Diploma project Gas cleaning and Conveyer MZ

Contents

Introduction

1 GENERAL SECTION. Process and equipment of Copper smelting shop

1.1 Characteristics of Copper Plant

1.2 Process and equipment of smelting compartment

1.3 Process and equipment of converter compartment

1.4 Anode Compartment Process and Equipment

2 SPECIAL SECTION. Modernization of gas cleaning equipment and horizontal converter rotation mechanism PC MZ

2.1 Design and operation principle of the gas cleaning equipment of the converter

2.1.1 Dynamic calculation of pneumatic drive

2.1.2 Calculation of cylindrical axes of the valve with pneumatic drive

2.2 Upgrade of the turning mechanism

2.2.1 Calculation of the main design parameters of the converter for the specified capacity Q = 80 t

2.2.2 Calculation of converter drive power

2.2.3 Calculation of open gear train

3 RELIABILITY, REPAIR, INSTALLATION AND LUBRICATION. Lubrication of converter friction units

3.1 Lubrication of converter units

3.1.1 Characteristics of friction units of horizontal converter

3.2 Lubrication selection and calculation for bearing of support rollers and bearing gear

3.3 Calculation of the central lubrication system of the converter

3.3.1 Calculation and selection of labor pipeline

3.4 Selection and calculation of lubricant for open gear train

3.5 Plastic lubrication system description

4 ELECTRICAL SECTION AND AUTOMATION. Converter power supply

4.1 Requirements for electric drive

4.2 Automated Converter Control

4.3 AC Motor Control Diagram

4.5 DC Motor Control Diagrams

5 ECONOMICS AND ORGANIZATION OF PRODUCTION. Calculation of economic efficiency

5.1 Calculation of labour intensity of works

5.2 Calculation of funds for labor

5.3 Calculation of overhead cost estimates

6 PROJECT SAFETY AND ENVIRONMENTAL FRIENDLINESS

6.1 Characteristics of main hazards

6.2 Harmful substances

6.3 Meteorological conditions

6.4 Production Noise

6.5 Electrical Safety

6.6 Fire Safety

6.7 Assessment of working conditions at workplaces

6.8 Actions of shop personnel in case of emergency

Conclusion

Bibliographic list

Attachments: for 7 liters. in 1 ex.

Introduction

The purpose of the diploma project is to reduce the cost of producing rough copper and improve working conditions in the smelting shop of the Copper Plant. There are several ways to solve the above-described problems, one of which is to upgrade equipment units. Modernization of equipment is one of the main reserves of production and increase of labor productivity. The equipment is updated in two ways: the replacement of physically and mentally worn out machines and equipment and the improvement of machines and mechanisms that carry out repairs (repair modernization). During operation, parts of metallurgical equipment are subjected to static, dynamic, alternating loads; mated parts work for wear. Many parts are under the influence of aggressive means, stationary or cyclically changing temperatures. In this regard, the operational reliability of the parts is directly dependent on their strength, wear resistance, thermal and corrosion resistance. In order to improve these characteristics, it is necessary to correctly select the material of the parts, improve their design, eliminate assembly inaccuracies, improve cold and hot treatment methods (including thermal treatment and build-up).

This diploma project considers the modernization of several equipment units involved in the conversion process: the modernization of dust collection and gas cleaning equipment, the converter turning mechanism.

In the converter compartment, a water-cooled napkin is used to capture the gases of the exhaust converter. It represents a rectangular frame on which box caissons are attached. The off-gas is converter gas ejected from the converter and is captured by the spray with the shutter lowered to the limit. From the rear side, the sprinkler is not hermetically connected to the converter, as a result of its rotational operation (drain and filling). Modernization of the sprayer will improve sealing and thereby reduce unorganized emissions of pollutants into the workshop atmosphere. Installation of a pneumatic-operated damper from the rear of the sprayer will improve the working conditions of the workshop personnel, as well as increase the service life of the parts.

