CN100485047C - Intelligent diagnosis and determination support system for blast furnace - Google Patents

Intelligent diagnosis and determination support system for blast furnace Download PDF

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CN100485047C
CN100485047C CNB2006101653405A CN200610165340A CN100485047C CN 100485047 C CN100485047 C CN 100485047C CN B2006101653405 A CNB2006101653405 A CN B2006101653405A CN 200610165340 A CN200610165340 A CN 200610165340A CN 100485047 C CN100485047 C CN 100485047C
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data
plc
furnace
blast furnace
database
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CNB2006101653405A
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Chinese (zh)
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CN1995401A (en
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徐化岩
何岱
祝小欧
朱文功
代晓莉
董逵
王丽娜
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冶金自动化研究设计院
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Abstract

The invention discloses an intelligent diagnosing and deciding support system of blast furnace in the automatic technical domain of iron-smelting course, which comprises the following parts: 5 operating parameter detecting and control PLC of blast furnace as bulk PLC of blast furnace, hot wind furnace PLC, feed PLC, coal spraying PLC, assay chamber PLC, PLC and server, wherein the server communicates customer end through industrial Ethernet, which constitutes hardware platform of system; the software mode and database are operated on the server, which reserves disposed PLC detecting parameter in the database; the intelligent diagnosing and deciding support system of blast furnace are operated on the customer end; the data gathering software mode on the server and intelligent diagnosing and deciding system of blast furnace also adopt two-layered structure of program-database.

Description

Blast furnace intelligent diagnostics and decision support system (DSS)
Technical field
The invention belongs to the iron manufacturing process technical field of automation, a kind of blast furnace intelligent diagnostics and decision support system (DSS) particularly are provided.
Background technology
Blast furnace ironmaking is the main source of hot metal in steelmaking, is the link of expecting that from former technology is the most complicated, influence factor is maximum, energy consumption is maximum the whole flow process of steel finished product.
Existing blast furnace operation technology comprises complete basic automation systems, and operator mainly finish production at master control room.According to last one class of write by hand form section chief the working of a furnace is carried out initial analysis when (1) succeeding; (2) section chief watches real time datas such as trend pictures such as hot-blast pressure, cold flow, permeability index, material chi and cross temperature, throat temperature, furnace body temperature to judge the working of a furnace at any time; (3) section chief is according to the operation of preparing burden of working of a furnace level, and batching is finished in an Excel program, after the batching material list is passed the material loading worker; (4) the material loading worker receives the material list that the section chief transmits, and sets the back and automatically performed by feeding system on the material loading computer; (5) when hotblast stove arrive change stove during the time section chief assign whether change the stove order, sets on the hotblast stove computer by burner and then automatically performs by Combustion System of Hot-Blast Stove; (6) section chief can directly be provided with air quantity on the blast-furnace body computer when needs carry out working of a furnace adjusting, or informs by telephone change injecting coal quantity, Rich Oxygen Amount; The section chief confirmed that hot metal ladle puts in place when (7) one stoves were smelted end, tap a blast furnace and assign the order of tapping a blast furnace after preparation work is finished in the stokehold, by opening machine drill tapping outlet, molten iron flows into hot metal ladle after the Weight Station weighing, and weight is directly delivered to and is presented at the master control room computer on the PLC of laboratory; (8) the sampling personnel take a sample from molten iron and send the laboratory, and the laboratory automatically sends to iron and slag ingredient after the chemical examination and is presented at the master control room computer on the PLC of laboratory; (9) to form, the section chief used counter to calculate cumulative production, consumption, index etc. when one day finished write by hands such as temperature, flow, output, chemical examination composition, feeding quantity, hot blast temperatures for section chief, material loading worker, burner.
As seen, higher in link basic automatization levels such as batching, material loading, hot blast stove burning, molten iron chemical examination weighings, but the linking of these systems scheduling will rely on section chief's commander, and whether commander correctly depends on that then the section chief judges whether accurately in conjunction with experience based on its observed instrumented data and trend.Instrumented data has hundreds of individual, and furnace superintendent can only be considered sub-fraction, and the not obvious human eyes of some short term variations are difficult to pinpoint the problems, and this just may make working of a furnace judgement inaccurate; The big analysis the past data that need of each blast furnace difference just can sum up proper operating duty, do not preserve data or do not have these analyses of analysis tool not know where to begin; One class is got off to copy a lot of data particularly the very end of the train was handed over to the next shift and wanted parameter every day, miscopies easily on the one hand, has disperseed section chief's energy on the one hand, has influenced the quality of relieving.
