JFE 技報 No. 38 (2016 年 8 月 )p JFE スチール西日本製鉄所 ( 福山地区 ) における製鋼工場の一貫生産能力向上対策 Improvement in Production Capacity at Steelmaking Plant in West Japan
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1 JFE 技報 No. 38 (2016 年 8 月 )p JFE スチール西日本製鉄所 ( 福山地区 ) における製鋼工場の一貫生産能力向上対策 Improvement in Production Capacity at Steelmaking Plant in West Japan Works (Fukuyama), JFE Steel 井上周大 INOUE Shuta JFE 西日本製鉄所 ( 福山地区 ) 製鋼部製鋼技術室主任部員 ( 係長 ) 加茂百紀 KAMO Momoki JFE 西日本製鉄所 ( 福山地区 ) 製鋼部製鋼技術室長 ( 部長 ) 錦織正規 NISHIKORI Masanori JFE 東日本製鉄所 ( 千葉地区 ) 製鋼部長 ( 理事 ) 要旨 JFE 西日本製鉄所 ( 福山地区 ), 生産性向上, 自動車向 中心 高級鋼拡販, 品質造 込 能力向上 削減 図 施策, 第 3 製鋼工場 単 連続鋳造機 第 7 連続鋳造機 新転炉 建設, 拡大 取 組 結果, 第 7 連続鋳造機 当初 計画 200 kt/month 上回 kt/month 生産量新記録 達成, 精錬工程 転炉 1 基 新設, 348 t/ 拡大 生産性 向上, 新転炉型予備処理 Double-slag Refining Process(DRP ) 行, 品質造 込 能力向上及 削減 図 建設 結果, 一貫生産能力 向上,2015 年 3 月 生産量 kt/month 達, 第 3 製鋼工場 生産量新記録 達成 Abstract: In JFE Steel West Japan Works (Fukuyama), various technological developments have been accomplished aiming for improvement in productivity, sales expansion of high quality steel sheet for automobiles, slab quality improvement, and cost reduction. To achieve these target, No. 7 continuous slab caster (CC) and a new converter were built, and heat size of No. 3 Steelmaking Plant has been increased. No. 7 CC has exceeded planned productivity of 200 kt/ month. In refining process, by constructing a new converter and increasing heat size to 348 t/charge, productivity has been increased. In addition, by performing dephosphorization pretreatment with converter, called Double-slag Refining Process (DRP ), cost and slab quality have been improved. As a result of these developments, the amount of production at No. 3 Steelmaking Plant increased to record kt/month in March はじめに 2. 福山地区銑鋼マテリアルフロー JFE 西日本製鉄所 ( 福山地区 ), 自動車向 中心 高級鋼拡販, 生産性向上, 第 3 製鋼工場 (3 製鋼 ) 第 7 連続鋳造機 (No. 7 continuous slab caster, 7CC) 2010 年 4 月 新設 1), 精錬工程, 生産性向上 拡大,3 製鋼 転炉出鋼能力向上及 転炉型予備処理 品質造 込 能力向上及 削減 目的 2015 年 1 月 転炉 1 基新設, 新転炉型予備処理 Double-slag Refining Process(DRP ) 行 上記設備 稼動以来順調 操業中 本論文, 上記建設工事 中心 3 製鋼 一貫生産能力向上施策 報告 図 1 7CC, 新転炉稼動後 福山地区 製造 図 示 7CC 稼動前 3 製鋼 転炉 2 基 対 2 連続鋳造機 第 5 連続鋳造機 (No. 5 continuous slab caster, 5CC),4 連続鋳造機 (BLCC) 2 基 連続鋳造機 稼動,3 製鋼 粗鋼生産能力 工程, 連鋳工程 解消,7CC 建設 行 7CC 稼動後 転炉 2 基 対 連続鋳造機 3 基稼動, 連続鋳造機能力 余力 発生,3 製鋼 生産量増及 転炉型予備処理 実施 目的,3 製鋼 転炉 新設 2016 年 1 月 22 日受付 Copyright 2016 JFE Steel Corporation. All Rights Reserved
