烧结自动化系统设计 —烧结配料自动控制系统设计 翻译文档

河北联合大学轻工学院COLLEGE OF LIGHT INDUSTRY, HEBEI UNITED UNIVERSITY 中英文翻译设计题目：烧结自动化系统设计—烧结配料自动控制系统设计学生姓名：学号：专业班级：09自动化3班学部：信息科学与技术部指导教师：2013年5月30日目录原文 (1)译文 (5)原文如今社会钢铁行业发展迅速，前景十分良好，随着高炉对烧结矿品质要求的不断提高，配料已成为烧结技术改造的关键环节。

众所周知，烧结厂配料系统是整个烧结生产的源头，它担负着所有烧结机的混合料供应任务，如果配料系统遇到问题，那么整个烧结生产都要被迫停止，而且配料系统的计算也要准确无误，以为烧结原料的种类多，配料成分随其供货渠道的变化而变化，各单配料的配合比例也会根据生产的要求随时变化，而且在生产过程中，物料的黏度、比重、粒度及环境的温度、湿度的变化，也会严重影响下斜的精度，因此，配料系统对于提高烧结矿的质量至关重要。

自上个世纪60 年代冶金自动化装备问世以来，取得了极其迅猛的发展。

特别是上世纪80 年代种类繁多的PLC和DCS 的出现，冶金自动化装备的可靠性和实时性、可操作性和可维护性都得到极大地改善。

方便的软件编制和友好的人机界面，不断提高的性能价格比，使冶金自动化装备技术得到极快的推广和使用。

“十五”期间,我国重点发展冶金生产过程自动化、工艺智能化和管理信息化技术，其中重点推广和研发技术中就有烧结过程自动化系统。

烧结是把粉状物料转变为致密体，是一个传统的工艺过程。

人们很早就利用这个工艺来生产陶瓷、粉末冶金、耐火材料、超高温材料等。

一般来说，粉体经过成型后，通过烧结得到的致密体是一种多晶材料，其显微结构由晶体、玻璃体和气孔组成。

烧结过程直接影响显微结构中的晶粒尺寸、气孔尺寸及晶界形状和分布。

无机材料的性能不仅与材料组成（化学组成与矿物组成）有关，还与材料的显微结构有密切的关系。

烧结配料自动控制系统在现在应用十分广泛，是在自动控制仪表方面尤其突出。

在此方面根据烧结工艺需求能将各种矿按照所需量自动投入，由皮带运到混合机中进行下一步工艺的生产。

而近年来，我国的钢铁冶炼行业发展十分迅速，烧结矿是炼铁的主原料，而配料这一工艺是影响烧结质量的重要环节，各称量设备只有达到一定精度才能保证矿的质量。

因此烧结配料自动控制系统是各大型钢铁厂必不可少的，也可大大提高生产效率。

烧结生产的工艺流程一般包括：原燃料接受，贮存及熔剂，燃料的准备，配料，混合，布料，点火烧结，热矿破碎，热矿筛分及冷却，冷矿筛分及冷矿破碎，铺底料，成品烧结矿的贮存及输出，返矿贮存等工艺环节。

烧结生产的主要目的是为高炉提供质量优良，强度高，粉末少，还原性好和成分稳定的烧结矿。

国内外普遍采用的是常式抽风烧结机，在我国地方小铁厂还有相当一部分用平地吹风堆烧和箱式抽风烧结。

此外，还有回转窑烧结法、悬浮烧结法。

据相关统计，目前我国有烧结机近500台，其中在建和投产的180～660 m2的大中型烧结机有125台，烧结机面积已达近40000平方米。

未来，我国的烧结机将继续推进全流程工艺技术装备的升级换代，西门子提供的全集成过程控制系统SIMATICPCS7，可以帮助钢铁企业在提升产品质量的同时也将进一步降低能源消耗、减少污染物排放。

