CN110472359A - High-temperature fusion molten aluminum and water contact explositions based on numerical simulation technology prevent method for early warning - Google Patents
High-temperature fusion molten aluminum and water contact explositions based on numerical simulation technology prevent method for early warning Download PDFInfo
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Abstract
The high-temperature fusion molten aluminum and water contact explositions that the invention discloses a kind of based on numerical simulation technology prevent method for early warning, comprising: the 3-D geometric model for carrying out geometric parameter measurement to foundry, establishing molten aluminum casting process；It acquires the characteristic parameter of foundry, parameter assignment carried out to 3-D geometric model according to measurement parameter, according to the molten aluminum casting condition under the boundary condition imitation different aluminum flow quantity of setting；Real-time molten aluminum flow is measured, judges whether the molten aluminum casting process under emulation mode under identical molten aluminum flow occurs overflow leakage accident, if it is issues alarm signal.By simulation, whether the molten aluminum casting process under different aluminum flow quantity can occur overflow leakage to this method, and when being leaked because of the excessive generation overflow of molten aluminum flow, obtain unit time molten aluminum leakage rate and leak molten aluminum form of stretching on the ground, the unit time stretches area, to quickly judge whether molten aluminum casting process can occur overflow leakage accident.
Description
Technical field
The present invention relates to metallurgical production security fields more particularly to a kind of high-temperature fusion molten aluminums based on numerical simulation technology
Prevent method for early warning with water contact explositions.
Background technique
Aluminium manufacturer, China generally uses following process to the casting process of primary aluminum: the primary aluminum generated by electrolytic tank electrolysis is electrolysed certainly
Station-service vehicle is transported to casting region, and is poured into holding furnace and is homogenized.Molten aluminum in holding furnace flows to casting from holding furnace outlet and slips
In slot, high-temperature fusion molten aluminum is transported in each casting mold on conveyer by chute by manual control craft chute,
Molten aluminum in mold is cooled to aluminium ingot by watering cooling zone and cooling trough.
Smelter production environment is complicated at present, and cast house floor has ponding distribution, and high-temperature fusion molten aluminum is if it happens
Leakage, contacting with water can explode under certain condition, the enormous impact wave for generation of exploding and the projectile of high-temperature fusion molten aluminum
Directly personnel, equipment and peripheral facilities can be caused with different degrees of destruction and damage.But it is directed to high-temperature fusion molten aluminum at present
It is not accurate enough with the prevention method for early warning of water contact explositions, therefore there are some potential safety problemss in metallurgical production process.
Summary of the invention
According to problem of the existing technology, the high-temperature fusion molten aluminum based on numerical simulation technology that the invention discloses a kind of
Prevent method for early warning with water contact explositions, specifically comprises the following steps:
The 3-D geometric model that geometric parameter measurement is carried out to foundry, establishes molten aluminum casting process；
The characteristic parameter of foundry is acquired, parameter assignment is carried out to 3-D geometric model according to measurement parameter, basis is set
Molten aluminum casting condition under the boundary condition imitation different aluminum flow quantity set；
Real-time molten aluminum flow is measured, judges whether the molten aluminum casting process under emulation mode under identical molten aluminum flow overflows
Stream leakage accident if it is issues alarm signal.
It include the geometric parameter for measuring holding furnace and chute when the progress geometric parameter measurement to foundry.
The characteristic parameter of the foundry include casting equipment density, specific heat at constant pressure and thermal coefficient information and
Aluminium liquid height information in the density of molten aluminum, viscosity, specific heat at constant pressure thermal coefficient information and holding furnace.
It include that multiple and different molten aluminum flows are arranged to carry out molten aluminum casting sunykatuib analysis when simulating different aluminum flow quantity, record is every
Whether overflow leakage phenomenon is occurred under a molten aluminum flow, to analyze unit time molten aluminum leakage rate, leakage molten aluminum on ground
On stretch form and the unit time stretches area.
