铝合金熔体制备供应能耗计算与分析

发布时间：2018-03-25 11:31

本文选题：铝合金　切入点：熔体制备供应　出处：《重庆大学》2015年硕士论文

【摘要】：“能耗测量及能耗级别标准化”是近年来根据我国为“发展能源高效利用技术、加强能耗管理,实现节能增效”提出的,以期为各领域单产能耗提供测量依据和评价标准。但我国铝压铸业的“熔体制备供应工序”能耗的测量及评价方法迄今仍然缺失。为了推动我国压铸铝合金熔体制备供应过程能耗的检测与评价体系建设,本文在对压铸铝合金熔炼理论能耗进行热力学计算,深入现场考察压铸铝合金熔体制备供应现行模式各工部(即:铝合金炉料熔化、熔体精炼、熔体转运及保温浇注)实施状况、记录能耗数据、分析耗能机制的同时,提出了各工序能耗的评价方法,甄别最具节能潜力的工艺环节,以期为日后研究节能技术、建立能耗测量评价方法提供数据支持;最后,作者提出了“压铸铝合金熔体制备供应一体化”思路,并在一个炉型上考核其节能潜力。上述研究的主要结论如下:①确定铝合金熔体制备供应全过程的热收入为:燃料燃烧热(电能)和元素氧化反应热,热支出为:铝合金熔体、烟气和炉渣物理热,炉门辐射热和炉墙辐射对流散热及炉料和熔体物流耗能;并根据能量守恒定律建立了铝合金熔体制备供应的热平衡模型;②除铝合金熔体在工部间转移产生的能耗和热损失外,现行铝合金熔体制备工艺模式的主要耗能设备为集中熔化炉、精炼炉及保温炉,其能耗分别占总能耗的73%、5%、22%;③集中熔化炉的能耗约为吨熔体75m3标准立方米天然气,其中有效利用的热能占燃料燃烧热的44%,而排放烟气物理热占35%,炉壁散热占8%,炉渣物理热和炉门辐射散热较小,分别为2%和4%;④理论上,铝合金熔体在精炼炉和保温炉中温度不发生变化,因此精炼炉和保温炉的热效率均为0,精炼炉的热损失分布主要是炉渣物理热7%,炉门辐射散热23%,排放烟气物理热38%,炉墙散热21%;保温炉的热损失分布主要是炉渣物理热0.5%,炉门辐射散热23%,排放烟气物理热35%,炉墙散热24.5%;⑤根据现行铝合金熔体制备供应过程能耗分布以及设备能耗分布的特点,提出了“一体化铝合金熔体制备供应”的构思,即:在单一熔体制备供应设备中实现“加料、熔化、精炼、保温、浇注”。这不仅能消除物流能耗和熔体转移热损失,还会减少烟气排放、炉门数量和炉体总表面积,进而实现显著节能;⑥采用比例燃烧和蓄热燃烧技术,将烟气排放温度降低至150oC后,每小时供液能力为1.5t的“一体炉”制备供应一吨铝合金熔体仅耗54m3标准立方米天然气,和现行铝合金熔体制备供应过程的能耗相比,降低了47.6%。
[Abstract]:In recent years, "Energy consumption Measurement and Energy Grade Standardization" has been put forward for the purpose of "developing energy efficient utilization technology, strengthening energy consumption management, realizing energy saving and increasing efficiency" in our country. In order to provide the measurement basis and evaluation standard for energy consumption per unit yield in various fields, however, the method of measuring and evaluating the energy consumption of "melt preparation supply process" in China's aluminum die casting industry is still missing. In order to promote the melt of die casting aluminum alloy in China, the method of measuring and evaluating energy consumption is still missing. Construction of energy consumption detection and evaluation system for manufacturing and supply process, In this paper, the thermodynamic calculation of the theoretical energy consumption of die-casting aluminum alloy melting is carried out, and the various parts of die casting aluminum alloy melt preparation and supply mode (I. e., aluminum alloy charge melting, melt refining) are investigated in the field. While recording the energy consumption data and analyzing the energy consumption mechanism, the evaluation method of energy consumption in each process is put forward, and the process with the most potential energy saving is identified in order to study the energy saving technology in the future. The method of energy consumption measurement and evaluation was established to provide data support. Finally, the author put forward the idea of "integration of preparation and supply of die cast aluminum alloy melt". The main conclusions of the above research are as follows: 1. The heat income of the whole process of aluminum alloy melt preparation and supply is determined as follows: fuel combustion heat (electric energy) and elemental oxidation reaction heat, and the heat expenditure is aluminum alloy melt. Physical heat of flue gas and slag, radiant heat of furnace door and radiation convection of furnace wall, energy consumption of charge and melt flow; According to the law of conservation of energy, the heat balance model for the preparation and supply of aluminum alloy melt is established except for the energy consumption and heat loss caused by the transfer of aluminum alloy melt between the parts of the aluminum alloy. The main energy consuming equipments in the current process mode of aluminum alloy melt preparation are concentrated melting furnace, refining furnace and heat preservation furnace. Their energy consumption accounts for 73% of the total energy consumption respectively. The energy consumption of the furnace is about the 75m3 standard cubic meter of natural gas. The effective utilization of heat energy accounts for 44% of the combustion heat of fuel, while the physical heat of flue gas is 35%, the heat dissipation of furnace wall is 8%, and the physical heat of slag and the radiative heat of furnace door are smaller, which are 2% and 4% respectively. The temperature of aluminum alloy melt does not change in refining furnace and heat preservation furnace. Therefore, the thermal efficiency of refining furnace and heat preservation furnace are both 0. The heat loss distribution of refining furnace is mainly about slag physical heat distribution, furnace door radiating heat dissipation is 23, flue gas physical heat dissipation is 38, wall heat dissipation is 21, heat loss distribution of heat preservation furnace is mainly slag physics. Heat 0.5, furnace door radiative heat dissipation 23, flue gas physical heat 35, furnace wall heat dissipation 24.5. according to the characteristics of energy consumption distribution and equipment energy consumption distribution in the current aluminum alloy melt preparation process, The idea of "integrated melt preparation supply" is put forward, that is, to realize "feeding, melting, refining, heat preservation and pouring" in a single melt preparation supply equipment, which can not only eliminate the loss of material flow energy consumption and melt transfer heat. It can also reduce flue gas emissions, the number of furnace doors and the total surface area of the furnace body, thus achieving significant energy saving. By adopting proportional combustion and regenerative combustion technology, the flue gas discharge temperature will be reduced to 150oC. One ton of aluminum alloy melt supplied by "one body furnace" with 1.5 t per hour liquid supply only consumes 54m3 standard cubic meter of natural gas, compared with the energy consumption of current aluminum alloy melt preparation supply process, the energy consumption is reduced by 47.6%.
【学位授予单位】：重庆大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG292

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