CN113111549B - Erosion model modeling method and modeling system for casting repaired blast furnace hearth - Google Patents
Erosion model modeling method and modeling system for casting repaired blast furnace hearth Download PDFInfo
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- 238000005266 casting Methods 0.000 title claims abstract description 82
- 238000000034 method Methods 0.000 title claims abstract description 55
- 230000003628 erosive effect Effects 0.000 title claims abstract description 47
- 238000009826 distribution Methods 0.000 claims abstract description 149
- 239000000463 material Substances 0.000 claims abstract description 75
- 230000008439 repair process Effects 0.000 claims abstract description 47
- 238000012546 transfer Methods 0.000 claims abstract description 20
- 239000011449 brick Substances 0.000 claims description 18
- 238000004364 calculation method Methods 0.000 claims description 18
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 15
- 229910052799 carbon Inorganic materials 0.000 claims description 15
- 238000001816 cooling Methods 0.000 claims description 8
- 238000001514 detection method Methods 0.000 claims description 4
- 239000000853 adhesive Substances 0.000 claims description 3
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- 238000004140 cleaning Methods 0.000 claims description 3
- 239000011819 refractory material Substances 0.000 description 12
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 230000008901 benefit Effects 0.000 description 7
- 239000000498 cooling water Substances 0.000 description 5
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- 229910052742 iron Inorganic materials 0.000 description 4
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- 239000000919 ceramic Substances 0.000 description 2
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- 238000011160 research Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
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Abstract
The invention discloses a modeling method of an erosion model after casting repair of a blast furnace hearth, which comprises the following steps: acquiring thickness data and materials of residual lining at the bottom of a blast furnace hearth and thickness data and materials of a castable layer; determining the thickness distribution of the residual lining, the thickness distribution of the castable layer and the heat conductivity coefficient distribution of the residual lining and the castable layer; constructing a positive problem model of the hearth and the bottom of the furnace in finite element simulation software by utilizing a heat transfer differential equation; solving a positive problem model of the hearth bottom of the hearth by combining boundary conditions to obtain first temperature field data; acquiring position data and real-time temperature data of a thermocouple of the blast furnace, and constructing an inverse problem model of the hearth and the bottom of the furnace in the finite element simulation software according to the first temperature field data, the position data and the real-time temperature data of the thermocouple; the method solves the problem that the casting repaired blast furnace is difficult to establish an accurate hearth and bottom erosion model.
Description
Technical Field
The application relates to the technical field of blast furnaces, in particular to a modeling method and a modeling system for erosion models for casting repair of a blast furnace hearth.
Background
In the using process of the blast furnace, the furnace lining materials of the furnace bottom and the furnace hearth are gradually eroded and damaged under the action of molten iron circulation to form foot-like erosion, pot bottom erosion or apple erosion, so that the temperature of a thermocouple at the furnace bottom of the furnace hearth of the blast furnace is increased, and the blast furnace is forced to gradually take measures of strengthening cooling, adding titanium to protect the furnace, reducing smelting strength, even cooling the furnace and the like, thereby influencing the safe and efficient production of the blast furnace.
In the production process of the blast furnace, an erosion model is generally adopted to monitor the running condition of the hearth and the bottom of the blast furnace, and when the furnace lining of the hearth and the bottom of the blast furnace is damaged, the hearth and the bottom of the blast furnace can be locally repaired and rebuilt according to the condition under the conditions of low efficiency, high cost and poor safety of the blast furnace production. In recent years, the ceramic material (aluminum-silicon carbide castable) has rapid technical development, particularly the castable developed and researched for special erosion mechanism of hearth has better effect on material metallurgical property, and has obvious technical advantages in the aspects of the comprehensive properties of heat conductivity coefficient, material micropore technology and anti-molten iron erosion index; meanwhile, casting or injection construction can be performed, and the method is suitable for construction repair of irregular surfaces.