由此可见，烧结配料自动控制系统的前景十分乐观，对它的需求只会越来越大，不会减少。

烧结工业的迅速发展是近些年的事，主要的技术新进展表现在:(1)烧结工艺进一步完善;(2)烧结设备进一步改进;(3)新工艺研究。

目前我国钢铁仍然多数生产设备陈旧，部分采用手动操作，自动化程度不高，在配料系统中由于自动化程度较低，而传统烧结工艺中主要依靠工作经验进行调节，因此存在以下几方面的问题：1.过分依靠配料工经验，配料工要熟知各个圆盘每变化1Hz频率所对应的各秤的流量变化应为多少，若配料工经验不足，就会延长调节时间2.调节不及时，圆盘下料始终为给定频率，若料重发生变化，就会使各秤之间配比发生变化；3.配料工半个小时跑盘一次，工作量较大。

4.由于物料的粉尘污染较严重，严重影响工人的身体健康。

随着烧结厂配料系统自动化程度的逐步提高，工业对配料的要求也越来越严格，如果配料系统异常，会造成烧结矿矾矿率增加，结矿率低，同时导致烧结矿消耗燃料上升，烧结矿应有成分波动较大、过少氧化等众多问题。

因此，完善烧结配料系统对提高工厂的技术经济指标十分重要。

本文介绍的事在配料系统中采用西门子S7-300/400系列PLC系列在实际中的成功设计及应用。

烧结生产工艺流程大体如下：1、原料接受、贮存、准备及配料受料系统-----主要包括翻车机系统，受料槽，精矿仓，溶剂仓，储煤仓，主要任务是担负厂内的原料接受、运送和储备。

原料准备系统-----包括含铁原料的中和，燃料的破碎，熔剂的破碎和筛分。

其任务是为配料工序准备好符合生产要求的原料、熔剂和燃料。

配料系统-----包括配料间的矿槽、给料圆盘、称量设备等。

根据规定的烧结矿化学成分，通过计算，按配比、重量进行给料，以保证混合料和烧结矿化学成分稳定，并担负生石灰的加水和燃料的调整。

2、混合、烧结、抽风、冷却混合、造球系统-----主要包括一次混合，混合料矿槽，二次混合等工作（如果使用热返矿，包括返矿打水），其任务是加水，湿润混合料，再经混合机将混合料混匀，造成小球，并对混合料进行预热。

烧结系统-----包括铺料，点火，烧结等。

抽风系统-----包括风箱，集尘管，除尘，抽风等。

产品处理系统-----包括破碎，冷却、筛分、返矿处理和铺底料的分出，成品运输等。

为了使烧结矿满足高炉冶炼的要求，必须根据原料条件，准确地计算出铁料、溶剂、燃料的配比，并根据配料比进行配料，使配合料的主要成分如铁、氧化钙、二氧化石硅、硫、固定碳等的含量合乎规定的技术标准。

烧结厂使用的原料品种比较多，各种原料的化学成分相差也较大，即使是同一品种的原料，其化学成分也有波动。

配料工序就是根据烧结矿的质量指标要求，进行计算配料，控制和稳定烧结矿的化学成分在允许的范围内波动。

同时还可根据各种原料的粒度、熔点及烧结性能配入适量的燃料，保证烧结料含碳量适合于烧结生产的要求，并为有效地除去有害渣质和控制FeO 的含量创造条件。

自动配料控制过程是一个多输入、多数出，且各条配料输送生产线严格协调控制，对料位、流量及时准确地进行监测和调节。

因此，系统由可编程控制器与电子皮带秤组成一个两极计算机控制系统。

通过现场总线连接现场仪器仪表、控制计算机、PLC、变频器等智能程度较高、处理速度快的设备。

在自动配料生产工艺过程中，将辅料与主料按一定比例配合，由皮带秤完成对皮带输送机输送的物料进行计量。

PLC主要承担对输送设备、秤量系统的过程进行实时控制，并完成对系统故障检测、显示及报警，同时向变频器输出信号调节皮带机转速。

WinCC是在生产和过程自动化中解决可视化和控制任务的工业技术中性系统。

它提供了适用于工业的图形显示、消息、归档以及报表的功能模板。

高性能的过程耦合、快速的画面更新、以及可靠的数据使其具有高度的实用性。

本套系统考虑采用集散控制配料系统。

综述了WinCC、PLC技术、变频调速技术的概况。

在这个控制系统中，各仪表的数据可由计算机键盘操作实现对每台仪表的配比设定及启停动作，计算机主要承担管理工作，不直接控制配料，故计算机出现故障时可关掉计算机，此时仪表仍可独自配料，形成一个小小的闭环。

