; (2) between the skateboard and the slide on both sides of the trolley; (3) the connection method of the main exhaust system Lan and dust control pipe at the lower double ash valve.
Reducing the air leakage rate of the sintering machine is an important measure to improve the production and quality of the sinter, save the power consumption of the main exhaust fan, and reduce the energy consumption of the process.
Second, reasonable sintering machine structure design (a) reasonable trolley structure design The leakage parts of the trolley are: deformation of the trolley body, between adjacent trolleys, between adjacent fences, and elastic seal box structure.
In order to solve the problem of deformation of the trolley body, the design of the trolley body should meet the reasonable main beam height under the alternating action of thermal stress. The structure of the two main beams and two sub-beams should be installed on the trolley body. Insulation to reduce temperature differences.
In order to eliminate the gap between adjacent car bodies as much as possible, the end of the trolley body should be nested with a wear plate made of high carbon steel and quenched.
The structure of the slab is preferably integral or upper and lower, and the arrangement of the ribs is conducive to thermal expansion and contraction. There should be high temperature and wear resistant sealing measures between adjacent panels.
The elastic sealing box not only requires sufficient elasticity, but also the activity should be sensitive, and the movable gap should be set to prevent leakage.
Fastener carriage should be used to select a low expansion coefficient alloy steel locknut and special bolts. Grate bar should be high chromium cast iron and to ensure its dimensional accuracy, in order to improve the life and prevent the formation of voids after falling.
All processing locations should meet dimensional accuracy and shape tolerance requirements.
(2) Reasonable bellows structure design The air leakage parts of the bellows include: bellows floating, lateral displacement of the bellows, deformation and loosening of the connecting flange, and unreasonable displacement compensation of the bronchi.
The bellows design must be provided to prevent the bellows from floating and to set the lateral displacement mechanism of the bellows. The connecting flange of the bellows should have sufficient rigidity, and the fasteners should be selected with alloy steel special bolts and locknuts with low expansion coefficient.
The amount of displacement compensation for the bronchi should be determined after a rigorous, evidenced calculation.
All welds after the bellows assembly must be tested for air tightness.
The consolidation of the slideway shall be made of alloy steel special bolts with low expansion coefficient and locknuts and welded on the inside to prevent air leakage. Seals should be provided at the joints of the frame beams.
All joints of the bellows must be coated with a flange sealant in addition to a reasonable selection of gaskets.
(III) Reasonable end seal structure design The end seal leak is caused by its unreasonable structure. The heavy-duty lever hinge-type sealing device set by the new sintering machine can adjust the sealing gap of the bottom beam of the trolley and properly handle the problem of ash discharge, and at the same time control the trolley beam without “slipping downâ€, therefore, sealing good results.
The effect of the device has a great relationship with the quality of fabrication and assembly. Zero and parts must be manufactured to meet the material, dimensional accuracy and shape tolerance requirements of the design. The assembly quality must meet the requirements of flexible swing.
(IV) Reasonable design of air duct and dust-reducing pipe The main air leakage parts of air-conducting pipe and dust-reducing pipe are: ash discharge valve, dust-reducing pipe, pipe connection and manhole, maintenance door, etc.
The structural design of the ash discharge valve is mainly a cone valve and a shaft end seal. At the same time, you must ensure that the activities are flexible. Moreover, the selection of its pneumatic components is crucial.
The dust-reducing pipe and pipe connection shall be designed to have sufficient flange connection rigidity. In addition to the gasket, the flange sealant shall be applied and the special steel alloy bolts and locknuts with low expansion ratio shall be applied. The selection of the compensator must be strictly calculated.
The structure of the manhole and the inspection door should not only consider the convenience of opening and closing, but also the tightness and reliability of the sealing. A currently effective method is to use a silicone rubber seal.
Welds everywhere shall be tested for air tightness. [next]
(V) Optimized chute lubrication design The chute lubrication of the sintering machine is not only required in the selection of lubricants and the design of the lubrication system, but also in the selection, circulation mode and automation level of the fuel supply pump. Otherwise, an oil film cannot be formed between the trolley sealing plate and the bellows sliding plate, which not only fails to provide lubrication, but also causes the sealing to be broken, resulting in the degree of wear of the sliding plate being different.
