今天，《中國日報》全英文刊發文章介紹太重集團的7.25米搗固焦爐設備。
Executives of Taiyuan Heavy Machinery Group and Jianyuan Coking attend an agreement signing ceremony for the delivery of the stamp-charging coking oven. ZHANG YAOTIAN/FOR CHINA DAILY
Taiyuan Heavy Machinery Group, a leading machine builder in Shanxi province, recently signed an agreement with Jianyuan Coking based in the Otog Banner in the Inner Mongolia autonomous region for the delivery of a large coking oven.
It was a landmark deal for the THMG this year, as the 7.25-meter-high stamp-charging coking oven is the tallest in China so far, breaking the record of 6.8 meters.
"The increase in height does not only mean growth in size and capacity," said Sun Naixin, one of the designers of the oven. "It also means greater efficiency and better performance in energy conservation and environmental protection."
He said the coking industry is an important link between the coal-producing and coal-consuming industries.
Coke, produced from coal, is widely used in the metallurgy and chemical sectors.
"In the context of China's carbon-neutrality strategy, our coking production is gearing up to higher efficiency and lower energy and resource consumption," Sun said. "And the latest large-capacity stamp-charging coking oven is designed to meet that trend."
He said the latest facility has a single-oven coke output of 47.6 metric tons, which is 10 percent more than the 6.8-meter one.
The increase in size and capacity requires the sustained optimization of the oven's carbonization chamber, coal-stamping machine and the coal-conveyance and loading system, according to Ma Lihui, head of the coking research institute at the THMG.
He said the coking process involves coal pulverization, stamping the pulverized coal into blocks and then piling the blocks into coal walls inside the carbonization chamber. "Such techniques are aimed at lifting coking efficiency," Ma said.
In addition to more complicated techniques designed for improving efficiency, the new oven is a comprehensive system. It combines intelligent operations and pollution-control solutions, according to Wu Xiaoqiang, deputy chief of the coking research institute.
"There is a control station with smart connections to all kinds of automatic devices for production," Wu said. "This has made 'push-button' operations possible."
In addition, the oven has an intelligent emission and dust-absorbing system, which can turn exhaust fumes into reusable resources.
The THMG evolved from the Taiyuan Heavy Machinery Factory, founded in 1950. It was the first self-developed heavy machinery manufacturer in the People's Republic of China.
The THMG is now a major equipment and solutions provider for enterprises across a wide range of industries including metallurgy, mining, energy, new materials, transportation, chemicals and aerospace.
9月15日，中國冶金報頭版以《太重7.25米搗固焦爐研制難在哪兒？》為題，重點報道太重集團聚焦“雙碳”目標，充分發揮高端裝備制造領域的豐富經驗和技術優勢，成功研制7.25米搗固焦爐設備，打破我國此前最高6.8米的紀錄，成為國內最大的智能搗固焦爐設備。
近日，太重集團與內蒙古鄂托克旗建元煤焦化有限責任公司簽署了7.25米搗固焦爐設備研制訂單。這將是太重為該公司提供的第7套分體搗固焦爐設備。7.25米搗固焦爐設備也將打破我國此前最高6.8米的紀錄，成為國內最大的智能搗固焦爐設備。
突破煤餅高寬比極限
太重此次研制的7.25米搗固焦爐單爐產量達到47.6噸，相比目前國內最大的6.8米搗固焦爐產量提高了近10%。“爐型大了意味著它更加節能環保、效率更高。但相應帶來的難題便是煤餅的高寬比之大前所未有，對穩定性、安全性的要求極高。”太重7.25米搗固焦爐主任設計師孫乃鑫說。
煤餅高寬比一直是焦爐設備大型化發展面臨的最大挑戰。煤餅指的是在煉焦過程中，把粉末狀的焦煤壓實壓緊，使之成為一堵可以經得住“推敲”的墻體。高寬比是指這堵煤墻的高度與寬度的比例，寬度0.5米是不可變的，因此，比例越大，就說明這堵墻越高。
“這次7.25米搗固焦爐所生產的煤墻就比目前國內最大的6.8米搗固焦爐高了48厘米。不要小看這48厘米，它意味著煤餅的高寬比將再次突破極限。”太重技術中心焦化所所長馬立輝講道。
為解決這一難題，太重的設計團隊在搗固機和裝煤系統上持續優化改進，提升搗固機搗固效率，加強搗固機有效做功轉化，配套設計裝煤系統，充分吸收搗固機對裝煤車的沖擊，確保裝煤過程平穩順暢。通過不斷搗固，把這塊又高又長而且很窄的煤墻壓緊壓實，再通過對設備優化升級，減少這堵煤墻在推進過程中的振動與摩擦，使之在沒有任何輔助力量的幫助下安全順利進入炭化室。
此次，太重為客戶量身打造了焦化全流程系統優化計劃，在設備設計之初便從焦化行業的本質入手，開展清潔生產、源頭控制，實現本質綠色發展。孫乃鑫表示：“淘汰落后焦爐、推動焦化行業轉型升級是落實國家綠色低碳環保政策的必然要求。我們首先要滿足工藝要求，保證生產穩定順行，讓穩定順行成為最大的安全環保措施；其次要完善工藝，盡量從工藝本身解決安全環保節能問題，避免被動的末端治理。”
為設備裝上“智慧大腦”
此前，太重已擁有豐富的智能焦爐設備設計制造經驗和諸多成功應用案例。此次為客戶量身定制的7.25米焦爐設備將助力客戶在“用煤不見煤”的基礎上實現“煉焦不見煙”。
“焦爐機、焦側爐頭煙突發性強、擴散速度快，而且煙塵量大、成分復雜、溫度高，很像做飯時產生的油煙。而我們的設備就相當于為焦爐的機、焦兩側各安裝了一臺大型抽油煙機。”太重技術中心焦化所副所長仵曉強做出形象比喻。太重3年前已為旗下所有的焦爐設備安裝了綠色節能高效環保除塵系統，目前這項技術已非常成熟。太重也因此成為國內外率先掌握焦爐爐頭煙特性的企業，高負壓抽煙罩技術還獲得國家發明專利授權。該技術創新集成了抽煙+儲煙的功能，可以對焦爐逸散物進行點對點捕集，還可以根據煙塵量大小智能調節抽吸力，在滿足環保要求的同時降低能耗，讓煉焦現場更清潔、生產更綠色、碳排放更少。
不僅如此，這套焦爐設備還擁有一顆“智慧大腦”。它可以通過作業管理及爐號識別系統傳送作業計劃和地址信號，讓車輛實現自動走行、自動定位等無人化智能操作，使客戶真正進入“無人操作”時代。此外，設計團隊還為客戶預留了太重獨有的“一鍵煉焦”端口，方便客戶隨時提檔升級。
“這套設備不僅將大大降低操作人員的勞動強度，而且會使我們的生產安全和產出效率得到大幅提高。”建元煤焦化有限責任公司的工作人員興奮地說，“以前的焦爐設備都需要人工操作，而智能焦爐設備只需一人監管。同時，由于它的定位和行走比人工更加精準，而且不會疲倦、不會受到人為因素的干擾，因此更安全、高效。”
據悉，在焦爐設備領域，太重現已形成頂裝焦爐成套設備、搗固焦爐成套設備、清潔型熱回收焦爐成套設備三大系列，實現了從3.6米到7.6米焦爐型號全覆蓋，設計水平、制造質量、投產運行過程均得到了用戶認可，在安全、穩定、智能、環保等方面均達到國際領先水平，產品遠銷亞歐地區。
