CN101886152A - Three-dimensional unstable state monitoring and abnormity diagnosis and maintenance system of blast furnace hearth - Google Patents
Three-dimensional unstable state monitoring and abnormity diagnosis and maintenance system of blast furnace hearth Download PDFInfo
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Abstract
The invention relates to a three-dimensional unstable state monitoring and abnormity diagnosis and maintenance system of a blast furnace hearth, belonging to the technical field of online monitoring, diagnosis, prewarning and maintenance of the blast furnace. The three-dimensional unstable state monitoring and abnormity diagnosis and maintenance system of the blast furnace hearth comprises a data acquisition module, a data filtering module, a hearth and furnace bottom corrosion and accretion calculation module, an abnormality diagnosis module, a prewarning displaying module and a hearth-guiding and maintaining module. Water temperature of a cooling wall of the hearth and galvanic couple temperature of a furnace body can be collected and filtered in real time; by combining the two data together and using pro and con questions of the heat transmission science in combination with the standard of abnormity diagnosis, the influence of the abnormity possibly occurring in the production of the thermal conductivity coefficient variation of refractories, the ring shake, the air gap, and the like on distribution and corrosion of a temperature field is comprehensively judged, a gradient-regularization method and a chaos optimization method are combined to solve, the online monitoring on the three-dimensional unstable state temperature field of the hearth and the furnace bottom, the internal corrosion type, the slag-metal skull variation and the hot state of the hearth is realized, the abnormal circumstance and the corrosion deterioration causes are diagnosed in real time, and the hearth maintenance means is pertinently guided according to the corrosion deterioration causes. The system is successfully applied to industry.
Description
Technical field
The invention belongs to the blast furnace hearth and bottom on-line monitoring, diagnosis, early warning and maintenance technology field, a kind of blast furnace hearth three-dimensional unstable state monitoring and abnormity diagnosis and maintenance system particularly are provided, how gather in real time and filtering blast furnace hearth coolant water temperature and body of heater bricking in electric thermo-couple temperature, how according to these two kinds of basic datas to cupola well furnace bottom three-dimensional unstable state temperature field, type in corroding, the slag iron-clad changes and carries out on-line monitoring and early warning, to ring crack, air gap, collaborate etc. unusual and the cupola well furnace bottom corrodes the aggravation reason and diagnoses, and corrode according to difference and to aggravate method and the industrial application system that reason takes means targetedly that cupola well is effectively safeguarded.
Background technology
Along with the raising of smelting strength of blast furnace and the fluctuation of material condition, the cupola well furnace bottom more and more becomes the restricted link that the blast furnace long-service life high-efficiency is produced.Serious " resembling the pin shape " erosion even the Serious Accident of hearth breakout have all appearred in domestic and international many blast furnaces at present.Therefore, monitor cupola well furnace bottom working order exactly and make rational production operation adjusting and furnace retaining measure in view of the above, it is the key that realizes that the blast furnace long-service life high-efficiency is produced, but blast furnace is a high temperature high pressure enclosed metallurgical reaction, when producing, can't utilize industry CT and some other non-destructive detecting devices to the erosion of its cupola well furnace bottom in type accurately detect, can only can detect data according to body of heater and judge and monitor its working order.
Present domestic and international existing blast furnace hearth and bottom monitoring method, be by independent collection body of heater electric thermo-couple temperature or cupola well cooling range hot-fluid mostly, set up " two-point method " one dimensional heat transfer model, or two-dimentional stable state/unsteady Model corrodes calculating, as document 1 (S.K.ISIJ International, 2005,45 (8): 1122), document 2 (K.T.ISIJInternational, 2001,41 (10): 1139), document 3 (Wu Lijun. the journal .2004 of Shanghai Communications University, 1733.) 38 (10): report such as, though these existent method are utilized neural network, means such as " virtual boundaries " have considered that indefinite the variation with the slag iron-clad of erosion boundary influences cupola well bottom temperature field and erosive in the operation of blast furnace process, but in the blast furnace rig-site utilization, still there is bigger defective, specific as follows:
(1) existing cupola well monitoring method or system existing problems on basic data is selected: all be to gather separately that electric thermo-couple temperature comes the furnace cylinder working state is judged in cupola well cooling stave water temperature difference or the bricking, but when relying on cupola well cooling stave water temperature difference hot-fluid to judge hearth erosion separately, the cooling stave hot-fluid can only reflect the average erosion degree of bricking before the monoblock cooling stave, and hearth breakout is put often and burnt but not face burns; Rely on separately when electric thermo-couple temperature is judged hearth erosion in the bricking, because the galvanic couple number is limited, there is not the place of galvanic couple will lose the erosion basis for estimation, and galvanic couple has often damaged morely in stove labour latter stage (blast furnace hearth needs the emphasis monitoring stage) bricking, and the gene basis data deficiencies will cause corroding monitoring accuracy and reduce greatly like this.
(2) existing cupola well monitoring method or system have problems on basic data acquisition: mostly the data of gathering are directly used in the furnace cylinder working condition diagnosing, shortage will directly cause the judged result mistake also may destroy the accuracy of continuous monitoring to the filtering of misdata as the basic data mistake.In addition, mostly adopt traditional multimode electric circuit analogy signal transmission aspect the coolant water temperature collection, the big and transmission course of data accumulation error is subject to disturb.
