CN107239035B - Expert system for diagnosis and maintenance measures of damage condition of lining refractory material of dry quenching furnace - Google Patents
Expert system for diagnosis and maintenance measures of damage condition of lining refractory material of dry quenching furnace Download PDFInfo
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Abstract
An expert system for diagnosing and maintaining damage conditions of refractory materials in a lining of a dry quenching furnace is characterized in that: the operation database module stores original data acquired by an online monitoring instrument in the production of the dry quenching furnace and secondary data generated in the control process, wherein the secondary data comprises production temperature, production pressure and circulating air volume; the dry quenching furnace design database module stores the structural form and the material characteristics of the dry quenching furnace; the detection database module stores the abrasion condition, the fracture condition and the mortar joint condition of the dry quenching furnace; and the maintenance database module stores the dry quenching furnace repair scheme and refractory material preparation. The method has the advantages of timely mastering the damage condition of the refractory lining of the dry quenching furnace, repairing the refractory lining according to an expert system and elaborately calculating and maintaining a refractory material plan, along with easy operation, stability, friendly interface, high running speed, convenience, quickness, saved maintenance and construction time of the lining of the dry quenching furnace and prolonged service life of the lining of the dry quenching furnace.
Description
Technical Field
The invention relates to furnace maintenance, in particular to an expert system for diagnosis and maintenance measures of the damage condition of a refractory material of a lining of a dry quenching furnace.
Background
With the development of society in recent years, the requirements on environmental protection and energy are higher and higher, and more steel mills in China adopt dry quenching devices. At present, about 240 dry quenching devices are in operation in China. The dry quenching device has more sizes and types, and is divided into 70t/h, 75t/h, 90t/h, 100t/h, 110t/h, 125t/h, 140t/h, 145t/h, 150t/h, 160t/h, 190t/h, 260t/h and the like according to the quenching production capacity.
The dry quenching device mainly comprises a dry quenching furnace, a primary dust remover, a waste heat boiler and the like. The refractory material lining of the dry quenching furnace is mainly distributed in the cooling section, the inclined air duct, the annular air duct and a plurality of parts of the pre-storage chamber. The dry quenching furnace lining refractory material has poor working environment, which causes large abrasion of the furnace lining refractory material and weak structural stability. The refractory material at each part is broken and damaged in 1-2 years. Production conditions of various coke-oven plants on the refractory material lining of the dry quenching furnace can not be mastered in time, and the damage condition of the refractory material lining of the dry quenching furnace is not clear when to be maintained, so that the damage of the refractory material lining of the dry quenching furnace is increased finally, and the production is seriously influenced.
Therefore, the known method for monitoring and maintaining the breakage condition of the refractory material of the dry quenching furnace has various inconveniences and problems.
Disclosure of Invention
The invention aims to provide a method for inquiring design data and operation data of a dry quenching furnace; the method comprises the steps of detecting data on line, inputting the data, comparing the data with a database of a computer to obtain maintenance data corresponding to an existing expert system knowledge rule base, reasoning, analyzing and deducing the state of lining damage by a reasoning machine, giving operating parameters for processing suggestions, instructing an execution mechanism to display a maintenance method and material plan data according to symptoms, and finally forming a maintenance report.