After the blast furnace is repaired by the ceramic castable, the original blast furnace erosion model which is based on the regular lining and is applied to a new blast furnace or is not repaired by the castable is not applicable any more, and the operation condition of the hearth and the bottom of the blast furnace can not be accurately monitored. Therefore, how to reconstruct an erosion model based on a castable repairing furnace hearth and a furnace bottom of a furnace becomes a new problem.
Disclosure of Invention
The invention provides a modeling method and a modeling system for an erosion model of casting repair of a blast furnace hearth, which aim to solve or partially solve the technical problem of how to build the erosion model based on a casting material repaired blast furnace.
In order to solve the technical problems, in one embodiment, the invention provides a method for modeling an erosion model after casting repair of a blast furnace hearth, which comprises the following steps:
acquiring thickness data and materials of a residual lining at the bottom of a blast furnace hearth before casting repair;
acquiring thickness data and materials of a castable layer at the bottom of the blast furnace hearth after casting repair;
determining thickness distribution of the residual lining, thickness distribution of the castable layer and heat conductivity coefficient distribution of the residual lining and the castable layer according to the thickness data and the material of the residual lining and the thickness data and the material of the castable layer;
According to the thickness distribution of the residual lining, the thickness distribution of the castable layer and the heat conductivity coefficient distribution, constructing a positive problem model of the hearth and the bottom of the furnace in finite element simulation software by utilizing a heat transfer differential equation;
solving a positive problem model of the hearth bottom of the hearth by combining boundary conditions to obtain first temperature field data;
and acquiring position data and real-time temperature data of a thermocouple of the blast furnace, and constructing an inverse problem model of the hearth and the bottom of the furnace in the finite element simulation software according to the first temperature field data, the position data and the real-time temperature data of the thermocouple.
Optionally, the determining the thickness distribution of the residual liner, the thickness distribution of the castable layer, and the thermal conductivity distribution of the residual liner and the castable layer according to the thickness data and the material of the residual liner and the thickness data and the material of the castable layer specifically includes:
intercepting a first preset layer number in the height range of the side wall of the hearth; determining the thickness distribution of the residual lining and the thickness distribution of the castable layer of each hearth side wall in the radial direction according to the thickness data of the residual lining and the thickness data of the castable layer;
Intercepting a second preset layer number in the height range of the furnace bottom; determining the thickness distribution of the residual lining or the thickness distribution of the castable layer of each layer of furnace bottom in the height direction according to the thickness data of the residual lining and the thickness data of the castable layer;
and determining the heat conductivity coefficient distribution of the residual lining and the castable layer according to the thickness distribution of the residual lining of each hearth side wall in the radial direction and the thickness distribution of the castable layer, the thickness distribution of the residual lining of each hearth in the height direction or the thickness distribution of the castable layer.
Further, the first preset layer number is 10, and the second preset layer number is 6.
According to a further alternative embodiment of the present invention, after the solving of the positive problem model of the hearth bottom in combination with boundary conditions, the modeling method further includes, after obtaining the first temperature field data:
after the blast furnace is opened for a preset time, obtaining the measured temperature of each thermocouple in the bottom and the side wall of the hearth of the blast furnace;
determining the calculated temperature corresponding to each thermocouple according to the first temperature field data;
and adjusting the heat conductivity coefficient distribution of the residual lining and the castable layer according to the difference value between the calculated temperature and the actually measured temperature of each thermocouple to obtain an adjusted positive problem model.
