December 22, 2024

Calculation method of main technical and economic indicators for blast furnace ferroalloy smelting

Manganese iron pass rate is the percentage of ferromanganese inspection during the reporting period and the total amount of ferromanganese test. Its calculation formula is:
Manganese iron pass rate (%) = ferromanganese test pass (ton) × 100%
Total amount of ferromanganese inspection (tons)
Calculation explanation: After the blast furnace starts, any qualified ferromanganese produced by any reason should participate in the calculation of the qualified rate of ferromanganese; the neutron and parent units are standard tons.
The low silicon ferromanganese ratio refers to the percentage of low silicon ferromanganese in the total amount of qualified ferromanganese. Its calculation formula is:
Low silicon ferromanganese ratio (%) = total amount of low silicon ferromanganese (tonnes) × 100%
Total qualified ferromanganese (tonnes)
Calculation Description: Low-silicon ferromanganese refers to ferromanganese that meets the requirements of the current national standard for a group of silicon; the neutron and parent units are standard tons.
The fuel ratio refers to the amount of incoming fuel consumed per ton of qualified ferromanganese (standard tons). It reflects fuel savings or waste as well as the level of blast furnace operation. The fuel is calculated on the dry basis of dehydration, and its calculation formula is:
Fuel ratio (kg / ton) = Intake coke consumption (kg) + injecting fuel consumption (kg)
Qualified ferromanganese production (tons)
In-burn coke ratio (kg/ton) = coke consumption (kg)
Qualified ferromanganese production (tons)
Pulverized coal consumption (kg / t) = the number of pulverized coal injected into the blast furnace (kg)
Qualified ferromanganese production (tons)
Calculation Description: The parent unit in the formula is standard tons.
Formula calculation step ferroalloy blast unit energy consumption reference ironmaking blast furnace unit.
The consumption of manganese ore into the furnace refers to the amount of manganese ore that is consumed per ton of qualified ferromanganese (standard tons), including natural ore and man-made ore. Natural ore is calculated on the basis of the dry basis for moisture removal. Its calculation formula is:
Manganese ore consumption (kg / ton) = natural ore consumption in the furnace (kg) + consumption of artificial ore in the furnace is (kg)
Qualified ferromanganese production (tons)
Calculation Description: The parent unit in the formula is standard tons.
The flux consumption in the furnace refers to the amount of flux that is consumed per ton of qualified ferromanganese (standard tons). It includes alkaline compounds used for slag formation such as limestone , dolomite, quicklime, and fluorite . This indicator comprehensively reflects the quality of the charge and the rationality of the slagging operation. Its calculation formula is:
Flux consumption (kg/ton) = total flux consumption (kg)
Qualified ferromanganese production (tons)
among them:
Clinker consumption (kg/ton) = clinker consumption (kg)
Qualified ferromanganese production (tons)
Calculation description
(1) The various fluxes do not deduct moisture when they are consumed in the furnace;
(2) Clinker includes quicklime and dolomite after calcination;
The parent unit in formula (3) is standard tons.
The manganese metal recovery rate refers to the percentage of manganese metal in the smelting of ferromanganese as a percentage of the manganese metal content in the furnace material. It reflects the recovery and loss of manganese metal during the smelting process. Its calculation formula is:
Manganese metal recovery rate (%) = total manganese iron manganese content (tons) - manganese oxide content of recycled manganese iron (tonnes) × 100%
Manganese content in manganese ore (ton) + other additives manganese content (tonnes)
Calculation instructions:
The sub-item of formula (1) is the manganese content of qualified ferromanganese;
(2) Other add-on refers to the quantity of purchased manganese-containing materials and the broken iron or iron powder that is refined when the ferromanganese is sold, excluding the returning iron and bottom slag used in the furnace from the blast furnace. . [next]
The physical labor productivity of iron-iron workers reflects the average labor efficiency of each iron-iron worker during the reporting period. It also reflects the increase and decrease trend of production levels and the degree of mechanization and the allocation of labor quotas during the period. Its calculation formula is:
Iron and steel workers physical labor productivity (ton / person) =      Qualified ferromanganese production (tons)
Average number of ironworkers and apprentices (person)
Calculation instructions:
(1) Iron-making workers include apprentices, contractors, temporary workers, and unscheduled workers. The specific types of work are blast furnace duty foreman, pre-furnace work (including cast iron machine workers), seeing water workers, hot wind workers, blast furnace gas workers, loading workers (including weighing workers, winping workers), excluding other types of work.
