CN111830084B - Furnace lining refractory material damage detection method - Google Patents
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- 239000011819 refractory material Substances 0.000 title claims abstract description 43
- 238000001514 detection method Methods 0.000 title claims abstract description 15
- 239000011159 matrix material Substances 0.000 claims abstract description 39
- 238000000034 method Methods 0.000 claims abstract description 28
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- 238000009529 body temperature measurement Methods 0.000 claims abstract description 6
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- 238000004458 analytical method Methods 0.000 description 5
- 238000000354 decomposition reaction Methods 0.000 description 5
- 239000011449 brick Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000000605 extraction Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000007670 refining Methods 0.000 description 2
- 239000011214 refractory ceramic Substances 0.000 description 2
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- 238000003723 Smelting Methods 0.000 description 1
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- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
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- 238000009776 industrial production Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
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- 239000002184 metal Substances 0.000 description 1
- 238000010310 metallurgical process Methods 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000009991 scouring Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
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Abstract
The invention discloses a method for detecting damage of a furnace lining refractory material, which comprises the following steps: s1, performing non-contact temperature measurement on a furnace lining refractory material by adopting an infrared thermometer to obtain a temperature field cloud picture of the furnace lining refractory material, and representing the temperature field cloud picture by a temperature field pixel matrix; s2, processing a temperature field pixel matrix by using a mathematical analogy method of the local difference function to obtain a temperature local difference function TLDF of a local rectangular area in an actual temperature field; step S3, TLDF calculation is carried out from four corners of the temperature field pixel matrix, so as to obtain non-uniform coefficients NUC of temperature field distribution, and whether the refractory material of the furnace lining is damaged or not is identified based on the NUC; and S4, selecting an area with NUC larger than a preset threshold value, repeating the steps S2-S3, determining the damage position of the refractory material, and finishing the damage detection of the refractory material of the furnace lining. The invention can effectively ensure the precision and reliability of the damage detection of the furnace lining refractory material.
Description
Technical Field
The invention relates to the technical field of heating and smelting in a metallurgical process, in particular to a method for detecting damage of a furnace lining refractory material.
Background
The furnace lining (furna lines) refers to the furnace wall of a furnace for refining (refining) metals, and is made of refractory ceramics (refractory ceramics). The blast furnace lining is built by refractory bricks, and the materials and the performances of the adopted refractory bricks are different due to different working conditions of the lining of each part. If the upper furnace lining in the furnace body is mainly considered to be wear-resistant, the lower furnace body and the waist are mainly considered to be thermal shock damage resistant and alkali metal corrosion resistant, the furnace belly is mainly considered to be primary slag corrosion of high FeO, and the hearth and the furnace bottom are mainly considered to be molten iron mechanical scouring resistant and differential thermal expansion of refractory bricks. When the furnace lining is damaged, if the damage is not found and remedied in time, serious influence on industrial production is necessarily brought. The furnace lining is damaged, and the heat conduction performance of the furnace lining is inevitably changed, so that the temperature of the furnace lining in work is unevenly distributed.
In recent years, a method of combining time-frequency domain analysis with nonlinear analysis is increasingly widely used in signal feature extraction and equipment fault diagnosis. For example, the use of wavelet decomposition in combination with fractal box dimensions for analysis of blast vibration signals is well known to the citizen; zhu Quanjie and the like perform mine microseism waveform identification research by adopting a method of combining wavelet packet decomposition and fractal box dimension; feng Fuzhou and the like realize the detection of abnormal states of the bearing by adopting a method of combining empirical mode decomposition and permutation entropy. The EMD (empirical mode decomposition) is used for effectively separating different frequency bands of the signal by decomposing the signal into a plurality of eigenvalues IMF and the sum of the remainder. Compared with wavelet analysis, EMD does not need to select a basis function, has more accurate spectrum structure and self-adaptive decomposition characteristics, is more suitable for analysis of nonlinear and non-stationary signals, but cannot accurately obtain damage positions. The fractal theory can well describe the complexity of signals, and currently, two methods of single fractal and multiple fractal exist. The single fractal method quantitatively describes the complexity and the irregularity of a signal by calculating the fractal dimension, but because the single fractal method only can describe the integrity and the average of a research object, much information is lost in feature extraction. During operation, the refractory materials have different damage mechanisms at different components, but can cause uneven heating. Therefore, a furnace lining refractory material damage detection method with high precision, high reliability and high applicability is needed at present, and the uniform distribution of the furnace lining temperature is ensured.