Optionally, the modeling method further includes:
based on the adjusted positive problem model, respectively thinning the thicknesses of the residual lining and the castable layer at the bottom of the hearth for N times to obtain N thinned positive problem models, wherein N is more than or equal to 2 and is an integer;
solving the N thinned positive problem models to obtain corresponding N pieces of second temperature field data;
according to the N pieces of second temperature field data, the calculated temperature of each thermocouple after N times of thinning is obtained;
fitting according to the calculated temperature of each thermocouple after N times of thinning, and obtaining a fitting equation of the calculated temperature of each thermocouple and the residual thickness of the refractory;
the method for constructing the inverse problem model of the hearth bottom in the finite element simulation software according to the first temperature field data, the position data of the thermocouple and the real-time temperature data specifically comprises the following steps:
according to the first temperature field data, the position data and the real-time temperature data of the thermocouples and the fitting equation of the calculated temperature of each thermocouple and the residual thickness of the refractory, constructing an inverse problem model of the hearth and the bottom of the furnace in the finite element simulation software;
after constructing the inverse problem model of the hearth bottom in the finite element simulation software, the modeling method further includes:
Obtaining basic parameters; the basic parameters comprise the positions and the number of the thermocouples, the number, elevation and angle of the cross section and the longitudinal section of the blast furnace determined according to the positions of the thermocouples, the thickness distribution of the residual lining, the thickness distribution of the castable layer, the heat conductivity distribution and the size of the cooling wall of the blast furnace;
performing grid division on the inverse problem model;
constructing an objective function of the difference between the detected temperature and the calculated temperature of the thermocouple;
according to the basic parameters and the detection temperature of the thermocouple at the current moment, carrying out iterative computation on the inverse problem model after grid division according to the principle of minimum objective function, and obtaining inverse problem computation result data; the inverse problem calculation result data comprises the modified erosion boundary and the residual thickness distribution of the refractory at the hearth bottom.
Further, based on the adjusted positive problem model, the thicknesses of the residual lining and the castable layer at the bottom of the hearth are respectively thinned for N times, so as to obtain N thinned positive problem models, which specifically include:
thinning the castable layer on the side wall of the hearth by one third, and thinning the castable layer on the bottom of the hearth by one half to obtain a positive problem model after the first thinning;
Thinning the castable layer on the side wall of the hearth by two thirds, and fully thinning the castable layer on the bottom of the hearth to obtain a positive problem model after the second thinning;
all casting material layers on the side wall of the hearth are thinned, and a layer of carbon bricks is thinned from the upper surface of the hearth, so that a positive problem model after the third thinning is obtained;
thinning the residual lining of the side wall of the hearth by one half, and thinning two layers of carbon bricks from the upper surface of the hearth to obtain a positive problem model after the fourth thinning;
and (3) thinning all residual linings on the side wall of the hearth, and thinning three layers of carbon bricks from the upper surface of the hearth to obtain a positive problem model after the fifth thinning.
Further, after the obtaining of the inverse problem calculation result data, the modeling method further includes:
and graphically displaying the inverse problem calculation result data.
Further, the meshing of the inverse problem model specifically includes:
and dividing the hearth and bottom entity of the inverse problem model into 80-120 ten thousand grids.
According to the technical scheme, before the thickness data and the materials of the residual lining at the bottom of the blast furnace hearth before casting repair are obtained, the modeling method further comprises the following steps:
And cleaning the adhesive and ineffective brick lining on the residual lining at the bottom of the blast furnace hearth.
Based on the same inventive concept as the previous technical solution, according to another alternative embodiment of the present invention, there is provided an erosion model modeling system after casting repair of a blast furnace hearth, including:
the device comprises an acquisition module, a casting repair module and a casting repair module, wherein the acquisition module is used for acquiring thickness data and materials of a residual lining at the bottom of a blast furnace hearth before casting repair and thickness data and materials of a casting material layer at the bottom of the blast furnace hearth after casting repair;
the determining module is used for determining thickness distribution of the residual lining, thickness distribution of the castable layer and heat conductivity coefficient distribution of the residual lining and the castable layer according to the thickness data and the material of the residual lining and the thickness data and the material of the castable layer;
the positive problem modeling module is used for constructing a positive problem model of the hearth and the bottom of the furnace in finite element simulation software by utilizing a heat transfer differential equation according to the thickness distribution of the residual lining, the thickness distribution of the castable layer and the heat conductivity coefficient distribution;
the positive problem solving module is used for solving a positive problem model of the hearth and the bottom of the hearth in combination with boundary conditions to obtain first temperature field data;
The inverse problem modeling module is used for acquiring position data and real-time temperature data of the thermocouple of the blast furnace, and constructing an inverse problem model of the hearth bottom in the finite element simulation software according to the first temperature field data, the position data and the real-time temperature data of the thermocouple.