At present, it is more suitable to select the 20MPa or 40MPa class oil supply pump, the circulating self-contained electric control box, and the automatic lubrication device with adjustable lubrication system.
(6) Preventing the “arching†of the trolley When the trolley is detached from the tail of the sintering machine and is running on the return lane, it is often easy to “archâ€. The reason is that the tail weight is too heavy and the star gear structure is designed. unreasonable.
After a long period of research, we have a unique aspect in the design of the tooth plate structure to ensure that it does not “archâ€.
(VII) Reasonable selection of standard parts and basic parts Standard parts and basic parts are essential zeros and components, which directly affect the performance and operation rate of the main machine. Due to the great difference in performance and reliability of the products of various manufacturers, it is necessary to conduct in-depth investigations in the design and determine the manufacturers after strict screening.
Some host manufacturers often change the ordering unit or self-made, and the result affects the performance and operating rate of the host, resulting in an increase in air leakage rate.
Therefore, the host design unit should specify the manufacturer of the standard parts and basic parts.
Third, strict production requirements
(1) Strict selection of the production plant The sintering air leakage rate is closely related to the material and production accuracy of the sintering machine. When selecting a host manufacturer, it is necessary to examine the equipment capabilities, the manufacturing process, the means, the qualifications, the technical strength, the quality of the workers, and the degree of collaboration with the design unit. After strict screening, they can be used as bidders. one. And technically, they should be ranked in order of their strengths and weaknesses.
(II) The bidding system has yet to be improved. Most of the equipment tenders in the past have been judged by the judges who are mainly owners. They don't know much about the performance, production requirements and production plants of the mainframe. There is no reserve price when singing. Therefore, it is easy to enter the misunderstanding of winning at the lowest price.
Therefore, the Tendering Bureau should hire the equipment design unit to propose the requirements for equipment production and the detailed design of the equipment. At the same time, the Tendering Bureau should employ an authoritative evaluation unit to evaluate the bidding equipment price. When calculating the reserve price, the profit and tax of the production plant should be fully considered. Any winning bid without profit or loss can not guarantee the quality of equipment production. Not conducive to the production of the owner. The composition of the bidding judges shall involve the owners, design and manufacture of the technical experts of the three parties, and the administrative and chief intervention from any party shall be excluded during the bid evaluation. In the process of bid evaluation, the technical standard and economic standard should be evaluated, and the technical standard should be the first place at any time.
(III) Adhere to equipment supervision In order to ensure the quality of equipment production, it is necessary to carry out equipment supervision. It guarantees the implementation of the design content, the implementation of the design intent, the description of certain special design requirements and the requirements for production, which is one of the important means to ensure the quality of equipment production.
Equipment supervision should be paid service. The equipment design unit shall prepare a supervisory outline, and make clear production requirements, inspection standards and acceptance rules for important parts and components, and supervise the whole process of the host production.
(4) Strict inspection and acceptance system According to the supervisory outline of the equipment design unit and the inspection report, assembly record, inspection record and accident handling opinions provided by the manufacturer, the equipment parts before leaving the factory are strictly inspected and signed by the owner, design and production. After leaving the factory.
Strict acceptance system is an important means to ensure the quality of equipment production, because according to the inspection results, the manufacturer can modify the factory before leaving the factory, which can eliminate the hidden dangers during equipment commissioning and trial production. [next]
IV. Strict installation requirements (1) Strictly select the installation unit of the installation unit to select equipment, not only to check its installation qualifications, installation process and equipment level, but also to examine its technical strength, the quality of workers and the degree of cooperation with the design unit. After strict screening, it can be used as one of the units participating in the bidding, and technically should be ranked in order of their superiority and inferiority.
(II) Adhere to the construction supervision The equipment design unit must send personnel to explain the design intent and design content to the construction and the owner, and explain the requirements for installation and some special installation requirements. And cooperate with the installation and supervision of the implementation of the design documents. Otherwise, the installation is wrong or not in place, which will seriously affect the debugging of the device and the performance of the host.