The rotation mechanism is a responsible unit. For the gear, it is necessary to select a material with better mechanical characteristics than for the gear rim, since the gear is a more loaded part.

RELIABILITY, REPAIR, INSTALLATION AND LUBRICATION. Lubrication of converter friction units

3.1 Lubrication of converter units

Currently, the process of supplying lubricant to the friction units of the envelopes of the smelting shop of the Copper Plant is carried out using lubricants. In this section, it is proposed to install a centralized plastic lubrication system to centrally supply a metered amount of plastic lubrication to the friction assemblies.

One effective way to improve the operability of metallurgical machines, and therefore increase the durability of friction assemblies, is to use lubricants which are essentially structural materials.

The main purposes of lubrication are to reduce energy consumption to overcome friction forces, reduce wear of friction surfaces, and therefore extend the overhaul periods of the equipment.

An appropriate type of lubricant can provide: liquid-bone friction, boundary friction, selective transfer, thereby preventing machine parts from intense wear, abrasion, painting of the upper layers of material surfaces, etc.

Responsible approach to the selection of lubricants and materials increases the service life of the equipment, preventing them from premature failure. Due to reduction of friction coefficient and partial protection against environmental aggressive action, various types of oils and lubricants extend operability of rolling bearings and sliding friction units, gear and worm gears, and in general operation of the whole machine. The use of a lubricating mat-rial in a particular friction unit depends on many factors: environmental conditions (temperature, humidity, dust content, etc.), specific load, displacement rate of contacting surfaces, the nature of movement (continuous, discontinuous, reversible), geometric parameters and materials of friction pairs, micro surface geometry, hardness of surface layers of friction surfaces, friction unit design, etc. In this diploma project, the necessary volumes and types of lubricants for friction units are calculated and adjusted. A centralized lubrication system is also calculated for friction links of a horizontal converter with a capacity of 80 tons, installed in the smelting shop of the Copper Plant.

4.2 Automated Converter Control

The scheme of the electric drive is provided on the sheet A4. The circuit is powered by a power circuit breaker (QF1). The voltage monitoring relay (KV1) in the AC motor power circuit operates through the fuse (FU1), opening its n.s. con-stroke in DC motor control circuits.

The circuit breaker (SA1.1) supplies power to the AC motor control circuit via fuses (FU2, FU3). At actuation:

- time relay (accelerators) (KT1), (KT2), (KT3), which will open their n.s. contacts (KT1), (KT2), (KT3) in AC motor control circuits.

- start blocking relay (KL1) of AC motor will close its n.r. contact (KL1) in electric motor control circuits

a lot of current.

-Rel for voltage monitoring (KL4) in AC motor control circuits, opening its n.s. contacts (KL4) in control circuits

by DC motor and in alarm circuits.

When the control circuit power switch is switched on (SA2.2 electro

DC motor operates through fuses (KL4):

- DC motor start-up interlocking relay (KV4); closing its n.z. contacts (KV4) in DC motor control circuits.

- voltage monitoring relay (KL5) in DC motor control circuits, opening its n.s. contacts of AC motor control circuits and emergency alarm circuits.

If the DC motor is of parallel excitation, the following shall be activated when the circuit breaker (SA2.1) is switched on via the shunt winding (LM1):

- current availability relay (KA5) in the DC motor excitation winding, closing its n.p. contact in the DC motor control circuits.

4.3 AC motor control diagram.

In the middle position of the command controller (SA1), when contacts (1) (2) are closed, the start lock relay (KL1) is activated and its n.r. the contact is closed. By pressing the pedal (SQ4), power is supplied to the coil of the start interlocking relay (KL1), through the closed contact of the start interlocking relay, pedal (SQ4), n.s. block of contacts of travel contactors (forward-backward), n.s. contact of emergency turning relay, n.s. contacts of the maximum current relay (KA1), (KA2), (KA3), therefore, when the command controller handle (SA1) moves to the position (drain) or (blow), the electric circuit does not rush and the starting interlocking relay coil does not de-energize.