画面监控可实现现场动态画面，显示设备运行状况，可以实施定值、配比、料种、时间的设定，可以进行记录的查询，显示历史实时趋势曲线，并对故障、异常情况进行记录、保存、打印和查询，所以这套系统应能很好的满足现场工艺的要求。

软件设计控制任务由S7-300可编程序控制器来完成，过程监视及远程操作由WinCC来完成。

译文Now the iron and steel industry the rapid development of society, foreground is very good, with the blast furnace to sinter quality requirements increasing, ingredients has become a key link in modification of sintering technology. As everyone knows, batching system sintering plant is the whole sintering production source, it undertakes the mixture supply task for all of the sintering machine, if you encounter problems batching system, then the whole sintering production could be forced to stop, and the calculation burden system should also be accurate, many think of sintering material, change of ingredients with delivery channel. The proportion of change, each single ingredients can change at any time according to the requirements of production, but also in the production process, material proportion, viscosity, particle size and environmental temperature, humidity changes, will seriously affect the lower accuracy, therefore, batching system for improving the quality of vital sinter.Since the last century since the 60's of metallurgical automation equipment available, has been developing very rapidly. Especially there are many kinds of PLC and DCS in the 80's of the last century, metallurgical automation equipment reliability and real-time performance, operability and maintainability are greatly improved. The software is convenient and friendly man-machine interface, continuously improve the performance price ratio, the equipment and technology of metallurgical automation has been popularized and use fast. "Fifteen" period, the development of key metallurgical production process automation, intelligent process and management of information technology in our country, which focus on the promotion and development of technology in sintering process automation system.Sintering is the powdery material into a compact body, is a traditional process. People are already using this technology to the production of ceramic, powder metallurgy, refractories, high temperature materials etc.. In general, the powder after forming, compact body obtained by sintering is a polycrystalline material, the microstructure consists of crystal, vitreous and hole. Sintering process directly affect the microscopic structure of the grain size, pore size and shape and the distribution of grain boundary. Properties of inorganic materials not only with material (chemical composition and mineral composition), it also has a close relation with the material's microstructure.Sintering batching control system now is widely used in automatic control instrument, especially. In this respect according to the demand of sintering process can be all kinds of mine in accordance with the required amount of automatic input, by the belt to the mixer for next process. In recent years, the development of iron and steel smelting industry in China is very rapid, sinter is the main raw material for iron making, and the ingredients of this process is an important link of influence of sintering quality, each weighing equipment only reaches a certain precision to ensure the quality of mine. Therefore the sintering batching control system is essential for the large-scale iron and steel plant, but also can greatly improve the production efficiency.The process of sintering production generally include: raw material acceptance, storage and flux, fuel preparation, batching, mixing, ignition cloth, sintering, hot ore crushing, hot mine sieving and cooling, cold sinter screening and cold ore crushing, bedding, storage and output of finished sinter, mineral storage process.The main purpose of sintering production is for the blast furnace to provide excellent quality, high strength, less powder, good reducibility and stable composition of sinter.Commonly used at home and abroad is often type draught sintering machine, in our local small iron works and quite a part of ground air firing and box draught sintering. In addition, there is the rotary kiln sintering method, suspended sintering method.According to the relevant statistics, at present our country sintering machine 500 sets, which in the construction and production of 180 ~ 660 m2 large sintering machine 125 Taiwan, sintering machine area has reached 40000 square meters. Future, sintering machine in China will continue to advance the process technology and equipment upgrading, SIMATICPCS7 fully integrated process control system provides the Siemens, can help the iron and steel enterprises in upgrading the quality of products at the same time will also further reduce the energy consumption, reduced pollutant discharge. Thus, the automatic control system of sintering burdening is very optimistic about the prospects, the demand for it will become more and more big, will not be reduced. The rapid development of sintering industry is in recent years, new technology developments in the performance of the:(1) to further improve the sintering process.(2) to further improve the sintering equipment.