(III) Strictly carry out equipment commissioning After the installation of the equipment is completed, it shall be tested and adjusted. Perform the necessary tests and tests to verify that the technical parameters meet the design requirements. The process of debugging is the rectification process, and sufficient debugging time must be given to meet the design requirements of the equipment.
5. Scientific design, manufacturing, and construction cycle
In the feasibility study or preliminary design stage of engineering design, the design unit shall propose scientific and practical equipment design, equipment manufacturing, equipment installation and commissioning cycle.
There is no quality guarantee for a period without science. Otherwise, it will enter a false misunderstanding, which will eventually result in greater waste of financial and material resources, and the result of delays in the progress of the project.
Six, strictly abide by the operating procedures of the sintering machine
The operating procedure of the sintering machine has been described in detail in the installation and operation instructions of the sintering machine.
The operator of the sintering machine must operate in strict accordance with the operating procedures, otherwise an accident will occur.
7. Strengthen production and maintenance and operation management
To reduce the air leakage rate of the sintering machine, in addition to good equipment design, equipment manufacturing and equipment installation, it is necessary to close the production and maintenance and operation management to facilitate the blockage of air leakage from the main exhaust system, the dust collector system and the sintering machine body system. . In the production operation, the hot deformation and collapse of the trolley are common problems in various factories, which may lead to poor contact between the bottom of the trolley and the floating seal plate of the nose and the tail; the trolley fence cracks, the stringer falls off or breaks. Failure to replace in time, causing the material layer to form a funnel-shaped hole; the gap between the shackle pin and the matching hole is too large, and the air leakage rate is improved due to uneven cloth production, groove drawing, etc. due to poor production and maintenance and operation management. Therefore, it is necessary to strengthen production maintenance and operation management.
Before the early 1970s, most of the sintering machines in China were old-fashioned sintering machines with curved curves. The structure was unreasonable, the sealing was not good, and the air leakage rate was as high as 45% to 75%. After the early 1970s, a new batch was built in China. The new sintering machine and the old-fashioned sintering machine have been technically modified to different degrees, so that the air leakage rate is reduced to 40% to 60%. Compared with foreign advanced countries, the leakage of the sintering machine in China is quite serious, and the leakage of the sintering machine in Japan The rate is not more than 30%. The main parts that affect the air leakage of the sintering machine are: (1) the head and tail of the sintering machine bellows; (2) between the skateboard and the slide on both sides of the trolley; (3) the connection method of the main exhaust system Lan and dust control pipe at the lower double ash valve.
Reducing the air leakage rate of the sintering machine is an important measure to improve the production and quality of the sinter, save the power consumption of the main exhaust fan, and reduce the energy consumption of the process.
Second, reasonable sintering machine structure design (a) reasonable trolley structure design The leakage parts of the trolley are: deformation of the trolley body, between adjacent trolleys, between adjacent fences, and elastic seal box structure.
In order to solve the problem of deformation of the trolley body, the design of the trolley body should meet the reasonable main beam height under the alternating action of thermal stress. The structure of the two main beams and two sub-beams should be installed on the trolley body. Insulation to reduce temperature differences.
In order to eliminate the gap between adjacent car bodies as much as possible, the end of the trolley body should be nested with a wear plate made of high carbon steel and quenched.
The structure of the slab is preferably integral or upper and lower, and the arrangement of the ribs is conducive to thermal expansion and contraction. There should be high temperature and wear resistant sealing measures between adjacent panels.
The elastic sealing box not only requires sufficient elasticity, but also the activity should be sensitive, and the movable gap should be set to prevent leakage.
Fastener carriage should be used to select a low expansion coefficient alloy steel locknut and special bolts. Grate bar should be high chromium cast iron and to ensure its dimensional accuracy, in order to improve the life and prevent the formation of voids after falling.
All processing locations should meet dimensional accuracy and shape tolerance requirements.
(2) Reasonable bellows structure design The air leakage parts of the bellows include: bellows floating, lateral displacement of the bellows, deformation and loosening of the connecting flange, and unreasonable displacement compensation of the bronchi.