(3) existing cupola well monitoring method or the system computation model when inferring hearth erosion is selected existing problems: adopt one dimension or two dimension, rectangular coordinates (rectangle) mostly, do not comprise the stable state computation model of molten steel solidification latent heat, this and blast furnace hearth and bottom designs on three-dimensional and corrode asymmetric, geometrical shape and be approximately practical situation cylindric, that the slag iron-clad forms the release latent heat of solidification and be not inconsistent, and cause hearth erosion estimation result and actual difference bigger.
(4) existing cupola well monitoring method or system judge cupola well whether exist exist when unusual blank: (present patent application person is devoted for years in blast furnace longevity technology and erosion study on monitoring for erosion monitoring by the erosion mechanism research of cupola well furnace bottom and domestic tens of blast furnaces and damaged investigation, born and finished the relevant country " eight or five " of hearth erosion monitoring, " 95 ", Eleventh Five-Year Plan, natural science fund problem and Shoudu Iron and Steel Co, Taiyuan Iron and Steel Co., Tang Gang, climb association of numerous factory projects such as steel), we find the gradually intensification of blast furnace operation back along with the cupola well bottom refractory, the operation of tapping a blast furnace, zinc basic metal corrodes, thermal stresses changes and fills out the removal of smashing moisture and fugitive constituent in the material, the reason of considerable change of cupola well furnace bottom working order and erosion aggravation is often because the generation of abnormal conditions, as cupola well carbon brick ring crack, air gap appears between carbon brick and cooling system, collaborate, the thermal conductivity of anti-material ANOMALOUS VARIATIONS, furnace bottom oozes iron etc., and present existing erosion monitoring method or system all do not have these abnormal conditions are judged and early warning.
(5) existing cupola well monitoring method or system have problems on the demonstration warning function: only show wall scroll cupola well furnace bottom encroachment line mostly, lack the demonstration to each position differing temps of cupola well furnace bottom; System is in non-responsive state and does not support man-machine dialogue when calculating the cupola well furnace bottom and corrode; When the cupola well state is carried out historical query, can only provide data query lack hearth erosion in the query display directly perceived of type; Do not possess real-time early warning prompt facilities such as hearth erosion transfinites, the cupola well knot is thick, cupola well is not lived.
(6) existing cupola well monitoring method or system are instructing existence blank on the furnace cylinder maintenance: can only make judgement to hearth erosion severity or bricking residual thickness mostly, all fail the reason that corrodes aggravation is made diagnosis, also just can't instruct furnace cylinder maintenance and production operation adjusting targetedly.
To sum up, present existing cupola well furnace bottom monitoring and pre-alarming method or system are still existing defective aspect basic data selection, the selection of erosion computation model, the furnace cylinder working state early warning, unusual and corrode the aggravation cause diagnosis, instruct and still exist blank aspect the furnace cylinder maintenance at cupola well, fail and organically combination of the safe and efficient production of blast furnace.
Summary of the invention
The object of the present invention is to provide a kind of blast furnace hearth three-dimensional unstable state monitoring and abnormity diagnosis and maintenance system, overcome the blank that existing cupola well furnace bottom monitoring method or system aggravate cause diagnosis in the deficiency that exists aspect basic data selection, the selection of erosion computation model, the furnace cylinder working state early warning and in abnormal erosion, instruct aspect existence such as furnace cylinder maintenance; Can gather in real time and filtering cupola well cooling stave water temperature and body of heater electric thermo-couple temperature, two kinds of data are combined thermal conduction study " positive indirect problem " combination " abnormity diagnosis " standard that adopts, comprehensive judgement refractory materials thermal conductivity changes, ring crack, ooze iron, what may occur in the productions such as air gap distributes to the temperature field and the erosive influence unusually, regularization of associating gradient and chaos optimization method are found the solution, realization is to cupola well furnace bottom three-dimensional unstable state temperature field, type in corroding, the slag iron-clad changes, the on-line monitoring of the hot state of cupola well, real-time diagnosis to abnormal conditions and erosion aggravation reason, early warning, and aggravate the reason intelligent guidance according to erosion and take furnace cylinder maintenance means targetedly, successfully realized the industrial application of this method.
Technical scheme of the present invention is: by the research of cupola well furnace bottom erosion mechanism, with Fluid Mechanics Computation, calculating thermal conduction study is the basis, use modern expert system theory, cupola well furnace bottom erosion mechanism is carried out knowledge processing, set up blast furnace hearth and bottom " abnormity diagnosis " module, gather the gentle body of heater electric thermo-couple temperature of cupola well cooling stave Inlet and outlet water in real time, adopt the method for thermal conduction study " positive indirect problem " combination " abnormity diagnosis ", comprehensive judgement refractory materials thermal conductivity changes, ring crack, ooze iron, what may occur in the productions such as air gap distributes to the temperature field and the erosive influence unusually, regularization of associating gradient and chaos optimization method are found the solution, to cupola well furnace bottom three-dimensional unstable state temperature field, type in corroding, the slag iron-clad changes, the hot state of cupola well carries out on-line monitoring, abnormal conditions and erosion aggravation reason are carried out real-time diagnosis, and instruct the furnace cylinder maintenance means targetedly of taking according to corroding the aggravation reason.