From the 1950's, carried out the research of a lot of blast furnace process controls aspect both at home and abroad.The working of a furnace based on theoretical reasoning from early stage single static model to the seventies is comprehensively judged (GO-STOP) system, the working of a furnace diagnostic expert system that the eighties occurred rule-based storehouse and inference engine, the nineties combined mathematical module the multiple goal expert systems, the closed loop expert systems of control has appearred again participating in directly in recent years.
The patent of NKK Corp's application that Patent Office of the People's Republic of China announced on December 23rd, 1987 " method of control operation of blast furnace " (CN87103633), the patent " method of artificial intelligence expert systems blast-furnace smelting " of Shoudu Iron and Steel Corp.'s application of announcing January 25 nineteen ninety-five (CN1097804), the patent " blast furnace comprhensive deterministic system " of Baoshan Iron ﹠ Steel Group Corp.'s application of announcing on October 22nd, 1996 (CN1132253) and the patent " system of intelligent blast furnace smelt controlling " of Zhejiang University's application of announcing on March 19th, 2003 (CN1403594), former three belongs to expert systems, set up expert knowledge library and inference engine separately from different perspectives, help the blast furnace section chief to strengthen the operational management and the control of blast furnace with giant-powered computer, carry out working of a furnace diagnosis, in time the prompting section chief takes adequate measures, the development of control furnace temperature is avoided the blast furnace fault and is ensured normally carrying out of producing.The latter then uses optimum seeking method to help section chief's selection operation system.
Above system does not all combine expert systems and decision support; The data analysing method that is based upon on the generation furnace life Basis of Database is not provided; Rule is not divided into body and thresholding two portions, does not set up the self-study mechanism of regular thresholding yet.
Summary of the invention
The object of the invention is to provide a kind of blast furnace intelligent diagnostics and decision support system (DSS), solve the section chief and judged working of a furnace one-sidedness problem, process modification shortage data and analytical procedure problem, the time-consuming fallibility problem of write by hand form by rule of thumb, by the long thinking of working as a substitute, the long thinking of helper and laborsaving to the section chief, the comprehensive action of artificial intelligence of performance computer and aid decision making, reduce unusual working of a furnace frequency and ensure direct motion, reach the purpose of " high yield, high-quality, low consumption, longevity ".
Blast furnace intelligent diagnostics of the present invention and decision support system (DSS), comprise totally 5 of operation of blast furnace parameter detecting and control PLC, be respectively blast-furnace body PLC, hotblast stove PLC, material loading PLC, coal powder injection PLC, laboratory PLC, each one of data gathering and database server (hereinafter to be referred as server), client terminal, be connected to one of printer on the client terminal, PLC and server, server and client terminal have constituted the hardware platform of system by the EPA communication; Service data acquisition software module and database on server, said data acquisition software module are stored in the database after the PLC detect parameters is handled, and blast furnace intelligent diagnostics and decision support system (DSS) software module operate on the client terminal.
Data acquisition software module on the above-mentioned server and the blast furnace intelligent diagnostics on the client terminal and decision support system (DSS) software module have all adopted application program-database double-layer structure.
The data acquisition software module that operates on the server divides 10 seconds, 1 minute, 1 hour, 1 day cycle to the detection data from blast-furnace body, hotblast stove, feeding system, laboratory, coal powder injection PLC, comprise temperature, pressure, flow, the slag ingredient that taps a blast furnace, weight of molten iron, the reinforced composition and weight, store database into after handling.Data-base recording the process data of all collections, manual logging data; Every table is preserved the data strip number and can be provided with, and the deletion stale data storage process periodic cleaning in the database surpasses the record of storage number and guarantees not overplumping of database; Database thresholding self study storage process regularly carries out the self study of data thresholding.
Operate in blast furnace intelligent diagnostics and decision support system (DSS) software module on the client terminal, provide and be used for the production management module that production data replenishes typing and report generation, comprise and become material Excel importing, the management of tapping a blast furnace, the typing of chemical examination gas composition, air port parameter typing, air port working order typing, the management of relieving, the generation and the printing of daily paper, monthly magazine, reinforced form; Be used to diagnose the expert system module of the working of a furnace, be included in radiodiagnosis x, reasoning process explanation; The data analysis module, process calculation module, the mathematical model module that are used for aid decision making, data analysis module comprises trend analysis, frequency analysis, regression analysis, correlation analysis, main analysis of Influential Factors, the process calculation module comprises that material balance, thermal equilibrium, direct reduction degree, theoretical coke ratio calculate, the Rist pilot wire, and the mathematical model module comprises that stove picks disconnected model, blanking locus model; The subsidiary function module comprises thresholding setting, iron-smelting process rules etc.