The bellows design must be provided to prevent the bellows from floating and to set the lateral displacement mechanism of the bellows. The connecting flange of the bellows should have sufficient rigidity, and the fasteners should be selected with alloy steel special bolts and locknuts with low expansion coefficient.
The amount of displacement compensation for the bronchi should be determined after a rigorous, evidenced calculation.
All welds after the bellows assembly must be tested for air tightness.
The consolidation of the slideway shall be made of alloy steel special bolts with low expansion coefficient and locknuts and welded on the inside to prevent air leakage. Seals should be provided at the joints of the frame beams.
All joints of the bellows must be coated with a flange sealant in addition to a reasonable selection of gaskets.
(III) Reasonable end seal structure design The end seal leak is caused by its unreasonable structure. The heavy-duty lever hinge-type sealing device set by the new sintering machine can adjust the sealing gap of the bottom beam of the trolley and properly handle the problem of ash discharge, and at the same time control the trolley beam without “slipping downâ€, therefore, sealing good results.
The effect of the device has a great relationship with the quality of fabrication and assembly. Zero and parts must be manufactured to meet the material, dimensional accuracy and shape tolerance requirements of the design. The assembly quality must meet the requirements of flexible swing.
(IV) Reasonable design of air duct and dust-reducing pipe The main air leakage parts of air-conducting pipe and dust-reducing pipe are: ash discharge valve, dust-reducing pipe, pipe connection and manhole, maintenance door, etc.
The structural design of the ash discharge valve is mainly a cone valve and a shaft end seal. At the same time, you must ensure that the activities are flexible. Moreover, the selection of its pneumatic components is crucial.
The dust-reducing pipe and pipe connection shall be designed to have sufficient flange connection rigidity. In addition to the gasket, the flange sealant shall be applied and the special steel alloy bolts and locknuts with low expansion ratio shall be applied. The selection of the compensator must be strictly calculated.
The structure of the manhole and the inspection door should not only consider the convenience of opening and closing, but also the tightness and reliability of the sealing. A currently effective method is to use a silicone rubber seal.
Welds everywhere shall be tested for air tightness. [next]
(V) Optimized chute lubrication design The chute lubrication of the sintering machine is not only required in the selection of lubricants and the design of the lubrication system, but also in the selection, circulation mode and automation level of the fuel supply pump. Otherwise, an oil film cannot be formed between the trolley sealing plate and the bellows sliding plate, which not only fails to provide lubrication, but also causes the sealing to be broken, resulting in the degree of wear of the sliding plate being different.
At present, it is more suitable to select the 20MPa or 40MPa class oil supply pump, the circulating self-contained electric control box, and the automatic lubrication device with adjustable lubrication system.
(6) Preventing the “arching†of the trolley When the trolley is detached from the tail of the sintering machine and is running on the return lane, it is often easy to “archâ€. The reason is that the tail weight is too heavy and the star gear structure is designed. unreasonable.
After a long period of research, we have a unique aspect in the design of the tooth plate structure to ensure that it does not “archâ€.
(VII) Reasonable selection of standard parts and basic parts Standard parts and basic parts are essential zeros and components, which directly affect the performance and operation rate of the main machine. Due to the great difference in performance and reliability of the products of various manufacturers, it is necessary to conduct in-depth investigations in the design and determine the manufacturers after strict screening.
Some host manufacturers often change the ordering unit or self-made, and the result affects the performance and operating rate of the host, resulting in an increase in air leakage rate.
Therefore, the host design unit should specify the manufacturer of the standard parts and basic parts.
Third, strict production requirements
(1) Strict selection of the production plant The sintering air leakage rate is closely related to the material and production accuracy of the sintering machine. When selecting a host manufacturer, it is necessary to examine the equipment capabilities, the manufacturing process, the means, the qualifications, the technical strength, the quality of the workers, and the degree of collaboration with the design unit. After strict screening, they can be used as bidders. one. And technically, they should be ranked in order of their strengths and weaknesses.
(II) The bidding system has yet to be improved. Most of the equipment tenders in the past have been judged by the judges who are mainly owners. They don't know much about the performance, production requirements and production plants of the mainframe. There is no reserve price when singing. Therefore, it is easy to enter the misunderstanding of winning at the lowest price.