The present invention includes data acquisition module, the data filter module, the cupola well furnace bottom corrodes the thick computing module of knot, abnormality diagnosis module, show the early warning module, instruct the furnace cylinder maintenance module, wherein data collecting model is responsible for gathering in real time cupola well cooling stave water temperature and body of heater electric thermo-couple temperature, the data filter model carries out automatic filter to the real time data of gathering, filtered data are imported abnormality diagnosis module into and are carried out unusual knowledge judgement, the data of acquisition filter and the diagnostic result that draws import the thick computing module of erosion knot together to carry out the temperature field and corrodes the thick calculating of knot, show that Early-warning Model feeds back to the blast furnace operating personnel with calculation result, instruct the furnace cylinder maintenance model to provide reasonable furnace retaining means suggestion according to calculating and early warning result.
1. basic data acquisition module
Native system judges that the cupola well state is to gather and rely on electric thermo-couple temperature in cupola well cooling stave water temperature difference hot-fluid and the cupola well bearth brick lining simultaneously, has not only realized " linking work at selected spots with that in entire areas ", can also judge unusual existence such as hot state of cupola well and ring crack, air gap.
When gathering cooling stave turnover water temperature, abandoned the big and transmission of traditional complexity, error accumulation and be subject to interferential circuit layout (thermopair → electric bridge leveling → amplification filtering → digital-to-analog conversion → microprocessor → upper computer).
. the basic data acquisition module designs based on the acquisition module of digital sensor: high accuracy number temperature sensor (0.03 ℃ of resolving power) is encapsulated in the stainless steel probe, transmitter has not only been simplified circuit and has also thoroughly been got rid of the influence of voltage of supply height to measuring by in the count cycle that is determined by the vibrator to the temperature altitude sensitivity at one temperature being measured in the calculating of oscillator clock counted number of pulses.Probe will insert centre of conduit in face of the direction of incoming flow and to minimize probe the resistance of in-pipe flow be decreased, avoid forming eddy flow or dead band, probe fully takes into account susceptibility and the followability to temperature variation in design, temperature probe wall thickness 1mm, when encapsulating, temperature probe inside use high thermal conductive silicon glue that the transmitter pouring is fixed in the probe, removing transmitter cavity in the past in the temperature probe all uses low thermally conductive material to fill the low thermally conductive material of use, make temperature probe change the interference that has very strong followability and real-time and don't be vulnerable to external heat source to coolant water temperature, whole temperature probe is drawn the waterproof Aviation Connector that comprises 4 leads, and (four leads are supply lead (positive and negative), data line, clock cable).Aviation Connector is directly inserted microprocessor IO port, just can the read sensor temperature data.Amplification, filtering, analog-digital converter circuit have been saved in this design, have eliminated analog signal processing circuit and have been subject to interferential middle-chain.Can a plurality of transmitters of serial on the universal serial bus of microprocessor, saved a large amount of circuits, also be beneficial to maintenance.In the practical application bus is used the signal accentuator, numerary signal in the bus is adopted the 0V/+12V level signal, microcontroller circuit uses the 0V/+5V signal, guarantees that numerary signal has very strong interference free performance in than longer transmission distance.Transmitter after microprocessor is patrolled and examined collection, encapsulate add CRC check by 485 bus transfer to upper computer, by the serial ports per minute whole microprocessors are sent temperature signal at upper computer and collect instruction, finish real-time collection blast furnace hearth cooling stave water temperature data.
In gathering the cupola well bearth brick lining during electric thermo-couple temperature, if blast furnace field data memory transactions adopts the OPC mode, then utilize the concrete tag name visit of the interior galvanic couple of DCOM technical basis bricking to read its temperature data, if data storage adopts Oracle, second databases servers such as SQL Server, FoxPro, then utilize the table name and the record position at galvanic couple temperature data place in the ADO technical basis server to read.
2. basic data filtration module
Because the complex environment at blast furnace scene, the galvanic couple temperature often may be owing to be interfered and distortion in cupola well state judgement basis data-cupola well cooling stave water temperature of gathering and the bricking in real time, and existing monitoring method or system lack the judgement to basic data validity mostly, when data distortion, may provide with cupola well in the judged result that differs greatly of virtual condition, therefore researched and developed the basic data filtration module innovatively in conjunction with the blast-furnace smelting characteristics behind data acquisition module, the filtering condition that comprises is as follows:
(1) according to heat transfer principle, heat reaches the outer cooling of stove system by the furnace high-temperature molten iron, temperature also is to reduce gradually, if therefore in the body of heater bricking front and back of same absolute altitude or the electric thermo-couple temperature up and down of the same degree of depth do not meet heat transfer principle, check these type of data;
(2) if the galvanic couple temperature is lower than 20 ℃ or be higher than its range (most bad point show 32767) in the body of heater bricking, this type of temperature is filtered;
(3) want real time record bricking galvanic couple temperature and cooling range, (change above 50 ℃ in 5 minutes if find that the temperature of certain galvanic couple or cooling range raise significantly in very short time or reduce as some galvanic couple, water temperature difference fluctuateed above 0.5 ℃ in 1 minute), to carry out mark to this type of temperature, adopt the seasonal effect in time series method to judge its validity;
(4) some body of heater galvanic couple temperature shows normally, but remains constantly, and the temperature that also will carry out mark and adjacent other galvanic couple to this type of temperature compares, and writes down its invariant time and judge its validity.