When overflow leakage then one timing of record according to analog result occurs for molten aluminum casting under the molten aluminum flow that judgement measures
The leakage rate of interior molten aluminum and its stretch form and area of stretching on the ground are to judging whether there is high temperature melting molten aluminum
Liquid contacts the risk exploded with water, obtains the shortest time that explosion occurs.
By adopting the above-described technical solution, a kind of high-temperature fusion molten aluminum based on numerical simulation technology provided by the invention
Prevent method for early warning with water contact explositions, which simulates molten aluminum casting process, only
The simulation to molten aluminum casting process can be completed in computer, can to avoid molten aluminum liquid high temperature threaten and high-temperature fusion molten aluminum with
The explosion hazard of water contact, guarantees the safety of related personnel to the full extent.
Detailed description of the invention
In order to illustrate the technical solutions in the embodiments of the present application or in the prior art more clearly, to embodiment or will show below
There is attached drawing needed in technical description to be briefly described, it should be apparent that, the accompanying drawings in the following description is only this
The some embodiments recorded in application, for those of ordinary skill in the art, without creative efforts,
It is also possible to obtain other drawings based on these drawings.
Fig. 1 is that high-temperature fusion molten aluminum and water contact explositions prevent method for early warning schematic diagram；
Fig. 2 is molten aluminum casting process 3-D geometric model；
The analog result that Fig. 3 is molten aluminum flow when being 41.31kg/s；
The analog result that Fig. 4 is molten aluminum flow when being 56.77kg/s；
The analog result that Fig. 5 is molten aluminum flow when being 81.04kg/s；
The leakage molten aluminum mass flow monitoring curve that Fig. 6 is molten aluminum flow when being 41.31kg/s；
The leakage molten aluminum mass flow monitoring curve that Fig. 7 is molten aluminum flow when being 56.77kg/s；
The leakage molten aluminum mass flow monitoring curve that Fig. 8 is molten aluminum flow when being 81.04kg/s.
Specific embodiment
To keep technical solution of the present invention and advantage clearer, with reference to the attached drawing in the embodiment of the present invention, to this
Technical solution in inventive embodiments carries out clear and complete description:
A kind of high-temperature fusion molten aluminum based on numerical simulation technology and water contact explositions as shown in Figure 1 prevents the pre- police
Method includes the following steps:
Step 1: geometric parameter measurement being carried out to foundry, and establishes the 3-D geometric model of molten aluminum casting process.
Step 2: characteristic parameter acquisition being carried out to foundry, and parameter is carried out to 3-D geometric model according to measurement result
Assignment carries out numerical simulation calculation.
Step 3: real-time molten aluminum flow measurement compares the analog result under same molten aluminum flow according to measurement result and carries out height
Warm molten aluminum liquid and water contact explositions prevent early warning.
In the high-temperature fusion molten aluminum of the invention based on numerical simulation technology and water contact explositions prevention method for early warning, step
Rapid 1 includes:
Step 1.1: the equipment of the molten aluminum casting of foundry specifically includes that holding furnace, chute.Its geometric parameter is carried out
Measurement.
Step 1.2: the 3-D geometric model of molten aluminum casting process is established according to the measurement result of foundry's geometric parameter.
In the high-temperature fusion molten aluminum of the invention based on numerical simulation technology and water contact explositions prevention method for early warning, step
Rapid 2 include:
Step 2.1: acquisition foundry's characteristic parameter is acquired casting equipment and molten aluminum material properties, casting vehicle
Between characteristic parameter include density, specific heat at constant pressure and the thermal coefficient information of casting equipment and the density of molten aluminum, viscosity, fixed
Aluminium liquid height information in pressure ratio thermal capacitance thermal coefficient information and holding furnace.Aluminium liquid height in holding furnace is measured.It is simulating
Corresponding parameter is carried out assignment in calculating.