The unit of sub-item in formula (2) is standard tons.
The blast furnace utilization factor refers to the average daily production of qualified ferromanganese per cubic meter of blast furnace effective volume within a specified time. It reflects the utilization of the blast furnace and the technical level of iron production. Its calculation formula is:
Blast furnace utilization factor (ton / meter 3 · day) =         Qualified ferromanganese production (tons)
Blast furnace effective volume (m 3 ) × specified working days (day)
Calculation instructions:
(1) The calculation of the effective volume of the blast furnace can be referred to the calculation method of iron production. After the overhaul of the blast furnace, the measured volume is taken as the effective volume;
(2) The number of working days is the calendar time of the reporting period minus the rest time of the large and medium repairs;
The unit of sub-item in formula (3) is standard tons.
The average daily output is the average daily output of the blast furnace during the reporting period, which reflects the actual production level of the blast furnace. Its calculation formula is:
Average daily production (ton/day) = qualified ferromanganese production (tons)
Specified number of working days (day)
Calculation explanation: The specified number of working days is the same as the specified number of working days in the parent of the utilization factor; the unit in the formula is standard tons.
The blast furnace wind rate refers to the blast furnace air time (in "minutes") as a percentage of the specified working time, which reflects the operating rate of the blast furnace and the operating conditions of the equipment.
Deducting the rate of wind that is waiting for electricity is an indicator of the temporary wind hazard caused by the daily maintenance of the blast furnace and other sudden failures. This is generally the wind caused by the internal causes of the blast furnace, which can be overcome and reduced through subjective efforts. Its calculation formula is:
Breath rate (%) =               Hourly time (minutes) - Waiting for electricity to take off time (minutes) × 100%
Calendar time (minutes) - Large and medium repairing furnace time (minutes) - waiting for waiting for electricity and cooling time (minutes)
        
The rate of restlessness that is not subject to waiting for electricity reflects both internal factors and the influence of external factors on the operation of the blast furnace. Its calculation formula is:
Breath rate (%) =         Hourly time (minutes) × 100%
Calendar time (minutes) - Dazhong repair shutdown time (minutes)
Calculation description
(l) Normal air volume (or wind pressure) is reduced to 0% for rest; 80% of normal air volume (or wind pressure) is full wind; normal air volume (or wind pressure) means adapted to the blast furnace under specific conditions Appropriate air volume (or wind pressure).
(2) The time of the break does not include the time of the large and medium repairs.
(3) Prescribed working hours = a large calendar time, a medium-repair time, and the division criteria for large and medium-sized repairs refer to the relevant provisions in the calculation method of ironmaking.
(4) In order to facilitate the analysis, in the column “Classification of the cause of the wind” after the “wind rate” indicator, the following columns: “waiting for electricity”, “temporary power outage”, “fan failure”, “planned maintenance” Ten items, such as "air supply system equipment", "feeding system equipment", "gas system equipment", "cooling equipment", "furnace accident", "other", etc., all use "minutes" as the unit of calculation.
(5) When the enterprise reports, it only reports the rate of restlessness that is not expected to be charged.
The blast furnace slow wind rate refers to the percentage of the blast furnace slow wind time as a percentage of the specified working time. It reflects the failure of the blast furnace to operate in full wind. The calculation formula is:
Slow wind rate (%) =             Slow wind time (minutes) × 100%
Calendar time (minutes), large repair time (minutes)
Calculation instructions:
(1) 80% of the normal air volume (or wind pressure) is slow.
