Article(id=1187341682589708655, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1187341678487679284, articleNumber=1009-5438(2022)02-0022-04, orderNo=null, doi=null, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1644422400000, receivedDateStr=2022-02-10, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1761013916871, onlineDateStr=2025-10-21, pubDate=1650816000000, pubDateStr=2022-04-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1761013916871, onlineIssueDateStr=2025-10-21, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1761013916871, creator=13701087609, updateTime=1761013916871, updator=13701087609, issue=Issue{id=1187341678487679284, tenantId=1146029695717560320, journalId=1185652524569653253, year='2022', volume='48', issue='2', pageStart='1', pageEnd='98', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1761013915892, creator=13701087609, updateTime=1761015806887, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1187349609945907689, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1187341678487679284, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1187349609945907690, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1187341678487679284, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=22, endPage=25, ext={EN=ArticleExt(id=1187341682732314992, articleId=1187341682589708655, tenantId=1146029695717560320, journalId=1185652524569653253, language=EN, title=Cause Analysis and Countermeasures for Sink Roll Mark of Thick Gauge Hot-dipped Galvanization Products, columnId=1187340472918880861, journalTitle=Science & Technology of Baotou Steel, columnName=Production Practice and Management, runingTitle=null, highlight=null, articleAbstract=

The sink roll mark defect of thick gauge hot-dipped galvanization products is always the bottleneck problem of hot-dip galvanizing line of Baotou Steel. The slagging composition of sink roll is analyzed with the XRD phase analysis. The main factors influencing the defect are the temperature of liquid, Al content of liquid zinc, cleaning quality of strip steel and tension control of cooling tower after galvanizing. The effective control measures are formulated based on the influence factors so that the defect is relieved or eliminated fundamentally.

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厚规格镀锌产品沉没辊印缺陷一直是包钢热镀锌机组的瓶颈问题。通过采用XRD物相分析法对沉没辊结渣成分进行分析,影响厚规格镀锌产品沉没辊印缺陷主要因素为锌液温度、锌液Al含量、带钢清洗质量以及镀后冷却塔张力控制,针对影响因素制定有效的控制措施,从根本上减轻或消除了厚规格镀锌产品沉没辊印缺陷。

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罗新龙(1988-),男,内蒙古乌兰察布市人,助理工程师,现从事镀锌生产技术工作。

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罗新龙(1988-),男,内蒙古乌兰察布市人,助理工程师,现从事镀锌生产技术工作。

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罗新龙(1988-),男,内蒙古乌兰察布市人,助理工程师,现从事镀锌生产技术工作。

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序号 厚度
/mm
宽度
/mm
单位张力
/(N·mm-2)
总张力
/kN
1 0.4 1 250 40 20.0
2 0.6 1 250 35 26.3
3 0.8 1 250 30 30.0
4 1.0 1 250 26 32.5
5 1.2 1 250 24 36.0
6 1.4 1 250 23 40.3
7 1.6 1 250 22 44.0
8 1.8 1 250 21 47.3
9 2.0 1 250 20 50.0
10 2.2 1 250 19 52.3
11 2.4 1 250 18 54.0
12 2.5 1 250 17 53.1
), ArticleFig(id=1187341873522815853, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1187341682589708655, language=CN, label=表1, caption=

镀后冷却塔张力表

, figureFileSmall=null, figureFileBig=null, tableContent=
序号 厚度
/mm
宽度
/mm
单位张力
/(N·mm-2)
总张力
/kN
1 0.4 1 250 40 20.0
2 0.6 1 250 35 26.3
3 0.8 1 250 30 30.0
4 1.0 1 250 26 32.5
5 1.2 1 250 24 36.0
6 1.4 1 250 23 40.3
7 1.6 1 250 22 44.0
8 1.8 1 250 21 47.3
9 2.0 1 250 20 50.0
10 2.2 1 250 19 52.3
11 2.4 1 250 18 54.0
12 2.5 1 250 17 53.1
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厚规格热镀锌产品沉没辊印形成原因分析及对策
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罗新龙 , 刘强 , 郝小龙
包钢科技 | 生产实践与管理 2022,48(2): 22-25
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包钢科技 | 生产实践与管理 2022, 48(2): 22-25
厚规格热镀锌产品沉没辊印形成原因分析及对策
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罗新龙, 刘强, 郝小龙
作者信息
  • 内蒙古包钢稀土钢板材有限责任公司, 内蒙古 包头 014010
  • 罗新龙(1988-),男,内蒙古乌兰察布市人,助理工程师,现从事镀锌生产技术工作。