Through one or more technical schemes of the invention, the invention has the following beneficial effects or advantages:
the invention provides a modeling method of an erosion model after casting repair of a blast furnace hearth, which comprises the steps of measuring thickness data of a residual lining at the bottom of the hearth of the blast furnace before casting repair, and measuring thickness data of a castable layer at the bottom of the hearth after casting repair; according to the thickness data before and after casting, determining thickness distribution data of the residual lining and the casting material layer; the residual lining and the castable layer are different in material and therefore different in heat conductivity coefficient, so that the heat conductivity coefficient distribution of the hearth bottom of the repaired hearth is determined according to the material and thickness distribution of the residual lining and the material and thickness distribution of the castable layer; thus, according to the thickness distribution and the heat conductivity coefficient distribution of the residual lining and the castable layer, the accurate structure of the hearth and the bottom of the blast furnace hearth after casting repair can be obtained; and then, a positive problem model is built by utilizing a heat transfer differential equation, a first temperature field is obtained by solving the positive problem model, and then, an inverse problem model is built by adopting a method of inverse problem of heat transfer according to the solved first temperature field and the position and real-time temperature of a thermocouple in a hearth of a blast furnace hearth, so that the problem that an accurate hearth and hearth erosion model is difficult to build due to uneven distribution of lining of the hearth and the hearth after casting and repairing of the blast furnace is effectively solved, and effective guarantee is provided for safe and long-life operation of the blast furnace.
The foregoing description is only an overview of the present invention, and is intended to be implemented in accordance with the teachings of the present invention in order that the same may be more clearly understood and to make the same and other objects, features and advantages of the present invention more readily apparent.
Drawings
Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention. Also, like reference numerals are used to designate like parts throughout the figures. In the drawings:
FIG. 1 shows a schematic flow diagram of a method for modeling an erosion model after casting repair of a blast furnace hearth according to one embodiment of the invention;
FIG. 2 shows a schematic diagram of the furnace type of the repaired blast furnace according to one embodiment of the invention;
FIG. 3 shows a schematic diagram of an erosion model modeling system after casting repair of a blast furnace hearth according to one embodiment of the invention.
Detailed Description
In order to make the technical solution more clearly understood by those skilled in the art, the following detailed description is made with reference to the accompanying drawings. Throughout the specification, unless specifically indicated otherwise, the terms used herein should be understood as meaning as commonly used in the art. Accordingly, unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict, the present specification will control. The various devices and the like used in the present invention are commercially available or can be prepared by existing methods unless otherwise specifically indicated.
Research shows that when ceramic castable is used for repairing a blast furnace lining, the hearth and the bottom of a hearth are usually removed in a protective way, and the residual lining is irregular after the protective way is removed, so that the thickness of the castable after casting construction is also irregular; meanwhile, the heat conductivity coefficients of the residual lining of the blast furnace and the castable are different, and under the condition, how to reestablish the erosion model becomes a problem to be solved continuously.