(2) As with the rate of rest, the “slow wind cause” should be added.
The utilization rate of artificial lump ore refers to the percentage of the consumption of artificial ore lump such as sinter and pellets to the total consumption of manganese ore in the furnace. Clinker generally has alkalinity, so the clinker ratio reflects the quality of the charge to some extent. Its calculation formula is:
Utilization rate of artificial lump ore (%) = consumption of sinter ore in the furnace (ton) + consumption of pellets in the furnace (ton) × 100%
Total consumption of manganese ore into the furnace (ton) [next]
The manganese ore grade entered into the furnace refers to the average manganese content of the manganese ore (including natural ore and man-made ore). Press without deduction calcium oxide, magnesium oxide, calcium oxide and deduction, magnesium two methods.
Its calculation formula is:
Grade of manganese ore in the furnace (%) = total manganese content in the manganese ore (ton) × 100%
Total amount of manganese ore in the furnace (tonnes)
Its calculation formula is:
Into the manganese ore grade (%) =            Total manganese contained in manganese ore (ton) × 100%
The total amount of physical material (tons) after deducting calcium oxide and magnesium oxide from manganese ore
Calculation instructions:
(l) The manganese content of various manganese ore and the content of calcium oxide and magnesium oxide, respectively, can be weighted by various manganese ore consumption × manganese content (%) or calcium oxide and magnesium oxide content (%) The arithmetic average calculation is obtained.
(2) The manganese content or the content of calcium oxide and magnesium oxide of various manganese ores are subject to the test data.
The incoming coke ash is an indicator of coke quality. Its calculation formula is;
In-burn coke ash (%) = total amount of coke ash in the furnace (ton) × 100%
Total amount of coke in the furnace (tons)
Smelting intensity refers to the effective volume per cubic meter of blast furnace and the average amount of fuel burned per day. It reflects the speed of the falling of the charge and the speed of the smelting. Without increasing the coke ratio, the higher the smelting strength, the higher the production level of the blast furnace.
Its calculation formula is:
Smelting strength (ton / meter 3 · day) =           Intake coke consumption (tons)
Blast furnace effective volume (m 3 ) × actual working days (day)
Calculation instructions:
(1) The actual working days refers to the calendar time minus all the rest time (including large, medium repair and daily maintenance and waiting for electricity, etc.).
(2) All fuel consumption is a dry basis for deducting moisture, which is the same as the sub-item of the coke ratio.
Hot air temperature refers to the hot air temperature actually used by the blast furnace. It reflects the ability of the hot blast stove and the utilization of the blast furnace for the wind temperature. Under the condition that the furnace condition is maintained, the higher the hot air temperature, the lower the coke ratio, but the temperature of the hot air is also related to the air volume. Its calculation formula is:
Hot air temperature (°C) = sum of arithmetic mean of daily hot air temperature (°C)
Number of days to participate in the calculation
The coke load refers to the amount of manganese ore that is melted into the furnace per ton of coke. It mainly reflects the effect of coke melting ore, the operating level of the blast furnace and the quality of the raw fuel. Its calculation formula is:
Coke load (ton / ton) = Total consumption of manganese ore into the furnace (tonnes)
Intake coke consumption (tons)
Calculation calculation: The parent data of the coke load should be consistent with the sub-item data in the coke ratio index.