Step 2.2: selection solving model, setting boundary condition carry out numerical simulation calculation.Wherein boundary condition includes pressure
Power export boundary condition, internal boundary condition and wall boundary condition.Simulation obtains the molten aluminum under different aluminum flow quantity and was poured
Whether journey can occur overflow leakage, and when generation overflow leakage excessive because of molten aluminum flow, obtain unit time molten aluminum leakage rate
It stretches area with leakage molten aluminum form of stretching on the ground, unit time.
In the high-temperature fusion molten aluminum of the invention based on numerical simulation technology and water contact explositions prevention method for early warning, step
Rapid 3 include:
Step 3.1: real-time measurement molten aluminum flow compares the analog result under same molten aluminum flow according to measurement result, fastly
Speed judges whether molten aluminum casting process can occur overflow leakage accident, leaks in case of overflow, according to analog result can be
Know the leakage rate of molten aluminum in certain time and its stretch form and area of stretching on the ground, judges whether there is high temperature melting
Molten aluminum liquid contacts the risk exploded with water, obtains the shortest time that explosion occurs.
Step 3.2: high-temperature fusion molten aluminum being carried out according to comparing result and water contact explositions prevent early warning, alert methods are as follows:
Prevent the flashing of early warning indicator light, and with jingle bell.
Embodiment:
Step 1: geometric dimension measurement is carried out to the molten aluminum casting equipment of Taiyuan foundry, Dong Lv aluminium Co., Ltd, it is main
It include: holding furnace, chute.
Step 2: according to geometric dimension parameter, carrying out Geometric Modeling and grid dividing using ICEM software, building molten aluminum is poured
The 3-D geometric model of note process, as shown in Figure 2.It include holding furnace 1, mixing outlet of still 2, workshop 3, chute 4, workshop in Fig. 2
Ground 5.
Step 3: foundry's characteristic parameter being measured, holding furnace and chute material are steel, and facility floor is cement
Ground measures its material properties, including density, specific heat at constant pressure and thermal coefficient.Workshop cement flooring roughness is measured, hair is worked as
When cast alumin(i)um hydrorrhea flows leakage, surface roughness is very big on the influence of stretching of leakage molten aluminum on the ground, and simulation process considers ground
The influence that roughness stretches on the ground to leakage molten aluminum.Measure molten aluminum material properties, including density, viscosity, specific heat at constant pressure
And thermal coefficient, wherein molten aluminum viscosity can change very big to molten aluminum flow effect with temperature, and simulation process considers that molten aluminum is glutinous
Degree varies with temperature the influence to molten aluminum flow process.Pass through molten aluminum viscosity calculation formula: η=1.49 × 10-4×e
(1987.29/T) calculates molten aluminum viscosity in real time and varies with temperature the influence flowed to it.
Step 4: being calculated and set according to the simulation of foundry's characteristic parameter measurement result logarithm.According to foundry
The actual conditions at scene select reasonable solving model and boundary condition, solving model using VOF model, k- ε turbulence model and
Energy model, boundary condition use pressure export boundary condition and wall boundary condition.Fluent software is used after the completion of setting
Carry out numerical simulation calculation.Simulation obtains whether the molten aluminum casting process under different aluminum flow quantity can occur overflow leakage, and
When generation overflow leakage excessive because of molten aluminum flow, obtains unit time molten aluminum leakage rate and leak the shape of stretching of molten aluminum on the ground
State, unit time are stretched area.
Step 5: real-time measurement molten aluminum flow compares the analog result under same molten aluminum flow according to measurement result, quickly
Judge whether molten aluminum casting process can occur overflow leakage accident, is leaked in case of overflow, it according to analog result can be known
The leakage rate of molten aluminum and its stretching on the ground and are stretched area at form in certain time, judge whether there is high-temperature fusion
Molten aluminum contacts the risk exploded with water, obtains the shortest time that explosion occurs.