Consider the operation of the circuit when moving the control knob (SA1) to the position (dump). At that contacts of commanding controller (5) and (6) are closed and travel contactor (KM2) is attracted through closed contact (SQ1) of track circuit breaker (if converter is above extreme limit during drain). Power contacts (KM2), when closed, supply voltage to the coil of voltage control relay (KV2), n.p. contact unit (KM2), which is closed, supplies voltage to coil of linear contactor (KM1. The power contact (KM1), closed, supplies voltage to the AC motor (M1), n.p. contact unit (KM1), which is closed, supplies voltage through closed n.p. contact unit (KM2), (KV2) to brake contactor coil (K1). Power contacts (K1), closed through additional resistances (R5), (R6) supply voltage to brake coils (YA1), (YA2), n.p. contact unit (K1), which is closed, supplies voltage to starting contactor carcass (KM4). Thus, the engine is switched on in the forward direction by contacting the starters KM1 and KM3, and in the reverse direction by KM1 and KM2. Power contacts (KM4) close and shunt a part of the starting resistance in the circuit of the rotor of the alternating-current motor (M1), n.s. contact unit (KM4) opens and de-energizes the accelerator start relay coil (KT1). Open n.s. contact (KT1), closed with time delay t = 0.9 s, supplies voltage to the coil of the acceleration contactor (KM5). Power contacts (KM5) close and shunt some of the starting resistance in the AC motor rotor circuit (M1), n.s. contact unit (KM5) opens and de-energizes the accelerator starting relay coil (KT2). Open n.s. contact (KT2), closed with time delay t = 0.7 s, supplies voltage to the coil of the acceleration contactor (KM6). Power contacts (KM6) close the starting co-resistance part in the AC motor rotor circuit (M1), n.s. contact unit (KM6) opens and de-energizes the accelerator starting relay coil (KT3). Open n.s. contact (KT3), closed with time delay t = 0.5 s, supplies voltage to the coil of the acceleration contactor (KM7). Power contacts (KM7), when closed, completely shunt the starting resistance in the circuit of the motor rotor of pe-belt current (M1).

Consider the operation of the diagram when moving the control knob (SA1) to the position (blow). In this case, contacts of the commanding controller (7) and (8) are closed through the closed contact (SQ2) of the track switch (if the converter is below the extreme limit during blowing), closed n.p. contacts of voltage availability relay (RB2), start permission relay (RBZ) are attracted by travel contactor (KM2). Further, operation of the circuit on (blow) is similar to operation of the circuit on (drain).

The contact of the track switch (SQ3) is used to block the raising of the converter by (blowing) the AC engine when the air or voltage in the DC motor circuit disappears.

Conclusion

This diploma project is devoted to the study of the work of the main and auxiliary mechanotechnological equipment of the converter department of the smelting shop of the Copper Plant in order to identify bottlenecks and develop options for improving the work of the designed facilities. The comprehensive modernization presented in this diploma project includes: modernization of dust collection and gas cleaning equipment, selection of materials for the converter turning mechanism .

According to the version of modernization of the dust collection and gas cleaning equipment of the KG80C horizontal converter, the pneumatic motor was calculated and the pneumatic cylinder was selected to ensure that the specified technological requirements were met.

According to the version of modernization of the converter turning mechanism, the main design parameters of the converter, drive power, design parameters of the parts were calculated, as well as the calculation of the open gear transmission of the converter turning mechanism, according to which the material for the gear and wheel was selected .

All the above proposed options for improving the equipment are designed to increase the service life of the parts, reduce downtime in the equipment due to labor-intensive repair operations, therefore increase the overhaul period, which will increase labor productivity, reduce the cost of producing rough copper and improve the working conditions of personnel.