The oxygen enrichment rate refers to the percentage of oxygen enrichment in the blast air. Its calculation formula is:
Oxygen-enriched rate (%) = 0.21 × air volume ( m3 / min) + oxygen ( m3 / min) × oxygen purity (%)
Air volume ( m3 / min) ten oxygen ( m3 / min) × 100% - 21%
Air volume refers to the amount of cold air (in standard cubic meters) that is blasted into the blast furnace per minute. Under normal conditions, the air volume is large, the material is cut off, and the smelting speed is fast. It reflects the degree of utilization of the blower output, and it is also related to whether the blast furnace is antegrade and whether the voltage is normal. The calculation formula is:
Air volume ( m3 / min) = sum of arithmetic mean of daily air volume
Number of days to participate in the calculation
Hot air pressure refers to the pressure (in Pa) expressed in the blast furnace hot air on an average area per square centimeter. The calculation formula is:
Hot air pressure (Pa) = the sum of the arithmetic mean of daily hot air pressure (Pa)
Number of days to participate in the calculation [next]
The top pressure refers to the pressure of the top gas on an average area per square centimeter. Its calculation formula is:
Top pressure (MPa) = sum of arithmetic mean of daily top pressure (MPa)
Number of days to participate in the calculation
The top temperature refers to the average temperature of the top gas. Its calculation formula is:
Top temperature (°C)= The sum of the arithmetic mean of the daily top temperature (C)
Number of days to participate in the calculation
The average chemical composition of ferromanganese is an indicator reflecting the quality and grade of ferromanganese. According to national standards, the following three indicators can be divided.
Its calculation formula is:
Manganese iron average manganese (%) =   Mn content of qualified ferromanganese (tonnes) × 100%
Manufactured quantities of qualified ferromanganese (tonnes)
Its calculation formula is:
Manganese iron average silicon content (%) = qualified manganese iron silicon content (tons) × 100%
Qualified ferromanganese physical quantity (tons)
Its calculation formula is:
Average phosphorus content of ferromanganese (%) = phosphorus content of qualified ferromanganese (tonnes) × 100%
Qualified ferromanganese physical quantity (tons)
The average chemical composition of the manganese ore in the furnace is an indicator reflecting the quality of the manganese ore. The average manganese content of the manganese ore has been specified in the “manganese grade of the furnace”, and the following seven indicators are listed.
Its calculation formula is:
The average iron content of the manganese ore in the furnace (%) = the total iron content of the manganese ore in the furnace (ton) × 100%
Total consumption of manganese ore into the furnace (tonnes)
Calculation instructions:
The total iron content of the manganese ore in the furnace = the consumption of manganese in the furnace (ton) × the average iron content of the manganese in the furnace (%), the consumption of manganese in the furnace (ton) × the average iron content of the manganese ore in the furnace (%)+...×...
The calculation formula is the same as the average iron content in the manganese ore.
The calculation formula is the same as the average iron content in the manganese ore.
The calculation formula is the same as the average iron content in the manganese ore.
The calculation formula is the same as that of the manganese ore.
Divided into the following two indicators:
Binary alkalinity
Its calculation formula is:
Binary basicity (times) (R 2 )=   Total manganese oxide content in manganese ore (ton)
Total amount of silica contained in manganese ore (ton)
2. Ternary alkalinity
Its calculation formula is:
Ternary alkalinity (times) (R 3 )=   The total amount of calcium oxide contained in manganese ore (ton) is the total amount of magnesium oxide (tonnes)
Total amount of silica contained in manganese ore (ton)
Its calculation formula is:
Ratio of manganese to iron in manganese ore (times) = total manganese content in manganese ore (ton)
Total iron content in manganese ore (ton)
Its calculation formula is:
Ratio of manganese to phosphorus in manganese ore (%) =   Total phosphorus content in the furnace (ton)
Total manganese content in manganese ore (ton)
The average chemical composition of the incoming flux is an indicator of the quality of the flux. In order to fully reflect the flux quality, it is divided into the following four indicators:
Its calculation formula is:
The flux contained in the furnace contains calcium oxide (%) = the total amount of calcium oxide contained in the furnace flux (ton) × 100%
Total flux consumption (tons)
The calculation formula is the same as the average flux of calcium oxide in the furnace flux.
The calculation formula is the same as the average flux of calcium oxide in the furnace flux.