Therefore, the Tendering Bureau should hire the equipment design unit to propose the requirements for equipment production and the detailed design of the equipment. At the same time, the Tendering Bureau should employ an authoritative evaluation unit to evaluate the bidding equipment price. When calculating the reserve price, the profit and tax of the production plant should be fully considered. Any winning bid without profit or loss can not guarantee the quality of equipment production. Not conducive to the production of the owner. The composition of the bidding judges shall involve the owners, design and manufacture of the technical experts of the three parties, and the administrative and chief intervention from any party shall be excluded during the bid evaluation. In the process of bid evaluation, the technical standard and economic standard should be evaluated, and the technical standard should be the first place at any time.
(III) Adhere to equipment supervision In order to ensure the quality of equipment production, it is necessary to carry out equipment supervision. It guarantees the implementation of the design content, the implementation of the design intent, the description of certain special design requirements and the requirements for production, which is one of the important means to ensure the quality of equipment production.
Equipment supervision should be paid service. The equipment design unit shall prepare a supervisory outline, and make clear production requirements, inspection standards and acceptance rules for important parts and components, and supervise the whole process of the host production.
(4) Strict inspection and acceptance system According to the supervisory outline of the equipment design unit and the inspection report, assembly record, inspection record and accident handling opinions provided by the manufacturer, the equipment parts before leaving the factory are strictly inspected and signed by the owner, design and production. After leaving the factory.
Strict acceptance system is an important means to ensure the quality of equipment production, because according to the inspection results, the manufacturer can modify the factory before leaving the factory, which can eliminate the hidden dangers during equipment commissioning and trial production. [next]
IV. Strict installation requirements (1) Strictly select the installation unit of the installation unit to select equipment, not only to check its installation qualifications, installation process and equipment level, but also to examine its technical strength, the quality of workers and the degree of cooperation with the design unit. After strict screening, it can be used as one of the units participating in the bidding, and technically should be ranked in order of their superiority and inferiority.
(II) Adhere to the construction supervision The equipment design unit must send personnel to explain the design intent and design content to the construction and the owner, and explain the requirements for installation and some special installation requirements. And cooperate with the installation and supervision of the implementation of the design documents. Otherwise, the installation is wrong or not in place, which will seriously affect the debugging of the device and the performance of the host.
(III) Strictly carry out equipment commissioning After the installation of the equipment is completed, it shall be tested and adjusted. Perform the necessary tests and tests to verify that the technical parameters meet the design requirements. The process of debugging is the rectification process, and sufficient debugging time must be given to meet the design requirements of the equipment.
5. Scientific design, manufacturing, and construction cycle
In the feasibility study or preliminary design stage of engineering design, the design unit shall propose scientific and practical equipment design, equipment manufacturing, equipment installation and commissioning cycle.
There is no quality guarantee for a period without science. Otherwise, it will enter a false misunderstanding, which will eventually result in greater waste of financial and material resources, and the result of delays in the progress of the project.
Six, strictly abide by the operating procedures of the sintering machine
The operating procedure of the sintering machine has been described in detail in the installation and operation instructions of the sintering machine.
The operator of the sintering machine must operate in strict accordance with the operating procedures, otherwise an accident will occur.
7. Strengthen production and maintenance and operation management
To reduce the air leakage rate of the sintering machine, in addition to good equipment design, equipment manufacturing and equipment installation, it is necessary to close the production and maintenance and operation management to facilitate the blockage of air leakage from the main exhaust system, the dust collector system and the sintering machine body system. . In the production operation, the hot deformation and collapse of the trolley are common problems in various factories, which may lead to poor contact between the bottom of the trolley and the floating seal plate of the nose and the tail; the trolley fence cracks, the stringer falls off or breaks. Failure to replace in time, causing the material layer to form a funnel-shaped hole; the gap between the shackle pin and the matching hole is too large, and the air leakage rate is improved due to uneven cloth production, groove drawing, etc. due to poor production and maintenance and operation management. Therefore, it is necessary to strengthen production maintenance and operation management.
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