In order to solve the problem, as shown in fig. 1, a modeling method of an erosion model after casting repair of a blast furnace hearth is provided, and the overall thought is as follows:
s1: acquiring thickness data and materials of a residual lining at the bottom of a blast furnace hearth before casting repair;
s2: acquiring thickness data and materials of a castable layer at the bottom of the blast furnace hearth after casting repair;
s3: determining thickness distribution of the residual lining, thickness distribution of the castable layer and heat conductivity coefficient distribution of the residual lining and the castable layer according to the thickness data and the material of the residual lining and the thickness data and the material of the castable layer;
s4: according to the thickness distribution of the residual lining, the thickness distribution of the castable layer and the heat conductivity coefficient distribution, constructing a positive problem model of the hearth and the bottom of the furnace in finite element simulation software by utilizing a heat transfer differential equation;
S5: solving a positive problem model of the hearth bottom of the hearth by combining boundary conditions to obtain first temperature field data;
s6: and acquiring position data and real-time temperature data of a thermocouple of the blast furnace, and constructing an inverse problem model of the hearth and the bottom of the furnace in the finite element simulation software according to the first temperature field data, the position data and the real-time temperature data of the thermocouple.
In general, the method comprises the steps of measuring thickness data of residual lining at the hearth and the bottom of a hearth of a blast furnace before casting repair, and then measuring thickness data of a castable layer at the hearth and the bottom of the hearth after casting repair; according to the thickness data before and after casting, determining thickness distribution data of the residual lining and the casting material layer; the residual lining and the castable layer are different in material and therefore different in heat conductivity coefficient, so that the heat conductivity coefficient distribution of the hearth bottom of the repaired hearth is determined according to the material and thickness distribution of the residual lining and the material and thickness distribution of the castable layer; according to the thickness distribution and the heat conductivity coefficient distribution of the residual lining and the castable layer, an accurate structure of the hearth and the bottom of the blast furnace after casting repair can be obtained, then a positive problem model is built by utilizing a heat transfer differential equation, a first temperature field is obtained by solving the positive problem model, then an inverse problem model is built by adopting a heat transfer inverse problem method according to the position and the real-time temperature of a thermocouple in the solved first temperature field and the hearth of the blast furnace bottom channel, the problem that the accurate hearth and bottom erosion model is difficult to build due to uneven lining of the hearth and the bottom of the blast furnace after casting repair is effectively solved, and effective guarantee is provided for safe and long-life operation of the blast furnace.
In the following, the above scheme will be described in detail:
in an alternative embodiment, the method described above is applied to a blast furnace that is to be cast-repaired. For the acquisition of thickness data of the residual liner and castable layer in steps S1 and S2, measurement may be performed using furnace type measuring equipment before and after repair, respectively. Fig. 2 shows a schematic diagram of a blast furnace after a casting repair, the casting repair process is as follows:
s11: before casting repair, measuring the hearth and bottom 1 of the blast furnace hearth by adopting a furnace type measuring device 5 to obtain thickness data of residual lining 4 (or residual lining bricks) at each part of the blast furnace;
s12: the material, the casting procedure and the thickness of the furnace bottom casting layer and the furnace hearth casting layer of the supporting die casting blast furnace are determined according to the technological requirements;
s21: after the casting is completed, the hearth bottom 1 of the casting hearth is measured by a furnace type measuring device 5, and thickness data of the casting material layer 3 of each part are obtained.
Optionally, before S11, the method further includes:
s01: and cleaning the adhesive and ineffective brick lining on the residual lining 4 of the blast furnace hearth bottom 1.
After obtaining thickness data of the residual liner 4 and the castable layer 3, next S3: and determining the thickness distribution of the residual lining, the thickness distribution of the castable layer and the heat conductivity coefficient distribution of the residual lining and the castable layer according to the thickness data and the material of the residual lining and the thickness data and the material of the castable layer.
Because the scheme of the invention focuses on the casting repaired blast furnace, the casting repaired blast furnace is different from a newly opened blast furnace with a complete furnace lining structure. In order to improve the calculation accuracy of the erosion model, the embodiment provides a preferred scheme for determining the thickness distribution and the thermal conductivity distribution, which is specifically as follows:
s3: the method for determining the distribution of the heat conductivity coefficients of the residual lining and the castable layer according to the thickness distribution and the material of the residual lining and the thickness distribution and the material of the castable layer specifically comprises the following steps:
s31: intercepting a first preset layer number in the height range of the side wall of the hearth; determining the thickness distribution of the residual lining and the thickness distribution of the castable layer of each hearth side wall in the radial direction according to the thickness data of the residual lining and the thickness data of the castable layer;
specifically, the hearth side wall height range refers to the height below the hearth side wall tap hole center line, a first preset layer number is cut in the hearth side wall height direction, and the height of each layer is divided according to the actual condition of the hearth and the hearth thermocouple distribution. Preferably, the first preset layer number is 10, and the whole height range of the hearth can be completely covered. From the thickness data measured by the layering and furnace type measuring device 5, the thickness of the remaining lining 4 and castable layer 3 of each hearth side wall in the radial direction can be calculated.
