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非高炉炼铁HIsmelt工艺特征是:向熔池内直接喷吹铁矿粉和煤粉,形成熔炼炉下部的熔炼和上部鼓入富氧热风形成的二次燃烧。其核心是:通过喷溅完成上部燃烧区(高氧势)到下部熔炼区(低氧势)的热传递。西澳奎纳纳(Kwinana)建成首座80万t/a的HIsmelt工厂。2005年4～10月完成热调试,从此进入长时间的生产摸索期。主体冶炼工艺表明其生产率可达设计产能的75%～80%,主工艺喷吹煤比约为800kg/t。热矿喷吹系统(外围)可进一步优化,如果2010年市场形势好转,将对其进行改进,并会将熔炼炉排出的煤气引入矿粉预热器,以期提高生产率,接近设计产能的100%,且煤比降至约700kg/t。由于一些原因,工厂作业率不是很理想。低的作业率(即频繁开停)导致耐材寿命很短。为了延长耐材寿命,2008年工厂安装了一套铜质水冷渣线冷却器,显著延长了炉役周期,并极大提升了工厂的操作水平。HIsmelt的熔炼炉是关键所在,除此外其他影响作业率的因素在奎纳纳已不是问题。目前就是不断解决限制产能发挥的各种问题。
HIsmelt process characteristics of non-blast furnace ironmaking are: direct injection of iron ore powder and pulverized coal into the molten pool to form the lower part of the smelting furnace and the upper part of the oxygen-enriched hot blast to form a secondary combustion. Its core is: through the splashing to complete the upper combustion zone (high oxygen potential) to the lower melting zone (low oxygen potential) heat transfer. Western Australia Kwinana built the first 800,000 t / a HIsmelt plant. April to October 2005 to complete the thermal test, from a long time to enter the production trial period. The main smelting process shows that its productivity can reach 75% ~ 80% of the design capacity, and the main process injection coal ratio is about 800kg / t. The hot mine injection system (periphery) can be further optimized and if the market improves in 2010, it will be improved and the gas emitted from the smelter will be introduced into the slag preheater in order to increase productivity close to 100% of the design capacity , And the coal ratio dropped to about 700 kg / t. For some reasons, the factory operating rate is not very satisfactory. Low operating rates (ie frequent opening and closing) lead to short refractory life. In order to prolong the life of refractory materials, a copper water-cooled slag cooler was installed in the factory in 2008, which significantly prolonged the service cycle and greatly improved the operation level of the factory. HIsmelt smelting furnace is the key, in addition to other factors that affect the operating rate in Kuena is no longer a problem. At present, we are constantly solving various problems that limit the production capacity.