2 Fig. 2 図 2 7CC 設備レイアウト Facility schematics of No. 7 continuous slab caster Fig. 1 図 1 福山地区製造プロセスフロー Production flow at Fukuyama District Table1 表 1 7CC 主仕様 Specification of No. 7 continuous slab caster Type Cast grades 3. 生産性向上の施策 7CC Vertical bending/ single strand sheet Slab thickness (mm) 235/260 Slab width (mm) Machine length (m) 44.7 Max. casting speed for low carbon (m/min) 2.6 (235 mm thickness) Productivity (kt/month) 連続鋳造工程における生産性向上の施策 第 7 スラブ連続鋳造機建設 表 1 7CC 主仕様 示 7CC, 福山第 6 連 続鋳造機 (No. 6 continuous slab caster, 6CC) 垂直曲 型 単 連続鋳造機 計画生産量 200 kt/month, 機長 44.7 m, 稼働率向 上 目的 JFE 初 浸漬 迅速 交換装置 導入, 内溶鋼流動制御, 自動車材等 品質厳格化 対応 5CC 同様 Flow Control(FC) 採用 2), 厚 替装置 ( 短辺迅速交換方式 ) 採用, 厚 235, 260 mm 2 鋳造可能 図 2 7CC 設備, 図 3 品種構成 示 生産能率向上の施策 remarks shared segments and common spare segmennts with 6CC quick mold thickness change system 7CC 稼働後, 生産性向上 目的, 非定常部 ( 鋳 造開始時, 浸漬 交換前後 ) 高能率化 取 組 鋳造開始時, (DB) 離脱 鋳造初期 (MD) 溶融層厚 Fig. 3 薄 (BO) 発生 懸念, 鋳造速度 加速 連続鋳造機 6CC 低, 浸漬 交換時, 交 換所要時間 85% 鋳造速度 変更 ( 降速及 昇速 ) 占, 鋳造速度 加減速 取 組 図 3 7CC の品種構成 (2014 年実績 ) Product mix of No. 7 continuous slab caster (2014 FY) 鋳造開始時 加速, 水準 1 6CC 同条件, 水準 2 6CC 1.5 倍 加速 目標 設定 ( 図 4), 試験 実施 試験 操業 発生 評価,1 DB 接続部 形状,2 鋳造初期 MD 溶融層厚 確認, 加速 品質影響,3 近傍 表面性状,4 表面 欠陥混入率 評価 図 4 鋳造開始時, ノズル交換時の加減速レート比較 Fig. 4 Comparison of start and submerged entry nozzle exchange accelerating rate JFE 技報 No. 38(2016 年 8 月 )
3 水準 従来条件 比較 同等以上 良好 結果 得, 水準 2 条件 工程化 浸漬 交換前後 加減速, 鋳造開始時 水準 1 条件 試験 品質影響評価 完了, 品質向上 確認, 工程化 結果, 交換 所要時間 従来 半分 短縮 生産量 能率推移図 5 稼動 生産能率推移, 図 6 生産量推移 示 生産能率 前述 改善等 建設計画 342 t/h 対,2015 年 2 月 生産能率 353 t/h 新記録 達成 結果, 生産量 2010 年 4 月 立 上 以降, 稼動 7 月目 (2010 年 10 月 ) 計画生産量 200 kt/month 達成, 後通年 200 kt/month 超 生産能力,2015 年 5 月 kt/month 生産量新記録 達成,7CC 生産量 生産能率 向上, 建設時 計画 大幅 上回 3.2 精錬工程における生産性向上の施策 ヒートサイズ拡大 