S32: intercepting a second preset layer number in the height range of the furnace bottom; determining the thickness distribution of the residual lining or the thickness distribution of the castable layer of each layer of furnace bottom in the height direction according to the thickness data of the residual lining and the thickness data of the castable layer;
the cutting is performed in the height range of the hearth similarly to the manner of the hearth cutting and layering, and the thickness of the remaining lining 4 or castable layer 3 of each hearth in the height direction is also calculated from the thickness data measured by the furnace type measuring device 5. Preferably, the second preset layer number is 6.
S33: and determining the heat conductivity coefficient distribution of the residual lining and the castable layer according to the thickness distribution of the residual lining of each hearth side wall in the radial direction and the thickness distribution of the castable layer, the thickness distribution of the residual lining of each hearth in the height direction or the thickness distribution of the castable layer.
After knowing the material and thickness distribution of the residual lining 4 and the castable layer 3, the material and thickness distribution can be checked into a tool book, a literature or a product manual to obtain the corresponding heat conductivity distribution. After these parameters are obtained, a database of raw parameters of the hearth and bottom of the hearth can be established as the basic parameters needed for modeling and solving the temperature sites in the positive problem model.
For the sake of visual sense, examples of the thickness distribution and thermal conductivity distribution data obtained by the above method are shown in tables 1 and 2:
table 1: thickness distribution and corresponding thermal conductivity of hearth remaining lining and castable layer
Note that: NMD, high thermal conductivity carbon brick; NMA, plain carbon brick; NMD and NMA are residual liners.
TABLE 2 thickness distribution and corresponding thermal conductivity of furnace bottom residual liner and castable layer
After obtaining the thickness distribution and the heat conductivity distribution of the residual lining and the castable layer, namely the structural parameters of the blast furnace after casting repair, the positive problem model is built:
s4: according to the thickness distribution of the residual lining, the thickness distribution of the castable layer and the heat conductivity coefficient distribution, constructing a positive problem model of the hearth and the bottom of the furnace in finite element simulation software by utilizing a heat transfer differential equation;
specifically, a positive problem model of blast furnace erosion is established in finite element simulation software according to the obtained blast furnace material and region geometric dimensions and by combining a heat transfer differential equation. The differential equation of heat transfer may be chosen as desired, two examples being given in this embodiment:
specifically, a heat transfer differential equation can be established according to the shell energy balance principle under a cylindrical coordinate system:
Where ρ: controlling density of unit body, kg/m 3 ；
C p : the heat capacity of the unit body, J/(kg. DEG C);
t: the temperature of the unit body, DEG C;
t: time, s;
k: the thermal conductivity of the unit body, W/(m.K);
s: heat flow intensity in unit body, w/m 2 。
In some cases, for simplicity, a simplified heat transfer differential equation may also be used to build the model, as follows:
s5: solving a positive problem model of the hearth bottom of the hearth by combining boundary conditions to obtain first temperature field data;
solving the problem requires determining corresponding boundary conditions according to the boundary conditions of the model and the heat exchange conditions to which each boundary belongs. Since the inner wall of the blast furnace is eroded by molten iron for a long time during production, it is necessary to assume an erosion boundary, which is a boundary condition of the positive problem model, when finite element analysis of the positive problem model is performed.