3. abnormality diagnosis module
As previously mentioned, blast furnace furnace cylinder working in operational process is not normal often owing to air gap, ring crack etc. cause unusually, if can not unusually accurately judge and only be to rely on cupola well water temperature difference hot-fluid or bricking galvanic couple temperature to infer that the stove internal state changes separately these, will produce very big deviation.As when cupola well produces air gap, but cooling stave water temperature difference hot-fluid reduces corrodes in the actual stove but in aggravation; Bricking galvanic couple temperature raises but the actual possibility and not serious that corrodes when oozing iron as furnace bottom.Therefore, the foundation of cupola well abnormality diagnosis module is particularly crucial, it also is one of core content of this invention difference and other method or system, this module is at concrete blast furnace, utilize modern expert system technology that its erosion mechanism is handled, basic data is gathered with filtering after, in conjunction with cooling stave hot-fluid, hot-fluid variation, bricking galvanic couple real time temperature, top temperature, galvanic couple temperature variation, bricking size, bricking thermal conductivity etc., set up following abnormity diagnosis standard innovatively:
(1) sets up the historical high database of cupola well cooling stave hot-fluid and bricking electric thermo-couple temperature, with the real time temperature data T and the historical high data T of online acquisition and filtering
wCompare, if T＞T
wThen upgrade the historical high database and judge that this position slag iron-clad comes off, otherwise then there is the slag iron-clad in judgement and does not upgrade the historical high database;
(2) by the real-time (T of the front and back thermopair at the same absolute altitude of cupola well sidewall place
f, T
b) temperature, temperature change value (Δ T
f, Δ T
b), thermopair spacing (L), the heat flow rate per unit area (q) of corresponding cooling stave, the original heat conduction parameter of heat flow rate per unit area changing value (Δ q) bricking (k
0) judge whether ANOMALOUS VARIATIONS of bricking thermal conductivity, as (Δ q* Δ T
f* Δ T
b〉=0) ﹠amp; ﹠amp; (T
f＞T
b) time, if
Then the bricking thermal conductivity raises, otherwise then the bricking thermal conductivity reduces.
(3) relatively judge ring crack by electric thermo-couple temperature before and after the cupola well sidewall, if (Δ q＜0) ﹠amp with different variation tendencies; ﹠amp; (Δ T
f＞0) ﹠amp; ﹠amp; (Δ T
b＜0), then there is ring crack in judgement.
(4) change in conjunction with cooling stave hot-fluid variation judgement air gap, if (Δ q＜0) by the thermopair of cupola well sidewall by hot side; ﹠amp; (Δ T
f＞0) ﹠amp; ﹠amp; (Δ T
b＞0), then air gap appears in judgement;
(5) judge by the original thermal resistance of furnace bottom refractory brick and furnace bottom electric thermo-couple temperature and furnace bottom cooling parameter and ooze iron, if T
u＜T
dJudging then that furnace bottom exists oozes iron;
(6) corrode calculating by cupola well furnace bottom three-dimensional unstable state and determine the susceptibility of corner region electric thermo-couple temperature with cupola well sidewall and furnace bottom variation in thickness.
4. the cupola well furnace bottom corrodes the thick computing module of knot
As previously mentioned, present existing monitoring method or system selected calculation model for temperature field and actual blast furnace on this module is not inconsistent.We are approximately cylindrical according to the true form of blast furnace hearth and bottom, consider that the cupola well furnace bottom belongs to the unstable state temperature-rise period when corroding variation, and molten iron will discharge latent heat of solidification in phase transition process, set up the cupola well bottom temperature field computation model that the three-dimensional unstable state cylindrical coordinates comprises latent heat of solidification innovatively, set up the control differential equation according to the housing principle of energy balance:
Select the method for latent heat of solidification as source item, as follows:
The source item that heat of phase transformation is constituted is directly carried out Difference Calculation as finding the solution object, and source item is relevant with timed interval front and back transformation ratio (temperature) separately, specifically handles as follows:
After setting up rational temperature field computation model and method, by the method that " positive indirect problem " combines, the difference of setting up basic data and accounting temperature is minimum objective function, constitutes the optimization model of finding the solution type in the erosion, and its solution procedure is as follows:
Step1 utilizes cupola well furnace bottom thermal conduction study direct problem, given initial inner boundary;
Step2 utilizes known blast furnace design data and production data, in conjunction with " abnormity diagnosis " module, the abnormal conditions that may occur is judged and is handled;
Step3 provides the objective function that corrodes the inner boundary prediction and optimizes mathematical model in conjunction with cupola well hot-fluid and thermocouple temperature measurement data and heuristic knowledge;
Step4 tries to achieve regular solution with gradient normalization method;
Step5 wait to ask inner boundary by transform to the span [0,1] of Chaos Variable to span.
Step6 carries out some steps of Chaos Search, if search is then calculated and finished less than than the better point of the inner boundary that has obtained; Otherwise the inner boundary so that the more better replacement that is searched has been obtained then as iterative value, changes step4.