3 製鋼, 図 7 示 2014 年 拡大 実施 溶鋼鍋 容量, 溶鋼鍋 嵩上, 格上 改造, 台車改造,+17.5 t/ 拡大 図 5 7CC 生産能率推移 Fig. 5 Throughput transition of No. 7 continuous slab caster 図 7 3 製鋼ヒートサイズ推移 Fig. 7 Change of heat size 工事 各種歩留向上対策, 従来 330 t/ 3 製鋼, 直近 348 t/ 拡大 転炉建設 新転炉建設の目的 JFE 溶銑 潜熱 利用, 溶解, 脱珪吹錬後 高 SiO2 系外 排出 後 脱 吹錬 行 DRP 福山第 2 製鋼工場 開発, 京浜地区 技術 確立 福山地区, 品質造 込 能力向上及 削減 目的 DRP 適用 推進 図 8 DRP 含 転炉 比較 示 一方, 福山地区,3 製鋼 傾斜生産 行,3 製鋼 従来, 生産量 確保, 転炉 2 基 脱炭操業 行 今回,3 製鋼 生産能力向上及 DRP 行 3 製鋼 転炉 1 基新設 設備構成図 9 3 製鋼工場 転炉 同時 建設 主要設備構成 示 今回 排 処理設備, 既設設備 同等設備 Oxygen Converter Gas Recovery System (OG) 法 設備 採用, 転炉 3 基操業 対応, 水処理設備 増強 行 共,, 副集塵機 新 設置 図 6 7CC 生産量推移 Fig. 6 Transition of production amount at No. 7 continuous slab caster Fig. 8 図 8 転炉プロセス比較 Types of converter process JFE 技報 No. 38(2016 年 8 月 )
4 図 9 転炉建設主要設備構成 Fig. 9 Equipment which have constructed at the same time as converter 図 11 DRP による T.CaO 削減効果 Fig. 11 Effect of DRP on reducing T.CaO 図 10 LD-NRP,DRP 処理での T.CaO 比較 Fig. 10 Relationship between input Si and CaO amount at pretreatment Fig. 12 図 12 3 製鋼生産量推移 Amount of production at No. 3 steelmaking plant 新転炉型予備処理プロセス効果図 10 従来 転炉型予備処理方法 LD-New Refining Process(LD-NRP) 新転炉型予備処理方法 DRP 転炉予備処理 炉内 投入 CaO 含有量 合計 (T.CaO) 比較 示 LD-NRP 転炉装入 Si 増加 伴,T.CaO 増加,DRP 中間排滓 高 SiO2 系外 排出 後 脱 吹錬 行, 転炉装入 Si 増加 T.CaO 変 DRP 処理後 従来 転炉型予備処理方法 LD-NRP 同等 脱炭炉 含 T.CaO 比較 図 11 示 DRP 時 T.CaO 普通吹錬時 比較,44% 削減 製鋼生産量推移図 年以降 3 製鋼生産量推移 示 7CC 稼動, 拡大, 新転炉稼動 3 製鋼 粗鋼能力 向上,2015 年 3 月 生産量 kt/month 達, 新記録 達成 4. おわりに西日本製鉄所 ( 福山地区 ), 自動車向 中心 高級鋼拡販, 生産性向上, 品質造 込 能力向上及 削減 図 施策,3 製鋼,7CC 建設, 拡大, 新転炉建設 行 結果, 以下 内容 達成 (1) 単 連続鋳造機 7CC 順調 稼動,2015 年 5 月 kt/month 生産量新記録, 2015 年 2 月 353 t/h 生産能率新記録 達成 (2)2014 年 拡大 実施, 従来 330 t/, 直近 348 t/ 拡大 (3) 新転炉 新転炉型予備処理 (DRP ) 行 事,T.CaO 対普通吹錬 44% 削減 (4) 各建設 中心 3 製鋼 一貫能力向上施策 行 結果, 粗鋼能力 向上,2015 年 3 月 kt/ month 生産量新記録 達成 JFE 技報 No. 38(2016 年 8 月 )
5 参考文献 1)Hori, Y. et al. CAMP-ISIJ. 2011, vol. 24, p )Hasunuma, J. et al. CAMP-ISIJ. 1996, vol. 9, p 井上周大加茂百紀錦織正規 JFE 技報 No. 38(2016 年 8 月 ) Copyright 2016 JFE Steel Corporation. All Rights Reserved. 禁無断転載
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