Said server is a Pentium IV server, and client terminal is a Pentium IV industrial control computer.
When the blast-furnace smelting application was of the present invention, the data acquisition software module that operates on the server was finished the collection of different clocks cycle data, the calculating of amount indirectly automatically, automatically data storage is arrived database.Database is regularly cleared up stale data automatically, carries out the thresholding self study automatically.The server said process does not need artificial participation.
When the blast-furnace smelting application was of the present invention, the section chief can carry out production management, data analysis on client terminal, and working of a furnace diagnosis is finished automatically by system.When (1) section chief carries out production management on client terminal, if used blast-furnace burden calculating Excel program to carry out batching then used becoming material list forms importing blast-furnace burden calculating Excel file; Have when newly tapping a blast furnace in picture input estimation composition, the molten iron whereabouts of slagging tap of tapping a blast furnace; Become split screen input gas composition at mixed gas during laboratory Advise By Wire stock gas chemical examination composition; Adjust behind the air port in parameters such as air port parameter picture input tuyere diameter, length; When order of classes or grades at school finishes at the picture input of the relieving record of relieving; Generate daily paper at blast furnace daily record picture when finish every day and also print, generate reinforced form and printing at reinforced form picture; Generate blast furnace monthly magazine and printing at blast furnace monthly magazine picture when every month finishes.(2) section chief opened online working of a furnace diagnosis picture, and system carried out the short-term diagnosis every 1 minute, at the edge too develop, edge deficiency, center too develop, the center deficiency, partially material, hanging, collapse material, pipeline; Carried out the diagnosis in mid-term every 15 minutes, do harm to, hang down stockline to cold, furnace temperature thermotropism, alkali at furnace temperature; Diagnosed for a long time every 2 hours, tie thick at cupola well accumulation, furnace wall; Show diagnostic result and Operating Guideline.(3) section chief can analyze picture in data trend and carries out trend analysis, frequency analysis, regression analysis, correlation analysis, main analysis of Influential Factors; Can analyze picture at distribution trend and carry out distributional analysis.In the system all in time the data of quantity growth can carry out above-mentioned analysis, can derive the analysis report of Excel form after the analysis, can also preserve/open an analysis and avoid repeating being provided with.(4) section chief can carry out material balance, thermal equilibrium at the process calculation picture, directly reduction degree, theoretical coke ratio calculate, check Rist operation line chart at Rist pilot wire picture, pick calculating Tc exponential sum molten iron temperature in the disconnected model at stove, at the furnace charge drop point of blanking Model Calculation chute angle.(5) section chief can be in thresholding, the retrieval technological process of subsidiary function module setting data.
Of the present inventionly be a little:
(1) write down data in the production process comprehensively, substitute the write by hand form fully, accurate and more representative than the write by hand data, alleviated section chief's burden;
(2) 14 kinds of unusual working of a furnaces of diagnosis have been considered 80 detection limits, and 300 rules help the section chief to find that early the working of a furnace is unusual, reduce the loss;
(3) set up generation furnace life database, and, made things convenient for the section chief to excavate smelting knowledge, summed up rule, found the optimum operation system on its basis for the section chief provides abundant analysis means;
(4) compare the like product of import, the test set that the present invention needs is few, does not require that crude fuel samples high stable components, expense have only its 30% and suitable medium and small blast furnace.
Description of drawings
Fig. 1 is the hardware structure diagram of patent system.
Fig. 2 is a conditions of blast furnace diagnostic reasoning machine structure flow chart.
Fig. 3 is a dual alkalinity distribution histogram in the blast-furnace slag.Numeral on the post is the original frequency of software.
Fig. 4 is dual alkalinity and a blast furnace blast kinetic energy recurrence scatter diagram in the blast-furnace slag.
Fig. 5 is top gas utilization ratio and blast energy, coal powder injection rate, Rich Oxygen Amount correlation analysis figure.
Fig. 6 is top gas utilization ratio and blast energy, coal powder injection rate, Rich Oxygen Amount master's analysis of Influential Factors figure.
Embodiment
With reference to Fig. 1 dotted line outside part, iron work is original to be positioned at two of the industrial computers of two of industrial computers, the monitoring hotblast stove of two of industrial computers, the monitoring material loading of the monitoring blast-furnace body of master control room, the PLC of image data comprises blast-furnace body PLC, hotblast stove PLC, material loading PLC, coal powder injection PLC, laboratory PLC, constitutes to produce local area network.The present invention is increasing by two computers at master control room: server, client terminal, a printer is as part in the dotted line among Fig. 1.Wherein server can be connected with information center, administrative office in a factory by company's net.Client terminal can increase to a plurality of, needs only all can of energy Connection Service device.