5. show the early warning module
This module mainly is that the judged result with above-mentioned module is shown to the blast furnace operating personnel simple and clearly, make the blast furnace personnel can grasp the state of cupola well inside to greatest extent by the demonstration early warning of system, but present existing monitoring method or system still exist deficiency in this regard, show as the 1150 ℃ of encroachment lines or the slag iron-clad line that mostly just will calculate, the temperature field of failing to provide whole cupola well furnace bottom distributes, and can not carry out early warning unusually to what cupola well occurred.In order to overcome these deficiencies, fully according to the demand of blast furnace personnel grasp erosion condition directly perceived, fast, accurate and comprehensive and cupola well thermal load, the innovative point that the demonstration early warning module of exploitation is comprised is as follows for we:
(1) handles automatically by adopting multithreading that data gathering and cupola well furnace bottom three-dimensional unstable state temperature field evaluation work are put into the backstage, but realize that man-machine interface is in responsive state all the time;
(2) with tabular form cupola well cooling stave water temperature difference and thermal load are sorted automatically, show the cupola well heat load distribution in circumference pie chart mode, with red, yellow, green three kinds of colors corresponding show the cupola well thermal load be in transfinite, early warning and safe work state;
(3) type and slag iron-clad generated and come off in the three-dimensional in update displayed cupola well furnace bottom horizontal stroke, longitudinal section corroded automatically, automatically statistics and show cupola well and furnace bottom the most serious erosion position and residue bricking thickness, and relatively provide the early warning whether cupola well is in safe work state according to the most serious corroding thickness and early warning standard;
(4) show three-dimensional temperature cloud atlas, the many temperature Isothermal Line Distribution of cupola well furnace bottom in real time from 50 ℃ to 1500 ℃ of smooth transition, support mouse to move and get the temperature, material and the location parameter that show cupola well furnace bottom any point, realize three-dimensional monitoring whole cupola well furnace bottom.
(5) provide type, slag iron-clad shape, temperature cloud atlas and isothermal inquiry and drafting in the historical erosion of cupola well furnace bottom.
6. instruct the furnace cylinder maintenance module
Cupola well being carried out unusually real-time diagnosis and hearth erosion being calculated on the basis of monitoring, researched and developed intelligent guidance furnace cylinder maintenance module innovatively, the summary of the invention of this module is as follows:
(1) if the cupola well furnace bottom does not exist unusually, the position that whether is higher than 1150 ℃ of encroachment lines and 800 ℃ of carbon brick embrittlement lines by the bricking hot-face temperature judges whether that erosion does not reach balance, if corrode and do not reach balance, mobile two aspects of molten iron are come cupola well is safeguarded in cooling and the stove outside stove.
(2), then take online mud jacking technology, but will note pressure-controlling and improve the thermal conductivity that is pressed into material if there is air gap in the cupola well sidewall.
(3) if the cupola well sidewall exists collaborates or ring crack, except taking the mud jacking technology, be also noted that, and, improve the slag alkaline discharging capacity going into the alkali-metal control of stove zinc to patrolling and examining that the air port leaks;
(4), when serious " resembling the pin shape " erosion especially occurring, take the stifled air port measure of appropriate time according to erosion condition if localized attack aggravates unusually;
(5) expect that ANOMALOUS VARIATIONS appears in thermal resistance in operation of blast furnace if the cupola well furnace bottom is filled out to smash, become the heat transfer limitations link, suitably take to increase the cloth water-cooled tube according to erosion condition.
(6) if cupola well thermosteresis excessive (its reasonable thermal load of cupola well at concrete material-structure is also different) will suitably be controlled cupola well furnace bottom cooling intensity and the operation of tapping a blast furnace.
Beneficial effect
The invention has the beneficial effects as follows: compare other cupola well furnace bottom monitoring method or system, this invention can be monitored the hot state of cupola well, the three-dimensional erosion and the variation of slag iron-clad simultaneously, unusual generation such as automatically judge ring crack, air gap, collaborate, automatically the reason that corrodes aggravation is made diagnosis, intelligent guidance blast-furnace technique personnel take effective furnace retaining means and rational production operation to regulate.This invention has successfully realized its industrial application on iron and steel enterprise's blast furnace, promptly prevented the generation of hearth breakout Serious Accident by monitoring timely and accurately, as accurate diagnose out No. 3 blast furnace hearths of No. 3 blast furnaces of Tang Gang and Laigang " to resemble the pin shape " to corrode instructed timely furnace retaining and blowing out, and The model calculation and blowing out overhaul are after this investigated consistent; Realized again to cupola well effective maintenance, reduced running cost and prolonged blast furnace campaign, as move the hearth erosion aggravation reason that No. 1 automatic monitoring diagnosis system of blast furnace hearth of steel is judged different times real-time and accurately, and then instruct the blast furnace scene to take maintenance service targetedly, greatly reduce its furnace retaining cost and cupola well thermosteresis, the economic benefit of bringing surpasses 1,000 ten thousand yuan/year, has realized the unification that cupola well is long-lived and be incubated.
Description of drawings
Fig. 1 is the schema of the present invention's realization to cupola well furnace bottom working state monitoring.
Fig. 2 forms and graph of a relation for each module of industrial application of the present invention system.
Fig. 3 is the temperature probe schema of encapsulation digital sensor among the present invention.
Fig. 4 corrodes the thick monitoring picture of knot for cupola well furnace bottom among the present invention.
Fig. 5 is cupola well furnace bottom thermoisopleth display frame among the present invention.
Fig. 6 is cupola well bottom temperature cloud atlas display frame among the present invention.
Embodiment
The present invention includes data acquisition module, data filter module, cupola well furnace bottom erosion knot thick computing module, abnormality diagnosis module, demonstration early warning module, instruct the furnace cylinder maintenance module; Wherein data collecting model is responsible for gathering in real time cupola well cooling stave water temperature and body of heater electric thermo-couple temperature, the data filter model carries out automatic filter to the real time data of gathering, filtered data are imported abnormality diagnosis module into and are carried out unusual knowledge judgement, the data of acquisition filter and the diagnostic result that draws import the thick computing module of erosion knot together to carry out the temperature field and corrodes the thick calculating of knot, show that Early-warning Model feeds back to the blast furnace operating personnel with calculation result, instruct the furnace cylinder maintenance model to provide reasonable furnace retaining means suggestion according to calculating and early warning result.