In order to achieve the purpose, the technical solution of the invention is as follows:
an expert system for diagnosis and maintenance measures of damage condition of refractory material of a lining of a dry quenching furnace, which operates on a windows platform in the environments of Microsoft Visual C + + V6.0 and Structured query language (Structured query language), comprises an operation database module, a dry quenching furnace design database module, a detection database module and a maintenance database module, and is characterized in that:
the operation database module stores original data acquired by an online monitoring instrument in the production of the dry quenching furnace and secondary data generated in the control process, wherein the secondary data comprises production temperature, production pressure and circulating air volume;
the dry quenching furnace design database module stores the structural form and the material characteristics of the dry quenching furnace;
the detection database module stores the abrasion condition, the fracture condition and the mortar joint condition of the dry quenching furnace;
the maintenance database module stores a dry quenching furnace repair scheme and refractory material preparation;
wherein:
the dry quenching furnace design database module comprises 70t/h, 75t/h, 90t/h, 100t/h, 110t/h, 125t/h, 140t/h, 145t/h, 150t/h, 160t/h, 190t/h and 260t/h according to quenching capacity, basic sizes of a plurality of parts of a cooling section, an inclined air duct, an annular air duct and a prestoring chamber, structural forms and refractory material characteristics of the annular air duct and the inclined air duct, and brick shapes and weights of refractory materials of the parts of the cooling section, the inclined air duct, the annular air duct and the prestoring chamber;
the detection database module comprises a cooling section refractory brick abrasion condition; the method comprises the following steps of (1) breaking a strut brick of an inclined air duct, damaging a lining of an annular air duct, damaging a lining of a pre-storage chamber, damaging a lining of a furnace opening, damaging a lining of a high-temperature telescopic joint, damaging a lining of a boiler inlet, damaging a lining of a primary dedusting lining, falling of a forking chute castable or a refractory brick, and falling of a lower cone bucket cast stone plate;
the maintenance database module comprises maintenance categories of the dry quenching furnace lining repair scheme, the table 1 is a table of the maintenance categories of the dry quenching furnace lining repair scheme,
TABLE 1 repair classification for lining repair of dry quenching furnace
| Serial number | Name (R) | Consumption of refractory material | Maintenance period | Determining furnace body basic characteristics according to detection report |
| 1 | Minor repair | Less than 5 tons | 3-5 days | The casting material falls off, brick joints are degraded and other special conditions |
| 2 | Annual repair | 30-50 tons | 15-25 days | The inclined air duct supports the falling of the facing brick, the refractory lining of the high-temperature expansion joint is damaged, and the refractory lining of the cooling section is abraded to a certain extent |
| 3 | Middle repair | 300-500 ton | 35-50 days | The deformation of the inner wall of the annular air passage is serious, the damage of the inclined air passage support bricks is serious, the damage of the ring beam is serious, and the abrasion of the cooling section is serious |
| 4 | Major repair | 1000 graded 1300 tons | 60-80 days | The furnace body has serious damage to the refractory lining, the local repair can not meet the production, and the furnace shell steel structure has certain deformation |
The repair scheme comprises the following steps: the cooling section is overhauled, and when the abrasion thickness is less than or equal to 100mm, the wear-resistant castable is poured for repair; when the wear thickness is larger than 100mm, the wear-resistant castable prefabricated part or the mullite brick is used for repairing. And (4) overhauling the inclined air duct, wherein the inclined air duct supporting bricks are repaired in an original material brick ceiling replacing mode, repaired in a castable prefabricated part ceiling replacing mode and repaired in a wear-resistant castable pouring mode. And (4) overhauling the annular air passage, namely repairing by partially replacing refractory bricks, and repairing by dismantling the inner wall of the annular air passage in a re-masonry mode. And (4) overhauling the lining of the furnace opening, namely repairing by replacing the uppermost three layers of refractory bricks. And (4) overhauling the inclined air duct and the annular air duct, dismantling the inner wall of the annular air duct and the support bricks of the inclined air duct, and then building again. And (4) overhauling the inclined air duct, the annular air duct and the pre-storage chamber, completely removing the annular air duct, the inclined air duct and the refractory bricks of the pre-storage chamber, and then building again. The primary dust removal lining maintenance comprises the steps of bricking and removing a furnace wall, bricking and removing a partition wall, bricking and removing a vault and bricking and removing a relief hole. And (4) overhauling the lining of the forking chute, and repairing the castable or refractory brick in a masonry mode. And (5) removing and building the lower cone bucket cast stone plate. The high-temperature expansion joint and the refractory lining at the boiler inlet are repaired by online casting materials or built by refractory bricks.
The expert system for diagnosis and maintenance measures of the damage condition of the refractory material of the lining of the dry quenching furnace can further realize the following technical measures.
According to the expert system for diagnosing and maintaining the damage condition of the refractory material of the lining of the dry quenching furnace, an online monitoring instrument in the production of the dry quenching furnace is a high-temperature camera, the high-temperature camera is installed on a bolting hole layer platform in the dry quenching furnace, a high-temperature camera and a high-temperature-resistant data line protection tube are connected, and interfaces of the high-temperature camera and a display are debugged; detecting the actual conditions of a cooling section, an inclined air duct support brick and an annular air duct lining in the coke dry quenching furnace; according to the image information transmitted by the high-temperature camera to the display, the damage condition of the refractory bricks of each part can be judged by contrasting the lining structure in the furnace.