Cause Analysis and Countermeasures for Sink Roll Mark of Thick Gauge Hot-dipped Galvanization Products
Xin-long Luo, Qiang Liu, Xiao-long Hao
Affiliations
  • Inner Mongolia Baotou Steel Rare Earth Steel Plate Co., Ltd., Baotou 014010, Inner Mongolia Autonomous Region, China
出版时间: 2022-04-25
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厚规格镀锌产品沉没辊印缺陷一直是包钢热镀锌机组的瓶颈问题。通过采用XRD物相分析法对沉没辊结渣成分进行分析,影响厚规格镀锌产品沉没辊印缺陷主要因素为锌液温度、锌液Al含量、带钢清洗质量以及镀后冷却塔张力控制,针对影响因素制定有效的控制措施,从根本上减轻或消除了厚规格镀锌产品沉没辊印缺陷。

连续热镀锌  /  沉没辊印  /  锌锅温度  /  锌液Al含量

The sink roll mark defect of thick gauge hot-dipped galvanization products is always the bottleneck problem of hot-dip galvanizing line of Baotou Steel. The slagging composition of sink roll is analyzed with the XRD phase analysis. The main factors influencing the defect are the temperature of liquid, Al content of liquid zinc, cleaning quality of strip steel and tension control of cooling tower after galvanizing. The effective control measures are formulated based on the influence factors so that the defect is relieved or eliminated fundamentally.