Disclosure of Invention
The invention aims to provide a method for detecting damage of a furnace lining refractory material, which solves the problems existing in the prior art and can effectively ensure the precision and reliability of the damage detection of the furnace lining refractory material.
In order to achieve the above object, the present invention provides the following solutions: the invention provides a method for detecting damage of a furnace lining refractory material, which comprises the following steps:
s1, performing non-contact temperature measurement on a furnace lining refractory material by adopting an infrared thermometer to obtain a temperature field cloud picture of the furnace lining refractory material, and representing the temperature field cloud picture by a temperature field pixel matrix;
s2, processing a temperature field pixel matrix by using a mathematical analogy method of the local difference function to obtain a temperature local difference function TLDF of a local rectangular area in an actual temperature field;
step S3, TLDF calculation is carried out from four corners of the temperature field pixel matrix, so as to obtain non-uniform coefficients NUC of temperature field distribution, and whether the refractory material of the furnace lining is damaged or not is identified based on the NUC;
and S4, selecting an area with NUC larger than a preset threshold value, repeating the steps S2-S3, determining the damage position of the refractory material, and finishing the damage detection of the refractory material of the furnace lining.
Preferably, the specific method for representing the temperature field cloud image through the temperature field pixel matrix comprises the following steps:
converting the temperature field cloud image into a gray image for representation;
each gray image is represented as a matrix of gray values with an integer value between 0 and 255, each matrix element corresponding to a pixel on the image, resulting in a temperature field pixel matrix.
Preferably, in the step S2, the expression of the temperature local difference function TLDF is as shown in formula 1:
wherein θ represents the total data amount in the matrix of the local rectangular area of the temperature field, m and n respectively represent the number of rows and columns corresponding to the numerical points in the local rectangular area of the temperature field, and θ 1 、θ 2 The total number of rows and total number of columns of numerical points in the local rectangular region of the temperature field are respectively represented, i and j respectively represent the number of rows and the number of columns corresponding to a certain point in the whole temperature field, P, Q respectively represent the number of rows and the number of columns of the pixel matrix in the whole temperature field, T ij Representing the pixel value at position (i, j), T mn Representing the pixel value at position (m, n).
Preferably, in the step S3, TLDF values are calculated from four directions of upper left, lower right and upper right of the temperature field pixel matrix, respectively.
Preferably, the calculation of the single non-uniform coefficient NUCq (q=1, 2,3, 4) of the temperature field distribution is as shown in equation 2:
wherein sup represents the upper bound, i.e. the minimum upper bound; NUC 1 ，NUC 2 ，NUC 3 ，NUC 4 The unevenness of the temperature distribution in the whole rectangular surface of the pixel matrix representing the temperature field corresponds to the four directions of upper left, lower right and upper right, respectively.
Preferably, the non-uniformity coefficient NUC of the temperature field distribution is calculated as shown in equation 3:
NUC＝max{NUC 1 ,NUC 2 ,NUC 3 ,NUC 4 }……………3
wherein, the smaller NUC indicates that the temperature field distribution is more uniform, and the larger NUC indicates that the temperature field distribution is less uniform, and when the NUC is larger than a preset threshold value, the damage of the refractory material of the furnace lining is indicated.
Preferably, the furnace lining refractory damage detection method is also applicable to a temperature value matrix.
The invention discloses the following technical effects:
(1) According to the invention, the damage detection is carried out on the furnace lining refractory material by utilizing the mathematical analogy of the infrared thermometer and the local difference function, and under the condition that the damage of the refractory material is detected, the area with uneven temperature field distribution is selected, and the method is repeated, so that the accurate position of the damage of the furnace lining refractory material can be obtained, and the detection precision is high; and moreover, information loss can not be caused in the detection process, and the reliability is high.