After the technical scheme is adopted, the expert system for diagnosing and maintaining the damage condition of the refractory material of the lining of the dry quenching furnace has the following advantages:
1. timely grasping the damage condition of the refractory lining of the dry quenching furnace, and performing refractory lining repair and meticulously calculating a refractory material maintenance plan according to an expert system;
2. the system is easy to operate, stable, friendly in interface, high in running speed, convenient and fast;
3. saves the maintenance construction time of the lining of the dry quenching furnace and prolongs the service life of the lining of the dry quenching furnace.
Drawings
FIG. 1 is a schematic structural diagram of an expert system for diagnosing and maintaining the damage condition of the lining refractory material of the dry quenching furnace in the embodiment of the invention.
Detailed Description
The present invention will be further described with reference to the following examples and the accompanying drawings.
Example 1
Referring to fig. 1, fig. 1 is a schematic structural diagram of an expert system for diagnosing and maintaining the damage condition of the refractory material of the lining of the dry quenching furnace according to the embodiment of the invention.
The expert system for diagnosis and maintenance measures of the damage condition of the refractory material of the lining of the dry quenching furnace runs on a windows platform under the environment of Microsoft Visual C + + V6.0 and Structured query language (Structured query language), and comprises an operation database module, a dry quenching furnace design database module, a detection database module and a maintenance database module.
The operation database module stores primary data acquired by an online monitoring instrument in the production of the dry quenching furnace and secondary data generated in the control process, wherein the secondary data comprises production temperature, production pressure and circulating air volume.
A dry quenching furnace design database comprising:
(1) the coke quenching capacity is divided into 70t/h, 75t/h, 90t/h, 100t/h, 110t/h, 125t/h, 140t/h, 145t/h, 150t/h, 160t/h, 190t/h, 260t/h and the like.
(2) The basic sizes of the cooling section, the inclined air duct, the annular air duct, the pre-storage chamber and the like. Mainly comprises the height and the diameter of a cooling section, the number of adjusting holes, the height of a chute, the number of brick layers and the like.
(3) The structural form and the refractory material property of the annular air passage and the inclined air passage.
(4) The brick shape and the weight of refractory materials at the positions of a cooling section, an inclined air duct, an annular air duct, a pre-storage chamber and the like.
A detection database comprising:
installing high-temperature camera equipment on a coke dry quenching medium-pore layer platform, connecting a high-temperature camera and a high-temperature-resistant data line protection tube, and debugging interfaces of a high-temperature camera and a display. Detecting the actual conditions of a cooling section, an inclined air duct support brick and an annular air duct lining in the coke dry quenching furnace; according to the image information transmitted by the high-temperature camera to the display, the damage condition of the refractory bricks of each part can be judged by contrasting the lining structure in the furnace.
(1) Wear of refractory bricks in the cooling section.
(2) The fracture condition of the inclined air duct support brick comprises the number of broken brick layers and the fracture position of the inclined air duct support brick.
(3) Annular air flue inside lining damage condition, interior wall deformation condition, mortar joint fracture condition.
(4) The damage conditions of the pre-storage chamber lining comprise the conditions of brick falling and mortar joint cracking.
(5) The condition of damaged lining of the furnace mouth is mainly the condition of falling off of bricks
(6) The damage of the lining of the high-temperature expansion joint comprises the falling of expansion joint filler, the falling of casting material, the burning-through of the top and the like
(7) The condition of the damage of the inner lining of the boiler inlet mainly comprises the falling of casting materials or bricks.
(8) The damage conditions of the primary dedusting lining comprise expansion joint filler falling, mortar joint cracking, furnace wall bulging, furnace wall collapse, partition wall inclination, partition wall collapse, vault hanging brick and diffusing hole cracking damage.
(9) The castable or refractory bricks of the forking rotary chute fall off.
(10) The lower cone bucket cast stone plate falls off.
(11) The high-temperature expansion joint and the refractory lining at the boiler inlet are repaired by online casting materials or built by refractory bricks.
