ity. Jintang adopted an automatic control system for charging, mixing and burning. The casting workshop is equipped with a spectrum analyzer and electronic mixing system for sintering.
6. The comprehensive use of resources In Jintang’s experience, 3,500 cu. m of gas can be pro-
duced by burning 1 ton of coke in a blast furnace. Te gas can be used two ways: in the boiler in the power plant or in the industrial blast furnaces, ovens or kilns. Comprehensive use of gas avoids waste and serves production. Since the energy content of the gas released from the
blast furnace is low, it is hard to achieve high temperatures by burning. So, both air and gas are preheated in the tem- pering furnace for ductile iron pipe. Meanwhile, a new and high efficiency heat exchange, high insulation fiber and dual valves and computer control system are applied to satisfy pipe production.
7. Recycling wastes and discharges Treatment systems for wastewater, slag, gas and
sintering and desulfurization equipment were installed at Jintang. A 60-ton/hour wastewater treating work- shop gathers all the wastewater of the sector and adopts biochemical methods for treatment. The recycled water can be used as cooling agent for the blast and induction furnaces, slag flushing and lawn watering. Zero discharge of wastewater is achieved. An electrostatic dust precipitator and desulfuriza-
tion station are equipped at the feed end of the sinter machine, and a dust collection system covers the dis- charge end of the sinter machine, taphole field, elevated charging hopper, shipping stations, induction furnaces and sand processing equipment. The gathered iron-containing dust is used for sinter-
ing, and the rest is used to make construction materials, such as brick.
8. External treatment system Because of the poor stability of Jintang’s small blast
furnace, the composition of the melt fluctuates widely, especially the detrimental elements sulfur, phosphorus, titanium and chromium. An external treatment system can be used to compensate. It would expand the supply of raw materials, stabilize the composition of the melt, reduce cost and improve quality. However, more work must be done for the method to be applied to the small blast furnace. Currently at Jintang, 80% of the melt of a 128-cu. m blast
furnace is used for the shortcut procedure production, the coke-iron ratio is below 490 kg, energy consumption during melting is 457 kg of standard coal (lower than the nationally specified standard of 520 kg), the usage of gas released by the blast furnace reaches 98%, and zero wastewater discharge is realized. ■
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6．实现能源综合利用
高炉煤气的利用是小高炉节能潜力最大的环节。根 据经验计算，高炉冶炼时，每吨焦炭可产生高炉煤气 3,500m3左右。当前利用高炉煤气的方式主要有两种， 一种是利用高炉煤气烧锅炉，建设发电机组进行发电。 另一种是作为工业炉窑的燃料。津唐公司高炉煤气主要 用于热处理炉，建设了煤气加压站。统一调配各用气站 点的煤气量，做到了既保证生产，又不浪费。 由于高炉煤气热值低，燃烧时难以获得高温，我们在 离心球墨铸铁管退火炉上采用了空气、煤气双预热燃烧 方式，并采用新型高效球式换热器、耐火纤维保温毡、 高效换向阀门、计算机集中控制等技术，满足了铸管生 产的要求。
7．重视废弃物回收与再利用，配备完善的废水、 废渣、废气处理设施和烧结脱硫设施。
津唐公司建设了60t/h的工业和生活污水处理厂，采 用生化技术，对工业园区内所有废水进行收集，集中处 理，处理后的中水可作为高炉冷却水、冲渣水、铸造厂 电炉冷却水、绿化用水等，做到了污水零排放。 在烧结机机头配备静电除尘器和脱硫站，在烧结机机 尾、高炉出铁场、高架料仓、各处转运站、中频电炉、 铸造砂处理等处配备布袋除尘器。
收集的含铁粉尘用于烧结配料，其他粉尘用于制造砂 砖等建筑材料。
8．建设高炉铁水炉外处理设施
小高炉稳定性较差，铁水成分波动较大，尤其是生 产铸造生铁，S、P、Ti、Cr等有害元素要严格控制。采 用低温冶炼+炉外处理工艺，增加了一种处理和补救手 段，可以扩大原燃料来源，稳定铁水成分，提高生铁质 量，降低生产成本。
铁水炉外处理工艺已被证明是一种有效工艺方法。用 于冶炼铸造生铁的小高炉，由于出铁量小、铁水物理温 度低，尚无合适的定型设备及工艺，还需进一步实验。 津唐公司高炉铁水炉外处理设施正在建设中。 目前，津唐公司用于短流程铸造的128m3高炉，短流 程工艺使用铁水占高炉产量的80%，高炉煤气利用率达 到98%，废水做到了零排放，高炉焦比490kg以下，炼铁 工序能耗457kg标煤，低于国家规定的520kg标煤标准。 短流程铸造工艺作为一种新的生产工艺，具有明显 的节能减排、降低成本优势，发展前景十分广阔。但其 中存在的一些问题更需要重视，特别是生产中小型铸铁 件时，铁水的运输、保温及铸造工序处理工艺，决定着 短流程铸造工艺的成败。作为短流程铸造工艺的重要环 节——小高炉炼铁，其技术进步，是短流程铸造工艺能 够得以继续存在和发展的重要前提。 ■
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION Fall 2011
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