(2) The invention does not need to contact in the process of detecting the damage of the refractory material of the furnace lining, and is more visual and reliable.
(3) The invention discloses a method for detecting damage of a furnace lining refractory material, which relates to a plurality of fields of metallurgy and the like and has strong applicability.
(4) The method for detecting the damage of the furnace lining refractory material not only can be used for researching the uniformity of a temperature field, but also can be used for evaluating the uniformity of a concentration field, and has strong applicability.
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In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the drawings that are needed in the embodiments will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flow chart of a method for detecting damage to a furnace lining refractory material according to the invention;
FIG. 2 is a temperature field cloud image of a furnace lining refractory material obtained by non-contact temperature measurement of the furnace lining refractory material using an infrared thermometer in an embodiment of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description.
Referring to fig. 1-2, the embodiment provides a method for detecting damage to a furnace lining refractory material, which comprises the following steps:
s1, performing non-contact temperature measurement on a furnace lining refractory material by adopting an infrared thermometer to obtain a temperature field cloud picture of the furnace lining refractory material, and representing the temperature field cloud picture by a temperature field pixel matrix;
different colors in the temperature field cloud picture represent different temperatures and are represented by a temperature field pixel matrix; the color image is converted into a gray image to be represented, the gray image being a matrix representing gray values with integer values between 0 and 255, each matrix element corresponding to a pixel on the image.
S2, processing the temperature field pixel matrix by utilizing a mathematical analogy method of the local difference function to obtain TLDF (Temperature local difference function ) of the local rectangular area in the actual temperature field
As shown in formula (1):
wherein θ represents the total data amount in the matrix of the local rectangular area of the temperature field, m and n respectively represent the number of rows and columns corresponding to the numerical points in the local rectangular area of the temperature field, and θ 1 、θ 2 The total number of rows and total number of columns of numerical points in the local rectangular region of the temperature field are respectively represented, i and j respectively represent the number of rows and the number of columns corresponding to a certain point in the whole temperature field, P, Q respectively represent the number of rows and the number of columns of the pixel matrix in the whole temperature field, T ij Representing the pixel value at position (i, j), T mn Representing the pixel value at position (m, n).
Step S3, TLDF calculation is carried out from four corners of the temperature field pixel matrix, and non-uniform coefficients NUC of temperature field distribution are obtained;
as can be seen from the formula (1),
depending on the calculated direction of the first position, the selection of the first position is accidental and +.>
The positions of the numerical values in (a) are counted from left to right and from top to bottom, and in order to avoid the influence of accidental factors on the calculation result, the invention calculates TLDF values from four directions of top left, bottom right and top right. The calculation of the single non-uniform coefficient NUCq (q=1, 2,3, 4) of the temperature field distribution is shown in formula (2):
wherein sup represents the upper bound, i.e. the minimum upper bound; NUC 1 ，NUC 2 ，NUC 3 ，NUC 4 The unevenness of the temperature distribution in the whole rectangular surface of the pixel matrix representing the temperature field corresponds to the four directions of upper left, lower right and upper right, respectively.
The calculation of the non-uniformity coefficient NUC for temperature field distribution uniformity evaluation is shown in formula (3):
NUC＝max{NUC 1 ,NUC 2 ,NUC 3 ,NUC 4 }……………(3)
in general, if the temperature fields are reasonably evenly distributed, the temperature measurements in a smaller area will differ less from the temperature field pixel matrix as a whole. In short, smaller NUCs indicate more uniform temperature field distribution, larger NUCs indicate less uniform temperature field distribution, and when NUCs are greater than a preset threshold, the refractory material of the furnace lining is indicated to be damaged; wherein the size of the NUC is related to the material and the damage degree, and in practical application, the NUC threshold is set according to different working conditions
And S4, repeating the steps S2 to S3 aiming at the uneven area, and determining the accurate position of the damage of the refractory material.