The basic data acquisition module designs based on the acquisition module of digital sensor: the high accuracy number temperature sensor of 0.03 ℃ of resolving power is encapsulated in the stainless steel probe, transmitter is by measuring temperature to the calculating of oscillator clock counted number of pulses in the count cycle that is determined by the vibrator to the temperature altitude sensitivity at one, probe will insert centre of conduit in face of the direction of incoming flow and to minimize probe the resistance of in-pipe flow be decreased, avoid forming eddy flow or dead band, temperature probe wall thickness 1mm, when encapsulating, temperature probe inside use high thermal conductive silicon glue that the transmitter pouring is fixed in the probe, removing transmitter cavity in the past in the temperature probe all uses low thermally conductive material to fill the low thermally conductive material of use, make temperature probe change the interference that has very strong followability and real-time and don't be vulnerable to external heat source to coolant water temperature, whole temperature probe is drawn the waterproof Aviation Connector that comprises 4 leads; Aviation Connector is directly inserted microprocessor IO port, the read sensor temperature data, the a plurality of transmitters of serial on the universal serial bus of microprocessor, in the practical application bus is used the signal accentuator, numerary signal in the bus is adopted the 0V/+12V level signal, microcontroller circuit uses the 0V/+5V signal, guarantees that numerary signal has very strong interference free performance in than longer transmission distance.Transmitter after microprocessor is patrolled and examined collection, encapsulate add CRC check by 485 bus transfer to upper computer, by the serial ports per minute whole microprocessors are sent temperature signal at upper computer and collect instruction, finish real-time collection blast furnace hearth cooling stave water temperature data;
The filtering condition that the basic data filtration module comprises is as follows:
(1) heat reaches the outer cooling of stove system by the furnace high-temperature molten iron, and temperature also is to reduce gradually, and the electric thermo-couple temperature up and down of the front and back of same absolute altitude or the same degree of depth does not meet heat transfer principle in the body of heater bricking, check these type of data;
(2) be lower than 20 ℃ or when being higher than the most bad points of its range and showing 32767 when galvanic couple temperature in the body of heater bricking, this type of temperature filtered;
(3) real time record bricking galvanic couple temperature and cooling range, rising or the reduction significantly in very short time when the temperature of finding certain galvanic couple or cooling range carried out mark to this type of temperature, adopts the seasonal effect in time series method to judge its validity;
(4) some body of heater galvanic couple temperature shows normally, but remains constantly, and the temperature that also will carry out mark and adjacent other galvanic couple to this type of temperature compares, and writes down its invariant time and judge its validity;
Abnormality diagnosis module is at concrete blast furnace, utilize modern expert system technology that its erosion mechanism is handled, basic data is gathered with filtering after, in conjunction with cooling stave hot-fluid, hot-fluid variation, bricking galvanic couple real time temperature, top temperature, galvanic couple temperature variation, bricking size, bricking thermal conductivity, set up normal Case definition:
The cupola well furnace bottom corrodes the thick computing module of knot and has set up the cupola well bottom temperature field computation model that the three-dimensional unstable state cylindrical coordinates comprises latent heat of solidification, sets up the control differential equation according to the housing principle of energy balance:
Show that the early warning module is that judged result with above-mentioned module is shown to the blast furnace operating personnel simple and clearly, makes the blast furnace personnel can grasp the state of cupola well inside to greatest extent by the demonstration early warning of system;
Instruct theing contents are as follows of furnace cylinder maintenance module:
(1) do not exist unusually when the cupola well furnace bottom, the position that whether is higher than 1150 ℃ of encroachment lines and 800 ℃ of carbon brick embrittlement lines by the bricking hot-face temperature judges whether that erosion does not reach balance, if corrode and do not reach balance, mobile two aspects of molten iron are come cupola well is safeguarded in cooling and the stove outside stove;
(2) there is air gap when the cupola well sidewall, then takes online mud jacking technology, but will note pressure-controlling and improve the thermal conductivity that is pressed into material;
(3) collaborate or ring crack when the cupola well sidewall exists, except taking the mud jacking technology, be also noted that, and, improve the slag alkaline discharging capacity going into the alkali-metal control of stove zinc to patrolling and examining that the air port leaks;
(4) corrode unusual aggravation when the part, when especially appearance serious " resembling the pin shape " is corroded, take the stifled air port measure of appropriate time according to erosion condition;
(5) when the cupola well furnace bottom fill out smash the material thermal resistance ANOMALOUS VARIATIONS appears in operation of blast furnace, become the heat transfer limitations link, suitably take to increase the cloth water-cooled tube according to erosion condition;
(6) excessive when the cupola well thermosteresis, control cupola well furnace bottom cooling intensity and the operation of tapping a blast furnace.
At concrete blast furnace, the high accuracy number temperature probe is installed on the water inlet pipe and water outlet pipe of blast furnace hearth cooling stave, adopt wired or wireless communication modes per minute to gather cupola well temperature of cooling water and flow, gather the body of heater bricking galvanic couple temperature in the bf server simultaneously in real time, the data that collect are carried out after the filtering as the required basic data of upper computer cupola well Monitoring systems, the filtration module that these basic datas are installed through upper computer, abnormality diagnosis module, corrode computing module, after showing that early warning module and maintenance guidance module are handled automatically, the blast furnace operating personnel just can be according to the cupola well bottom temperature field distribution of man-machine interface demonstration, type in corroding, slag iron-clad shape, cupola well thermal load etc. is intuitively grasped cupola well all sidedly and whether is in the normal working order of safety, and the furnace cylinder maintenance that provides automatically according to system prompting takes furnace retaining means targetedly, to realize the longevity and the High-efficient Production of blast furnace.