(3) the new technology research.At present, China's steel production is still the majority of obsolete equipment, part of the manual operation, the degree of automation is not high, in batching system due to a lower degree of automation, the traditional sintering process mainly depends on the experience of regulation, so the existing problems in the following aspects:1. relying too much on ingredients work experience, flow rate changes to the scale of each ingredient known as a variation of 1Hz frequency corresponding to the should for how many, if the ingredients work experience, will prolong the adjustment time2. the adjustment is not timely, disc material is always given frequency, if the feed weight changes, will make the ratio of the scale changes between;3. ingredients work half an hour to run a time, workload.4.due to dust pollution material is more serious, serious impact on the health of workers.Along with the gradually improve the degree of automation of sintering plant dosing system, industrial requirements of ingredients are also more stringent, if batching system abnormalities, can cause the sinter ore rate increases, nodes ore rate is low, at the same time lead sinter fuel consumption rise, many problems of sinter composition fluctuation is too large, due to oxidation. Therefore, improving sintering batching system is very important to improve the technical and economic index of plant. This paper introduces the design and application of the success of Siemens S7-300/400 series PLC Series in practice in batching system.Production process of sintering of roughly as follows:1.raw material receiving, storage, preparation and ingredientsFeeding system, mainly including car dumper system, feeding trough, concentrate warehouse, solvent warehouse, storage bunker, the main task is to take the raw material receiving, shipping and storage.Raw material preparation system, including neutralization iron-containing raw material, fuel flux crushing, crushing and screening. Its task is ready for raw materials, flux and fuel production requirements for batch process.Batching system, including ore groove, between ingredients feed disc, weighing equipment etc.. According to the chemical composition, sintering ore specified by calculation, according to the ratio, weight of feeding, mixed feeding to ensure stable and sinter chemical composition, and responsible for lime water and fuel adjustment.2.mixed, sintering, cooling, ventilationMixing, pelleting system, including a mixed, mix mine groove, two mixed work (if you use hot returning ore, including mineral water), whose mission is to add water, wet mixture, then mixed the mixture mixing, resulting in the ball, and preheating the mixture.The sintering system, including paving, ignition, sintering etc..The ventilation system, including wind, dust, dust, exhaust and so.Product handling system, including crushing, cooling, screening, mineral processing and bedding out, finished product transportation.In order to meet the requirements of blast furnace sinter, must according to the raw material conditions, the accurate calculation of iron material, solvent, fuel ratio, and according to the proportion of ingredients, the technical standard with the main content of material such as iron, calcium oxide, silicon oxide, sulfur two stone, fixed carbon, according to the provisions. Comparison of multiple sintering plant using a variety of raw materials, chemical composition of various raw materials are also great, even with a variety of raw materials, its chemical composition has fluctuation. The batching process is according to the requirement of quality index of sinter, calculate ingredients, chemical composition and control of stabilized sinter fluctuations in the allowed range. At the same time can also be based on a variety of grain size of raw material, melting and sintering properties of adding fuel, ensure sinter carbon content is suitable for sintering production requirements, and effectively remove the content of harmful residues and control FeO conditions.The automatic batching control process is a multiple input, the majority, and each ingredient conveying production line strictly coordinated control, on the material level, flow of timely and accurate monitoring and regulation. Therefore, the system consists of a programmable controller and electronic belt scale is composed of a bipolar computer control system. On-site instrumentation, control computer, PLC, frequency converter and intelligent degree high, processing equipment speed through the field bus connectionIn the production process of the automatic batching process, the material and main material in certain proportion, completed by the belt weigher conveying belt conveyor material measurement. PLC is mainly responsible for the process of conveying equipment, weighing system for real-time control, and complete the system fault detection, display and alarm, and adjust the speed of belt conveyor to the transducer output signal.WinCC is industrial technology-neutral system to solve the visualization and control tasks in production and process automation. It provides suitable for industrial graphic display, news, filing and report function template. The process coupling, high performance fast picture updating, and the reliable data which has high practicability. This set of system to consider the use of distributed control system. An overview of WinCC, PLC technology, variable frequency speed control technology. In this control system, the computer keyboard operation of each instrument ratio setting and start and stop the action of each instrument data, computer is mainly responsible for the management, not directly control the ingredients, so the computer failure can be shut off the computer, this instrument can only from the ingredient, forming a small loop. Realization of field dynamic picture monitor, display equipment status, can implement a fixed value, proportion, material, time setting, can record query, display real-time trend curve of history, and the fault, abnormal situation record, save, print and query, so this system can meet the process very good requirements. The design of the control software of S7-300 to complete the task by the programmable controller, process monitoring and remote operation is completed by WinCC.9。