The calculation formula is: the average effective alkali oxide content of the flux in the furnace = the average calcium oxide content of the flux in the furnace (%), the average flux of the flux contained in the furnace (%), and the average flux of the flux contained in the furnace (%) × Slag basicity (CaO+MgO)/SiO 2 [next]
The average chemical composition of the slag is a data reflecting whether the slagging system is reasonable and operational. Divided into the following six indicators.
Its calculation formula is:
The slag contains calcium oxide (%) = total slag containing calcium oxide (tonnes) × 100%
Total slag (tonnes)
The calculation formula is equivalent to the average slag containing calcium oxide.
The calculation formula is equivalent to the average slag containing calcium oxide.
The calculation formula is equivalent to the average slag containing calcium oxide.
The calculation formula is equivalent to the average slag containing calcium oxide.
Divided into the following two indicators:
Binary alkalinity
Its calculation formula is:
Binary basicity (times) (R 2 ) = average slag containing calcium oxide (%)
Slag contains an average of silica (%)
2. Ternary alkalinity
Its calculation formula is:
Ternary alkalinity (times) (R 3 ) = average slag containing calcium oxide (%) + average magnesium oxide (%)
Slag contains an average of silica (%)
The amount of slag and the slag-iron ratio refer to the total amount of slag produced in smelting and the amount of slag produced per ton of qualified ferromanganese. It reflects the quality of the charge and is also related to the alkalinity of the slag.
Slag is generally not too pounds, and two methods are generally used in metering: one is estimation; the other is theoretical calculation. For the uniformity of each factory, there is comparability. The calculation of slag quantity of blast furnace ferromanganese uses the theoretical calculation method of balance of calcium oxide. For the sake of simplicity, it is assumed that calcium oxide and furnace top and other blown oxidation are contained in the coke. The calcium phase is offset and does not participate in the simple theoretical calculation of the calculation.
Its calculation formula is:
The total amount of calcium oxide contained in the manganese ore in the furnace (ton) + calcium oxide in the flux
Number of slag (tons) =   Total (tons) + other purchased in-furnace additives containing total calcium oxide (tonnes)
The slag contains calcium oxide on average (%)
Its calculation formula is:
Slag-to-iron ratio (ton/ton)=    Number of slag (tons)
Qualified ferromanganese physical quantity (tons)
The amount of gas ash and the ratio of gray to iron refer to the amount of gas ash collected by the precipitator and the amount of gas ash produced per ton of qualified ferromanganese. The less the amount of ash, the better.
The amount of gas ash is generally not too large, and most methods are estimated.
Its calculation formula is:
Gray to iron ratio (kg/ton) = estimated number of gas ash collected by the dust collector (kg)
Qualified ferromanganese physical quantity (tons)
The net gas dust content refers to the amount of dust (in milligrams) in the net gas per cubic meter of blast furnace after washing and dust removal. It is an indicator of the quality of the net gas. The lower the dust content, the better, which helps to extend the life of the stove. Its calculation formula is:
Net gas dust content (mg/ m3 ) = cumulative amount of each measurement (mg/ m3 )
Number of measurements
The blast furnace suspension means that during the smelting process, the charge stops the downward movement, the amount of air entering the furnace becomes smaller, and the wind pressure rises, which is an abnormal sign in smelting; the sitting material refers to the adjustment means using the wind reduction (up to the wind). Forced suspension to land; collapsed material means that the suspension suddenly falls by itself. Because the material and the collapsed material are caused by the suspension material, there is no need to sit and collapse the material without hanging the material. Therefore, only the “sitting material” and “collapse material” are counted according to the actual number of occurrences.
The number of damaged air outlets and slag mouth water jackets refers to the number of blast furnaces burned out during the production process (including the blown objects), and the number of vents and slag water jackets that have been used for a long time, the crack surface leaks, and should be respectively according to their models ( Such as large sets, middle sets, small sets) for statistics. If the non-smelting process is damaged and the piping leaks but the slag mouth does not leak, it is not included.

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