When the section chief carries out production management on client terminal, if used blast-furnace burden calculating Excel program to carry out batching then used becoming material list forms importing blast-furnace burden calculating Excel file; Have when newly tapping a blast furnace in picture input estimation composition, the molten iron whereabouts of slagging tap of tapping a blast furnace; Become split screen input gas composition at mixed gas during laboratory Advise By Wire stock gas chemical examination composition; Adjust behind the air port in parameters such as air port parameter picture input tuyere diameter, length; When order of classes or grades at school finishes at the picture input of the relieving record of relieving; Generate daily paper at blast furnace daily record picture when finish every day and also print, generate reinforced form and printing at reinforced form picture; Generate blast furnace monthly magazine and printing at blast furnace monthly magazine picture when every month finishes.
The section chief opens online working of a furnace diagnosis picture, and system carried out the short-term diagnosis automatically every 1 minute, carried out the diagnosis in mid-term every 15 minutes, diagnosed for a long time every 2 hours; Diagnostic result is arranged from high to low according to probability, and shows the various unusual working of a furnaces in the mode of eye-catching pie chart, and the color red expression odds of healing is big more, otherwise green more more little.Corresponding every kind of unusual working of a furnace provides Operating Guideline.Rule base is preserved with the form of XML file, the editor of rule base finishes in special expert system develoment tool (this instrument is the product of our stand-alone development), it is convenient just as Edit Document to revise rule, changes directly to cover the renewal that old rule base file has just been realized rule base.The inference engine service regulations storehouse and the known fact are carried out reasoning, its reasoning flow process such as Fig. 2.Used rule belongs to production rule, regular shape as:
" If air quantity〉the normal value upper limit and hot-blast pressure<lower limits of normal then working of a furnace=furnace temperature to cool probability=30 "
If represents prerequisite, and then represents conclusion, and present regulations may be interpreted as: if air quantity were bigger than normal and blast is less than normal under 30% the situation furnace temperature to cold.Corresponding every kind of unusual working of a furnace all has many rules, like this when two rules are released furnace temperature simultaneously to cold, if it is (1-(1-0.2) * (1-0.3)) * 100=44 through the probability after the comprehensive computing of probability that probability is respectively 20,30, we claim that this probability comprehensive method is independent product.There has been probability comprehensively just many influence factors can be placed in many simple rules, simplified regular complexity." the normal value upper limit " in the attention rule, " lower limits of normal " are the thresholding of revising to be set by the thresholding self study or at the data boundary value picture of subsidiary function module, this is one of innovative point of the present invention, by rule is divided into body and thresholding rather than directly in rule, write dead as:
" if air quantity〉the 1500and hot-blast pressure<200then working of a furnace=furnace temperature to cool probability=30 "
Distinguished regular change and constant, regular body is constant, and thresholding becomes, and has caught the essence of blast-furnace smelting problem.On the one hand, the smelting rule of regular body reflection is to smelt iron empirical accumulation both at home and abroad for many years, all is suitable on different blast furnaces, belongs to the aspect of matter; On the other hand, thresholding has reflected the otherness of different blast furnaces and same seat blast furnace different times, the aspect of the amount of belonging to.
The section chief can analyze picture in data trend and carry out trend analysis, frequency analysis, regression analysis, correlation analysis, main analysis of Influential Factors; Can analyze picture at distribution trend and carry out distributional analysis.In the system all in time the data of quantity growth can carry out above-mentioned analysis, can derive the analysis report of Excel form after the analysis, can also preserve/open an analysis and avoid repeating being provided with, this part is one of innovative point of the present invention.When carrying out trend analysis, the section chief only need configure the row name of choosing the table that will analyze after the time range in alternate list, be dragged to the district that draws with mouse, trend map will be drawn by system, the section chief only need drag red pull bar just can check certain occurrence constantly, and the section chief can also switch to the histogram picture such as Fig. 3 sees distribution situation.When carrying out regression analysis such as Fig. 4, the section chief only need select that the drawing variable is dragged to the drawing variable box more than 2, and system promptly draws scatter diagram and calculates regression equation, and regression equation can be linear or polynomial expression.When carrying out correlation analysis such as Fig. 5, the section chief only need pull at least one causal variable and at least one outcome variable, and system calculates relation conefficient between variable automatically, represents positive correlation more near 1 more, and approaching more-1 represents negative correlation more, and is uncorrelated near 0 expression.All be to pull back calculating to get final product in operation.When carrying out main analysis of Influential Factors such as Fig. 6, the class of operation patibhaga-nimitta closes to be analyzed, last form display result with contribution plot.A typically used of distributional analysis is to analyze the coal gas distributions curve that cross temperature characterizes in for some time.Above-mentioned these powerful analytical procedures make the section chief can analyze over certain working of a furnace constantly easily, the relation between the amount of finding and the amount, and it is helpful to excavate smelting knowledge for summing up experience.