Further optimizing scheme, the damage detection can be carried out on the furnace lining refractory material through the temperature value matrix, and the detection process is the same as that of the temperature field pixel matrix.
In the description of the present invention, it should be understood that the terms "longitudinal," "transverse," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like indicate or are based on the orientation or positional relationship shown in the drawings, merely to facilitate description of the present invention, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus should not be construed as limiting the present invention.
The above embodiments are only illustrative of the preferred embodiments of the present invention and are not intended to limit the scope of the present invention, and various modifications and improvements made by those skilled in the art to the technical solutions of the present invention should fall within the protection scope defined by the claims of the present invention without departing from the design spirit of the present invention.
Claims (3)
1. The method for detecting the damage of the furnace lining refractory material is characterized by comprising the following steps of:
s1, performing non-contact temperature measurement on a furnace lining refractory material by adopting an infrared thermometer to obtain a temperature field cloud picture of the furnace lining refractory material, and representing the temperature field cloud picture by a temperature field pixel matrix;
s2, processing a temperature field pixel matrix by using a mathematical analogy method of the local difference function to obtain a temperature local difference function TLDF of a local rectangular area in an actual temperature field;
step S3, TLDF calculation is carried out from four corners of the temperature field pixel matrix, so as to obtain non-uniform coefficients NUC of temperature field distribution, and whether the refractory material of the furnace lining is damaged or not is identified based on the NUC;
s4, selecting an area with NUC larger than a preset threshold value, repeating the steps S2-S3, determining the damage position of the refractory material, and finishing the damage detection of the refractory material of the furnace lining;
in the step S2, the expression of the temperature local difference function TLDF is shown in formula 1:
wherein θ represents the total data amount in the matrix of the local rectangular area of the temperature field, m and n respectively represent the number of rows and columns corresponding to the numerical points in the local rectangular area of the temperature field, and θ 1 、θ 2 The total number of rows and total number of columns of numerical points in the local rectangular region of the temperature field are respectively represented, i and j respectively represent the number of rows and the number of columns corresponding to a certain point in the whole temperature field, and P, Q respectively represent the whole temperatureRow and column number, T of pixel matrix in field ij Representing the pixel value at position (i, j), T mn Representing the pixel value at position (m, n);
in the step S3, TLDF values are calculated from the upper left, lower right and upper right directions of the temperature field pixel matrix, respectively;
the calculation of the single non-uniform coefficient NUCq (q=1, 2,3, 4) of the temperature field distribution is shown in equation 2:
wherein sup represents the upper bound, i.e. the minimum upper bound; NUC 1 ，NUC 2 ，NUC 3 ，NUC 4 Representing the unevenness of the temperature distribution in the entire rectangular surface of the temperature field pixel matrix, corresponding to the upper left, lower right and upper right directions, respectively;
the calculation of the non-uniformity coefficient NUC of the temperature field distribution is shown in equation 3:
NUC＝max{NUC 1 ,NUC 2 ,NUC 3 ,NUC 4 }……………3
wherein, the smaller NUC indicates that the temperature field distribution is more uniform, and the larger NUC indicates that the temperature field distribution is less uniform, and when the NUC is larger than a preset threshold value, the damage of the refractory material of the furnace lining is indicated.
2. The method for detecting damage to furnace lining refractory according to claim 1, wherein the specific method for representing the temperature field cloud image by the temperature field pixel matrix comprises the following steps:
converting the temperature field cloud image into a gray image for representation;
each gray image is represented as a matrix of gray values with an integer value between 0 and 255, each matrix element corresponding to a pixel on the image, resulting in a temperature field pixel matrix.
3. The method for detecting damage to a refractory lining according to claim 1, wherein the method for detecting damage to a refractory lining is further adapted to a temperature value matrix.
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| CN113190995B (en) * | 2021-04-28 | 2024-02-02 | 华中科技大学 | Refractory material service performance evaluation method and system based on ultimate heat load |
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