Claims (5)
1. blast furnace hearth three-dimensional unstable state monitoring and abnormity diagnosis and maintenance system, it is characterized in that, comprise data acquisition module, the data filter module, the cupola well furnace bottom corrodes the thick computing module of knot, abnormality diagnosis module, show the early warning module, instruct the furnace cylinder maintenance module, wherein data collecting model is responsible for gathering in real time cupola well cooling stave water temperature and body of heater electric thermo-couple temperature, the data filter model carries out automatic filter to the real time data of gathering, filtered data are imported abnormality diagnosis module into and are carried out unusual knowledge judgement, the data of acquisition filter and the diagnostic result that draws import the thick computing module of erosion knot together to carry out the temperature field and corrodes the thick calculating of knot, show that Early-warning Model feeds back to the blast furnace operating personnel with calculation result, instruct the furnace cylinder maintenance model to provide reasonable furnace retaining means suggestion according to calculating and early warning result;
The basic data acquisition module designs based on the acquisition module of digital sensor: the high accuracy number temperature sensor of 0.03 ℃ of resolving power is encapsulated in the stainless steel probe, transmitter is by measuring temperature to the calculating of oscillator clock counted number of pulses in the count cycle that is determined by the vibrator to the temperature altitude sensitivity at one, probe will insert centre of conduit in face of the direction of incoming flow and to minimize probe the resistance of in-pipe flow be decreased, avoid forming eddy flow or dead band, temperature probe wall thickness 1mm, when encapsulating, temperature probe inside use high thermal conductive silicon glue that the transmitter pouring is fixed in the probe, removing transmitter cavity in the past in the temperature probe all uses low thermally conductive material to fill, use low thermally conductive material, make temperature probe change the interference that has very strong followability and real-time and don't be vulnerable to external heat source to coolant water temperature, whole temperature probe is drawn the waterproof Aviation Connector that comprises 4 leads; Aviation Connector is directly inserted microprocessor IO port, the read sensor temperature data, the a plurality of transmitters of serial on the universal serial bus of microprocessor, in the practical application bus is used the signal accentuator, numerary signal in the bus is adopted the 0V/+12V level signal, microcontroller circuit uses the 0V/+5V signal, guarantees that numerary signal has very strong interference free performance in than longer transmission distance.Transmitter after microprocessor is patrolled and examined collection, encapsulate add CRC check by 485 bus transfer to upper computer, by the serial ports per minute whole microprocessors are sent temperature signal at upper computer and collect instruction, finish real-time collection blast furnace hearth cooling stave water temperature data;
The filtering condition that the basic data filtration module comprises is as follows:
(1) heat reaches the outer cooling of stove system by the furnace high-temperature molten iron, and temperature also is to reduce gradually, and the electric thermo-couple temperature up and down of the front and back of same absolute altitude or the same degree of depth does not meet heat transfer principle in the body of heater bricking, check these type of data;
(2) be lower than 20 ℃ or when being higher than the most bad points of its range and showing 32767 when galvanic couple temperature in the body of heater bricking, this type of temperature filtered;
(3) real time record bricking galvanic couple temperature and cooling range, rising or the reduction significantly in very short time when the temperature of finding certain galvanic couple or cooling range carried out mark to this type of temperature, adopts the seasonal effect in time series method to judge its validity;
(4) some body of heater galvanic couple temperature shows normally, but remains constantly, and the temperature that also will carry out mark and adjacent other galvanic couple to this type of temperature compares, and writes down its invariant time and judge its validity;
Abnormality diagnosis module is at concrete blast furnace, utilize modern expert system technology that its erosion mechanism is handled, basic data is gathered with filtering after, in conjunction with cooling stave hot-fluid, hot-fluid variation, bricking galvanic couple real time temperature, top temperature, galvanic couple temperature variation, bricking size, bricking thermal conductivity, set up normal Case definition;
The cupola well furnace bottom corrodes the thick computing module of knot and has set up the cupola well bottom temperature field computation model that the three-dimensional unstable state cylindrical coordinates comprises latent heat of solidification, sets up the control differential equation according to the housing principle of energy balance:
Show that the early warning module is that judged result with above-mentioned module is shown to the blast furnace operating personnel simple and clearly, makes the blast furnace personnel can grasp the state of cupola well inside to greatest extent by the demonstration early warning of system;
Instruct theing contents are as follows of furnace cylinder maintenance module:
(1) do not exist unusually when the cupola well furnace bottom, the position that whether is higher than 1150 ℃ of encroachment lines and 800 ℃ of carbon brick embrittlement lines by the bricking hot-face temperature judges whether that erosion does not reach balance, if corrode and do not reach balance, mobile two aspects of molten iron are come cupola well is safeguarded in cooling and the stove outside stove;
(2) there is air gap when the cupola well sidewall, then takes online mud jacking technology, but will note pressure-controlling and improve the thermal conductivity that is pressed into material;
(3) collaborate or ring crack when the cupola well sidewall exists, except taking the mud jacking technology, be also noted that, and, improve the slag alkaline discharging capacity going into the alkali-metal control of stove zinc to patrolling and examining that the air port leaks;
(4) corrode unusual aggravation when the part, when especially appearance serious " resembling the pin shape " is corroded, take the stifled air port measure of appropriate time according to erosion condition;
(5) when the cupola well furnace bottom fill out smash the material thermal resistance ANOMALOUS VARIATIONS appears in operation of blast furnace, become the heat transfer limitations link, suitably take to increase the cloth water-cooled tube according to erosion condition;
(6) excessive when the cupola well thermosteresis, control cupola well furnace bottom cooling intensity and the operation of tapping a blast furnace.