continuous hot dip galvanizing  /  sink roll mark  /  temperature of zinc pot  /  Al content of liquid zinc
罗新龙, 刘强, 郝小龙. 厚规格热镀锌产品沉没辊印形成原因分析及对策. 包钢科技, 2022 , 48 (2) : 22 -25 .
Xin-long Luo, Qiang Liu, Xiao-long Hao. Cause Analysis and Countermeasures for Sink Roll Mark of Thick Gauge Hot-dipped Galvanization Products[J]. Science & Technology of Baotou Steel, 2022 , 48 (2) : 22 -25 .
热镀锌产品由于其良好的耐蚀性能及美观性在汽车、家电以及建筑等行业得到广泛应用,由于镀锌产品使用领域越来越广,对镀锌产品的表面质量要求逐步提高,因此对热镀锌生产线表面质量的控制提出了更高的要求。包钢稀土钢板材公司2 030 mm热镀锌机组自2017年投产以来,一直受到沉没辊印的困扰,尤其是厚规格(厚度1.5 mm以上)镀锌产品,表面沉没辊印缺陷非常明显,而且厚度越厚,沉没辊印缺陷越严重,严重时沉没辊印手感严重,造成高表面级别厚规格产品无法接受订单,同时在生产过程中由于沉没辊印缺陷造成产生大量的带出品。
本文通过对厚规格产品沉没辊印缺陷形成原因以及影响因素进行系统分析,确定沉没辊印形成的主要因素,并针对这些因素制定有效的控制措施,从而从根本上减轻或消除了厚规格镀锌产品沉没辊印缺陷,在提高厚规格镀锌产品表面质量的同时降低了生产过程中的带出品,对提高包钢镀锌机组产品竞争力以及降低质量成本具有重要意义。
热镀锌机组在生产过程中,带钢通过炉鼻子进入锌锅热浸镀时,带钢与锌锅中的沉没辊接触,由于沉没辊有加工的沟槽,在带钢上表面产生周期性的沟槽印,如图1所示[1]。一般情况下沉没辊印主要出现在厚规格带钢,带钢越厚缺陷越严重,且与沉没辊使用时间有关,沉没辊使用末期沉没辊印更为严重。
对镀锌生产线使用一个辊期(15天)后下线的沉没辊辊面进行检查,整个沉没辊沟槽位置结满锌渣。对沉没辊沟槽结渣进行取样分析[2],通过XRD物相分析,沉没辊沟槽结渣中的Fe2Al5的含量占到80%以上,基本可以确定沉没辊结渣为FeAlZn的化合物,并且Fe含量较高。图2为沉没辊辊面结渣实物照片。
根据沉没辊结渣成分分析结果以及长时间生产实践,沉没辊印的产生受多种因素影响,从工艺角度分析主要影响因素为锌液温度和成分波动大、镀后冷却塔张力控制不合理、清洗质量差,上述因素控制不好造成锌液中的悬浮渣较多,随着生产时间延长,锌渣逐渐粘附在沉没辊表面造成沉没辊印。
根据热镀锌的理论,带钢热镀锌过程是Fe-Zn-Al反应的过程,带钢进入锌锅后会与锌锅中的Zn和Al发生反应,由于Fe在锌液中的反应为不可逆反应,因此锌液温度的变化会造成锌渣(FeAlZn化合物)不断的生成[3],如图3所示。产生的锌渣随着生产在沉没辊的沟槽上逐渐富集,导致沉没辊沟槽结渣越来越严重,带钢在经过沉没辊时形成沉没辊印。
同样根据热镀锌理论,锌液中Fe的溶解度是随着Al含量的变化而变化,如图4所示。正常生产过程中,锌液中的Al含量控制在0.2%左右,Al含量的波动造成锌渣源源不断的产生并在沉没辊结渣。
带钢经过退火炉还原进入锌锅时,表面的铁粉带入锌锅造成锌液中Fe含量增加,从而产生大量锌渣,因此带钢清洗质量对于控制锌渣和沉没辊印的产生至关重要。
由于锌锅沉没辊是被动辊,是由镀后冷却塔张力提供驱动力进行转动,镀后冷却塔张力在为沉没辊转动提供驱动力的同时也会使带钢与沉没辊表面产生压力,由于厚规格带钢镀后冷却塔张力普遍较大,造成厚规格带钢表面沉没辊印表现明显,因此镀后冷却塔张力的大小关系到带钢表面沉没辊印的轻重程度。
由于锌锅是由锌锅感应器以及带钢入锅温度提供双重热源,锌锅感应器通过控制感应器功率对锌锅温度进行调节,但是锌锅感应器对锌锅温度的调节滞后且调节范围有限,因此控制锌液温度的稳定关键是控制带钢入锅温度。同一入锅温度下,不同规格带钢带入锌锅的热量是不同的,厚规格由于存在核心热,带入锌锅的热量多,易造成锌液温度上升;薄规格带钢所携带的热量少,易造成锌液温度降低。因此需要重视带钢入锅温度控制,通过锌锅热平衡计算,针对不同带钢厚度制定不同的带钢入锅温度,减少锌锅温度的波动,提高锌液温度的稳定性(如图5所示),尽可能将锌液温度波动范围稳定在±1 ℃。
在正常生产过程中,不同带钢厚度、不同镀层类型对于Al的消耗是不一样的,如果无法及时监测锌液Al含量的变化,会造成锌液Al含量的大幅度波动。为了减少锌液中Al含量的波动,一方面镀锌机组尽量采用在线Al含量检测分析仪,通过在线Al含量分析仪可以对锌液中的Al含量进行实时监测,另一方面操作人员根据生产计划及时调整加入锌锅中锌锭类型,保证锌液中Al含量的稳定,尽量将Al含量波动范围稳定在±0.01%。
带钢清洗质量受到多方面因素的因素影响,重点从以下几个方面提高带钢清洗质量。
(1)对于原料表面的残油残铁进行管控,建立残油残铁的管控标准,一般要求残油控制在400 mg/m2,残铁控制在150 mg/m2
(2)通过优化清洗温度、清洗电导率以及刷辊的压下量提高清洗段的清洗能力。
(3)每次检修将预清洗以及电解清洗的立式槽以及循环箱液体排空,对箱体进行彻底清理;定期对预清洗段以及刷洗段的喷梁进行彻底清理,并且保持磁分离设备运行状态良好。
(4)调整清洗段各段挤干辊压力,提高挤干效果,防止各段发生窜液。
(5)建立清洗质量评价标准,对清洗质量进行定量评价,保证清洗质量长期稳定控制。
目前大部分镀锌机组镀后冷却塔张力都采用二级自动控制,但是有些机组二级张力值设定不合理,厚规格带钢单位张力设定值过大,生产过程中加剧沉没辊印以及造成沉没辊振动等问题,薄规格带钢单位张力设定不合理会造成沉没辊转动不良产生速差划伤带钢。镀后冷却塔单位张力设定原则为带钢从薄到厚单位张力逐步减小,见表1。按此原则并根据机组实际情况对镀后冷却塔二级张力进行修改,另外在生产厚规格带钢时如果带钢存在沉没辊印缺陷可以通过手动降低镀后冷却塔张力来减轻沉没辊印[4]
采用XRD物相分析法对沉没辊结渣成分分析,确定沉没辊结渣为FeAlZn化合物,将控制沉没辊印的重点放在减小锌液温度和Al含量的波动,提高带钢清洗质量,减少锌液中Fe的带入,通过上述针对性的措施大幅度减少锌渣的产生量和沉没辊的结渣速度;并通过优化镀后冷却塔张力进一步减轻带钢与沉没辊之间的压力,从根本上减轻或消除了厚规格镀锌产品的沉没辊印缺陷,提高了厚规格镀锌产品的表面质量,延长了沉没辊使用周期,进一步降低了生产成本。
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  • 接收时间:2022-02-10
  • 首发时间:2025-10-21
  • 出版时间:2022-04-25
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  • 收稿日期:2022-02-10
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    内蒙古包钢稀土钢板材有限责任公司, 内蒙古 包头 014010
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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