The section chief can carry out material balance, thermal equilibrium at the process calculation picture, directly reduction degree, theoretical coke ratio calculate, and check Rist operation line chart at Rist pilot wire picture.By process calculation, the section chief can check blast furnace whether to exist to lose material, not clear thermosteresis, and how many blast furnaces saves burnt potentiality in addition.Stove picks in the disconnected model and calculates the Tc index, and this index helps the section chief to understand the furnace temperature level indirectly.The furnace charge drop point of blanking Model Calculation chute angle, when making the section chief adjust the chute angle of ore, coke no longer blindly.
Experiment shows that the present invention diagnoses hit rate more than 90% to the unusual working of a furnace, helps to ensure working of a furnace stable smooth operation; Data analysis makes section chief's smelting knowledge refinement, quantification, helps section chief's summing up experience to formulate the optimum operation system; Production management frees the section chief and concentrates one's energy to mix up the working of a furnace from the work of making a copy of data.The present invention has realized the long thinking of temporary substitute, the long thinking of helper and has given section chief labour-saving purpose, obtained the distinct economic of volume increase consumption reduction.

Claims (4)

1, a kind of blast furnace intelligent diagnostics and decision support system (DSS), comprise: totally 5 of operation of blast furnace parameter detecting and control PLC, be respectively blast-furnace body PLC, hotblast stove PLC, material loading PLC, coal powder injection PLC, laboratory PLC, each one of data gathering and database server, client terminal, be connected to one of printer on the client terminal, PLC and server, server and client terminal have constituted the hardware platform of system by the EPA communication; Service data acquisition software module and database on server, data acquisition software module are stored in the database after the PLC detect parameters is handled, and database has been stored blast furnace generation furnace life data; Operation blast furnace intelligent diagnostics and decision support system (DSS) software module on client terminal, by regular body and threshold value are separated, the mode of threshold value self study carries out the working of a furnace and diagnoses.
2, according to the described system of claim 1, it is characterized in that, operate in that data acquisition software module on the server was divided 10 seconds, 1 minute, 1 hour and 1 day cycle to detection data from blast-furnace body, hotblast stove, feeding system, laboratory and coal powder injection PLC, comprise temperature, pressure, flow, the slag ingredient that taps a blast furnace, weight of molten iron and reinforced the composition and weight, store database into after handling; Data-base recording the process data and the manual logging data of all collections; Every table is preserved the data strip number and can be provided with, and the deletion stale data storage process periodic cleaning in the database surpasses the record of storage number and guarantees not overplumping of database; Database threshold value self study storage process regularly carries out the self study of data threshold.
3, according to the described system of claim 1, it is characterized in that, operate in blast furnace intelligent diagnostics and decision support system (DSS) software module on the client terminal, provide and be used for the production management module that production data replenishes typing and report generation, comprise and become material Excel importing, the management of tapping a blast furnace, the typing of chemical examination gas composition, air port parameter typing, air port working order typing and the management of relieving, the generation of daily paper, monthly magazine and reinforced form and printing; Be used to diagnose the expert system module of the working of a furnace, be included in radiodiagnosis x and reasoning process and explain; The data analysis module, process calculation module and the mathematical model module that are used for decision support, data analysis module comprises trend analysis, frequency analysis, regression analysis, correlation analysis and main analysis of Influential Factors, the process calculation module comprises that material balance calculating, heat calculation, directly reduction degree calculating, theoretical coke ratio calculate and the Rist pilot wire, and the mathematical model module comprises that stove picks disconnected model and blanking locus model; The subsidiary function module comprises threshold value setting and iron-smelting process rules.
According to the described system of claim 2, it is characterized in that 4, the data acquisition software module that operates on the server is finished the collection of different clocks cycle data and the calculating of amount indirectly automatically, automatically data storage is arrived database; Database is regularly cleared up stale data automatically, carries out the threshold value self study automatically.
CNB2006101653405A 2006-12-18 2006-12-18 Intelligent diagnosis and determination support system for blast furnace CN100485047C (en)

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