A repair database comprising:
(1) repair category of lining repair scheme of dry quenching furnace
| Serial number | Name (R) | Consumption of refractory material | Maintenance period | According to the detection report (furnace body basic characteristics) |
| 1 | Minor repair | Less than 5 tons | 3-5 days | The casting material falls off, brick joints are degraded and other special conditions |
| 2 | Annual repair | 30-50 tons | 15-25 days | The inclined air duct supports the falling of the head-on brick, the damage of the refractory lining of the high-temperature expansion joint and the abrasion of the refractory lining of the cooling section have certain abrasion (80-100 mm) |
| 3 | Middle repair | 300-500 ton | 35-50 days | The deformation of the inner wall of the annular air passage is serious, the damage of the inclined air passage support brick is serious, the damage of the ring beam is serious, and the abrasion of the cooling section is serious (more than 100 mm) |
| 4 | Major repair | 1000 graded 1300 tons | 60-80 days | The furnace body has serious damage to the refractory lining, the local repair can not meet the production, and the furnace shell steel knotSome deformation of the structure occurs. |
(2) Repair scheme
The cooling section is overhauled, and when the abrasion thickness is less than or equal to 100mm, the wear-resistant castable is poured for repair; when the wear thickness is larger than 100mm, the wear-resistant castable prefabricated part or the mullite brick is used for repairing.
And (4) overhauling the inclined air duct, wherein the inclined air duct support bricks are repaired in an original material brick ceiling replacing mode, repaired in a castable prefabricated part ceiling replacing mode and repaired in a wear-resistant castable pouring mode.
And (4) overhauling the annular air passage, namely repairing by partially replacing refractory bricks, and repairing by dismantling the inner wall of the annular air passage in a re-masonry mode.
And (4) overhauling the lining of the furnace opening, namely repairing by replacing the uppermost three layers of refractory bricks.
And (4) overhauling the inclined air duct and the annular air duct, dismantling the inner wall of the annular air duct and the support bricks of the inclined air duct, and then building again.
And (4) overhauling the inclined air duct, the annular air duct and the pre-storage chamber, completely removing the annular air duct, the inclined air duct and the refractory bricks of the pre-storage chamber, and then building again.
The primary dust removal lining maintenance comprises the steps of furnace wall dismantling and building, partition wall dismantling and building, vault dismantling and building, relief hole dismantling, building and the like.
And (4) overhauling the lining of the forking chute, dismantling the castable or the refractory brick and repairing the castable or the refractory brick in a masonry mode.
And (5) removing and building the lower cone bucket cast stone plate.
The high-temperature expansion joint and the refractory lining at the boiler inlet are repaired by online casting materials or built by refractory bricks.
The invention has substantive characteristics and obvious technical progress, and the expert system for diagnosis and maintenance measures of the damage condition of the refractory material of the lining of the dry quenching furnace utilizes Microsoft Visual C + + V6.0 and SQL to inquire dry quenching design parameters, monitor the working condition of the refractory lining of the dry quenching furnace on line and grasp the damage condition of the refractory lining of the dry quenching furnace in time by means of a windows platform, and carries out refractory lining repair and elaborate calculation and maintenance of a refractory material plan according to the expert system. The system is easy to operate, stable, friendly in interface, high in running speed, convenient and fast. By adopting the system, the overhaul construction time of the lining of the dry quenching furnace can be saved, and the service life of the lining of the dry quenching furnace can be prolonged.
The above embodiments are provided only for illustrating the present invention and not for limiting the present invention, and those skilled in the art can make various changes or modifications without departing from the spirit and scope of the present invention. Accordingly, all equivalents are intended to fall within the scope of the invention, which is defined in the claims.