Step 6: high-temperature fusion molten aluminum being carried out according to comparing result and water contact explositions prevent early warning, if molten aluminum does not occur
Overflow leakage accident, then do not issue early warning；If molten aluminum overflow leakage accident can occur, early warning is issued, and tie according to simulation
Fruit shows warning information, stretches including unit time molten aluminum leakage rate, leakage molten aluminum form of stretching on the ground, unit time
The shortest time that area and explosion occur.Alert methods are as follows: prevention early warning indicator light flashing, and with jingle bell.
Embodiment 1: it is 10.5kg/s that real-time traffic measurement, which obtains molten aluminum flow, corresponds to numerical simulation molten aluminum flow
Analog result when 10.77kg/s, according to analog result it is found that molten aluminum overflow leakage thing will not occur for molten aluminum casting process at this time
Therefore do not issue early warning.Predictablity rate is 100%.
Real-time example 2: it is 14.8kg/s that real-time traffic measurement, which obtains molten aluminum flow, corresponds to numerical simulation molten aluminum flow
Analog result when 14.94kg/s, according to analog result it is found that molten aluminum overflow leakage thing will not occur for molten aluminum casting process at this time
Therefore do not issue early warning.Predictablity rate is 100%.
Embodiment 3: it is 41kg/s that real-time traffic measurement, which obtains molten aluminum flow, corresponds to numerical simulation molten aluminum flow
Analog result when 41.31kg/s, according to the analog result under this flow it is found that molten aluminum overflow can occur for molten aluminum casting process lets out
Leakage, leakage molten aluminum stretching on the ground are distributed as shown in Figure 3.The distribution of stretching of leakage molten aluminum on the ground is presented left width and (rises
Beginning) right narrow (end) strip distribution, unit time molten aluminum leakage rate is 15.54kg/s at this time, and simulation process is to leakage
Molten aluminum mass flow is monitored, and is obtained leakage molten aluminum mass flow when molten aluminum flow is 41.31kg/s in chute and is monitored song
Line, as shown in Figure 6.Molten aluminum leakage rate in integral acquisition a period of time is carried out to curve, obtains the unit time divided by the time
Molten aluminum leakage rate.The area of stretching of unit time leakage molten aluminum on the ground is 0.34m2/s.Leak molten aluminum and water contact explositions
The shortest time of generation is 13s.Early warning is issued according to analog result, and prevention early warning indicator light flashes, and with jingle bell, early warning is quasi-
True rate is 99%.
Real-time example 4: it is 56.5kg/s that real-time traffic measurement, which obtains molten aluminum flow, corresponds to numerical simulation molten aluminum flow
Analog result when 56.77kg/s, according to the analog result under this flow it is found that molten aluminum overflow can occur for molten aluminum casting process lets out
Leakage, leakage molten aluminum stretching on the ground are distributed as shown in Figure 4.The distribution of stretching of leakage molten aluminum on the ground still presents left wide right
Narrow strip distribution, unit time molten aluminum leakage rate is 34.97kg/s at this time, when molten aluminum flow is 56.77kg/s in chute
Leakage molten aluminum mass flow monitoring curve as shown in fig. 7, similarly obtain unit time molten aluminum leakage rate.Unit time leaks aluminium
The area of stretching of liquid on the ground is 0.54m2/s.The shortest time for leaking molten aluminum and water contact explositions generation is 10s.According to mould
Quasi- result issues early warning, and prevention early warning indicator light flashes, and with jingle bell, early warning accuracy rate is 100%.