2. system according to claim 1 is characterized in that, described abnormity diagnosis standard comprises:
(1) sets up the historical high database of cupola well cooling stave hot-fluid and bricking electric thermo-couple temperature, with the real time temperature data T and the historical high data T of online acquisition and filtering
wCompare, if T＞T
wThen upgrade the historical high database and judge that this position slag iron-clad comes off, otherwise then there is the slag iron-clad in judgement and does not upgrade the historical high database;
(2) by the real-time (T of the front and back thermopair at the same absolute altitude of cupola well sidewall place
f, T
b) temperature, temperature change value (Δ T
f, Δ T
b), thermopair spacing (L), the heat flow rate per unit area (q) of corresponding cooling stave, the original heat conduction parameter of heat flow rate per unit area changing value (Δ q) bricking (k
0) judge whether ANOMALOUS VARIATIONS of bricking thermal conductivity, as (Δ q* Δ T
f* Δ T
b〉=0) ﹠amp; ﹠amp; (T
f＞T
b) time, if
Then the bricking thermal conductivity raises, otherwise then the bricking thermal conductivity reduces;
(3) relatively judge ring crack by electric thermo-couple temperature before and after the cupola well sidewall, if (Δ q＜0) ﹠amp with different variation tendencies; ﹠amp; (Δ T
f＞0) ﹠amp; ﹠amp; (Δ T
b＜0), then there is ring crack in judgement;
(4) change in conjunction with cooling stave hot-fluid variation judgement air gap, if (Δ q＜0) by the thermopair of cupola well sidewall by hot side; ﹠amp; (Δ T
f＞0) ﹠amp; ﹠amp; (Δ T
b＞0), then air gap appears in judgement;
(5) judge by the original thermal resistance of furnace bottom refractory brick and furnace bottom electric thermo-couple temperature and furnace bottom cooling parameter and ooze iron, if T
u＜T
dJudging then that furnace bottom exists oozes iron;
(6) corrode calculating by cupola well furnace bottom three-dimensional unstable state and determine the susceptibility of corner region electric thermo-couple temperature with cupola well sidewall and furnace bottom variation in thickness.
3. system according to claim 1 is characterized in that, described latent heat of solidification is as the method for source item, and is as follows:
The source item that heat of phase transformation is constituted is directly carried out Difference Calculation as finding the solution object, and source item is relevant with timed interval front and back transformation ratio (temperature) separately, specifically handles as follows:
After setting up rational temperature field computation model and method, by the method that " positive indirect problem " combines, the difference of setting up basic data and accounting temperature is minimum objective function, constitutes the optimization model of finding the solution type in the erosion, and its solution procedure is as follows:
Step1 utilizes cupola well furnace bottom thermal conduction study direct problem, given initial inner boundary;
Step2 utilizes known blast furnace design data and production data, in conjunction with " abnormity diagnosis " module, the abnormal conditions that may occur is judged and is handled;
Step3 provides the objective function that corrodes the inner boundary prediction and optimizes mathematical model in conjunction with cupola well hot-fluid and thermocouple temperature measurement data and heuristic knowledge;
Step4 tries to achieve regular solution with gradient normalization method;
Step5 wait to ask inner boundary by transform to the span [0,1] of Chaos Variable to span;
Step6 carries out some steps of Chaos Search, if search is then calculated and finished less than than the better point of the inner boundary that has obtained; Otherwise the inner boundary so that the more better replacement that is searched has been obtained then as iterative value, changes step4.
4. system according to claim 1 is characterized in that, shows that the early warning module comprises following content:
(1) handles automatically by adopting multithreading that data gathering and cupola well furnace bottom three-dimensional unstable state temperature field evaluation work are put into the backstage, but realize that man-machine interface is in responsive state all the time;
(2) with tabular form cupola well cooling stave water temperature difference and thermal load are sorted automatically, show the cupola well heat load distribution in circumference pie chart mode, with red, yellow, green three kinds of colors corresponding show the cupola well thermal load be in transfinite, early warning and safe work state;
(3) type and slag iron-clad generated and come off in the three-dimensional in update displayed cupola well furnace bottom horizontal stroke, longitudinal section corroded automatically, automatically statistics and show cupola well and furnace bottom the most serious erosion position and residue bricking thickness, and relatively provide the early warning whether cupola well is in safe work state according to the most serious corroding thickness and early warning standard;
(4) show three-dimensional temperature cloud atlas, the many temperature Isothermal Line Distribution of cupola well furnace bottom in real time from 50 ℃ to 1500 ℃ of smooth transition, support mouse to move and get the temperature, material and the location parameter that show cupola well furnace bottom any point, realize three-dimensional monitoring whole cupola well furnace bottom;
(5) provide type, slag iron-clad shape, temperature cloud atlas and isothermal inquiry and drafting in the historical erosion of cupola well furnace bottom.
5. system according to claim 1 is characterized in that, described 4 leads are positive and negative wire, data line, clock cable.
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Application publication date: 20101117 |