Claims (2)
1. The utility model provides a dry quenching stove inside lining refractory material damage condition diagnosis and maintenance measure expert system, this expert system utilizes visual6.0 and Structured Query Language environment to operate under the windows platform, and expert system includes operation database module, dry quenching stove design database module, detects database module and maintenance database module, its characterized in that:
the operation database module stores original data acquired by an online monitoring instrument in the production of the dry quenching furnace and secondary data generated in the control process, wherein the secondary data comprises production temperature, production pressure and circulating air volume;
the dry quenching furnace design database module stores the structural form and the material characteristics of the dry quenching furnace;
the detection database module stores the abrasion condition, the fracture condition and the mortar joint condition of the dry quenching furnace;
the maintenance database module stores a dry quenching furnace repair scheme and refractory material preparation;
wherein:
the dry quenching furnace design database module comprises 70t/h, 75t/h, 90t/h, 100t/h, 110t/h, 125t/h, 140t/h, 145t/h, 150t/h, 160t/h, 190t/h and 260t/h according to quenching capacity, basic sizes of a plurality of parts of a cooling section, an inclined air duct, an annular air duct and a prestoring chamber, structural forms and refractory material characteristics of the annular air duct and the inclined air duct, and brick shapes and weights of refractory materials of the parts of the cooling section, the inclined air duct, the annular air duct and the prestoring chamber;
the detection database module comprises a cooling section refractory brick abrasion condition; the method comprises the following steps of (1) breaking a strut brick of an inclined air duct, damaging a lining of an annular air duct, damaging a lining of a pre-storage chamber, damaging a lining of a furnace opening, damaging a lining of a high-temperature telescopic joint, damaging a lining of a boiler inlet, damaging a lining of a primary dedusting lining, falling of a forking chute castable or a refractory brick, and falling of a lower cone bucket cast stone plate;
the maintenance database module comprises maintenance categories of dry quenching furnace lining repair schemes,
TABLE 1 repair classification for lining repair of dry quenching furnace
The repair scheme comprises the following steps: the cooling section is overhauled, and when the abrasion thickness is less than or equal to 100mm, the wear-resistant castable is poured for repair; when the wear thickness is larger than 100mm, adopting a wear-resistant castable prefabricated part or a mullite brick masonry mode for repairing; the inclined air duct is overhauled, and the inclined air duct support bricks are repaired in a ceiling replacing mode of original material bricks, a ceiling replacing mode of prefabricated casting material prefabricated parts and a casting mode of wear-resistant casting materials; repairing the annular air passage, namely repairing by partially replacing refractory bricks, and repairing by removing the inner wall of the annular air passage and building again; overhauling the lining of the furnace mouth, and repairing by replacing the uppermost three layers of refractory bricks; overhauling the inclined air duct and the annular air duct, dismantling the inner wall of the annular air duct and the supporting bricks of the inclined air duct, and then building again; overhauling the inclined air duct, the annular air duct and the pre-storage chamber, completely removing the annular air duct, the inclined air duct and the refractory bricks of the pre-storage chamber, and then building again; primary dust removal lining maintenance comprises furnace wall dismantling and building, partition dismantling and building, vault dismantling and building and relief hole dismantling and building; overhauling the lining of the forking chute, and repairing the castable or refractory brick in a masonry mode; removing and building the lower cone bucket cast stone plate; the high-temperature expansion joint and the refractory lining at the boiler inlet are repaired by online casting materials or built by refractory bricks.
2. The expert system for diagnosis and maintenance measures of the damage condition of the refractory material of the lining of the dry quenching furnace as claimed in claim 1, wherein the online monitoring instrument in the production of the dry quenching furnace is a high-temperature camera, the high-temperature camera is arranged on a coke dry quenching medium-hole layer platform, a high-temperature camera and a high-temperature resistant data line protection tube are connected, and interfaces of the high-temperature camera and a display are debugged; detecting the actual conditions of a cooling section, an inclined air duct support brick and an annular air duct lining in the coke dry quenching furnace; according to the image information transmitted by the high-temperature camera to the display, the damage condition of the refractory bricks of each part can be judged by contrasting the lining structure in the furnace.
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| JP2000282044A (en) * | 1999-03-31 | 2000-10-10 | Nippon Steel Corp | Inner cylinder brick-laid structure of coke dry quenching facility |
| CN102692131B (en) * | 2011-03-23 | 2014-12-17 | 五冶集团上海有限公司 | Method for overhauling fire-resistant material for annular air duct and chute in coke dry quenching furnace |
| KR101262596B1 (en) * | 2011-12-12 | 2013-05-08 | 주식회사 포스코 | Method of producing ferro-coke through low temperature dry distillation |
| CN103509566B (en) * | 2012-06-20 | 2015-05-06 | 五冶集团上海有限公司 | Overhaul construction method of double chute position of dry quenching furnace |
| CN104016692B (en) * | 2014-06-06 | 2016-03-16 | 武汉钢铁(集团)公司 | A kind of coke dry quenching furnace cooling section refractory materials and preparation method |
| CN104449770B (en) * | 2014-10-28 | 2017-03-22 | 武汉钢铁(集团)公司 | Lining brick structure for cooling section of coke dry quenching furnace and building method |
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