Embodiment 5: it is 81kg/s that real-time traffic measurement, which obtains molten aluminum flow, corresponds to numerical simulation molten aluminum flow
Analog result when 81.04kg/s, according to the analog result under this flow it is found that molten aluminum overflow can occur for molten aluminum casting process lets out
Leakage, leakage molten aluminum stretching on the ground are distributed as shown in Figure 5.Leakage molten aluminum stretching to be distributed left width be equally presented on the ground
Right narrow strip distribution, unit time molten aluminum leakage rate is 66.97kg/s at this time, and molten aluminum flow is 81.04kg/s in chute
When leakage molten aluminum mass flow monitoring curve it is as shown in Figure 8.Unit time leaks the area of stretching of molten aluminum on the ground
0.68m2/s.The shortest time for leaking molten aluminum and water contact explositions generation is 8s.Early warning is issued according to analog result, prevents early warning
Indicator light flashing, and with jingle bell, early warning accuracy rate is 100%.
In addition method disclosed by the invention also has preventative, can be with since the technical solution uses numerical simulation technology
The molten aluminum casting condition under different aluminum flow quantity is simulated in advance, is leaked in case of molten aluminum overflow, it can be with known unit time aluminium
Liquid leakage rate and leakage molten aluminum form of stretching on the ground, unit time stretch area, realize to high-temperature fusion molten aluminum and water
The prevention of contact explositions.This method also has accuracy, numerical simulation technology mature, to the simulation knot of molten aluminum casting process
Fruit can control with actual error 5% hereinafter, technical solution has high-temperature fusion molten aluminum and water contact explositions prevention early warning
Accuracy；This method also has the effect of at low cost, and technical solution does not need expensive equipment and a large amount of manpower and material resources, it is only necessary to
Computer is wanted to carry out numerical simulation calculation and molten aluminum flow measurement equipment；This method also has rapidity, technical solution
The prevention early warning of high temperature molten aluminum liquid and water contact explositions relies on the comparison of analogue data and molten aluminum data on flows, and simulates number
According to precalculated, pre-warning time can be greatly saved, early warning is fast implemented.
The foregoing is only a preferred embodiment of the present invention, but scope of protection of the present invention is not limited thereto,
Anyone skilled in the art in the technical scope disclosed by the present invention, according to the technique and scheme of the present invention and its
Inventive concept is subject to equivalent substitution or change, should be covered by the protection scope of the present invention.
Claims (5)
1. a kind of high-temperature fusion molten aluminum based on numerical simulation technology and water contact explositions prevent method for early warning, it is characterised in that packet
It includes:
The 3-D geometric model that geometric parameter measurement is carried out to foundry, establishes molten aluminum casting process；
It acquires the characteristic parameter of foundry, parameter assignment carried out to 3-D geometric model according to measurement parameter, according to setting
Molten aluminum casting condition under boundary condition imitation different aluminum flow quantity；
Real-time molten aluminum flow is measured, judges whether the molten aluminum casting process under emulation mode under identical molten aluminum flow occurs overflow and let out
Leakage accident if it is issues alarm signal.
2. according to the method described in claim 1, it is further characterized in that: it is described to foundry carry out geometric parameter measurement when packet
Include the geometric parameter of measurement holding furnace and chute.
3. according to the method described in claim 2, it is further characterized in that: the characteristic parameter of the foundry includes casting equipment
Density, specific heat at constant pressure and thermal coefficient information and the density of molten aluminum, viscosity, specific heat at constant pressure thermal coefficient information and mixed
Close aluminium liquid height information in furnace.
4. according to the method described in claim 1, it is further characterized in that: simulation different aluminum flow quantity when include be arranged it is multiple and different
Molten aluminum flow carries out molten aluminum and is poured sunykatuib analysis, records and overflow leakage phenomenon whether occurs under each molten aluminum flow, to analyze
Out unit time molten aluminum leakage rate, leakage molten aluminum on the ground stretch form and the unit time stretches area.
5. according to the method described in claim 1, it is further characterized in that: when molten aluminum casting hair under the molten aluminum flow that measures of judgement
Raw overflow leakage then record according to analog result the leakage rate of molten aluminum in certain time and its on the ground stretch form and
It stretches area and contacts the risk exploded with water to judge whether there is high-temperature fusion molten aluminum, obtain the most short of explosion generation
Time.
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