Boundary conditions used in solving the positive problem model also include: cooling water pipes are arranged at the bottom of the furnace hearth and the side wall of the furnace hearth for heat dissipation, which belongs to the third class of boundary conditions, and the convective heat transfer coefficients of the cooling water pipes and the furnace shell are calculated according to cooling parameters such as the flow rate of the cooling water and the like; the center and upper edge of the hearth are the second type of boundary conditions, i.e., adiabatic boundary conditions.
In the present embodiment, the relevant parameters of the boundary conditions used in solving the positive problem model are:
hearth side wall cooling water flow rate: 5.2m/s;
furnace bottom cooling water flow rate: 2.8m/s;
atmospheric temperature: 25 ℃;
molten iron temperature: 1500 ℃.
When the positive problem model is solved by utilizing the finite element method, grid division is carried out on the furnace hearth and bottom positive problem model, and then the heat transfer differential equation and the boundary condition are combined to obtain the temperature field distribution inside the furnace hearth and the bottom, namely the first temperature field data. During grid division, 80-120 ten thousand grid nodes can be divided by the model, and parameters of each node are returned to the calculation module to prepare for calculating the whole temperature field. When the grids are divided, only one refractory material is required to be contained in one node control body. And then, reading the heat flow of the cooling wall of the hearth and the temperature data of the thermocouple in the bottom of the hearth in real time, automatically filtering, and calculating by adopting a positive problem method to obtain a first temperature field.
After solving the positive problem model to obtain a first temperature field, the following is followed:
s6: and acquiring position data and real-time temperature data of the thermocouple 2 of the blast furnace, and constructing an inverse problem model of the hearth and the bottom of the furnace in the finite element simulation software according to the first temperature field data, the position data and the real-time temperature data of the thermocouple 2.
When S5, calculating and solving the positive problem model, deducing the corrosion condition of the current blast furnace, namely a first temperature field by using the assumed corrosion boundary as a boundary condition; next, the calculated erosion state and the known conditions, that is, the position and the measured temperature of the thermocouple 2, are compared with the first temperature field, and the erosion boundary is corrected until the calculated temperature and the measured temperature of the thermocouple 2 reach within the temperature error range, and the corrected erosion boundary is considered to be the estimated position of the actual erosion boundary of the current blast furnace, which is the inverse problem method in the blast furnace erosion analysis.
The erosion model modeling method for determining the thickness distribution and the heat conductivity coefficient distribution of the residual furnace lining and the castable layer in a cutting and layering mode in the hearth side wall and the hearth height range is beneficial to more accurately establishing a hearth and hearth erosion model.
In practical application, the problem of low accuracy sometimes occurs in a temperature field obtained by the positive problem model established by the method, and further research discovers that the thermal conductivity coefficient used in modeling is a theoretical value determined according to the material of the refractory material, and when in actual service, the thermal conductivity coefficients of the furnace lining and the castable refractory material can change to a certain extent in a high-temperature environment, and the thermal conductivity coefficient of the refractory material is stable after a period of time of blast furnace opening.
Based on the above studies, the same inventive concept as the previous embodiments was found, in yet another alternative embodiment, at S5: solving a positive problem model of the hearth bottom of the hearth in combination with boundary conditions, and after obtaining first temperature field data, the modeling method further comprises:
s511: after the blast furnace is opened for a preset time, obtaining the measured temperature of each thermocouple 2 in the bottom and the side wall of the hearth of the blast furnace;
s512: determining a calculated temperature corresponding to each thermocouple 2 according to the first temperature field data;
s513: and according to the difference value between the calculated temperature and the actually measured temperature of each thermocouple 2, the thermal conductivity distribution of the residual lining and the castable layer is adjusted, and an adjusted positive problem model is obtained.
Specifically, the measured temperature of the thermocouple at the moment can be obtained after the blast furnace is opened for a period of time, the difference value between the calculated temperature and the measured temperature at the thermocouple can be determined according to the calculated first temperature field because the position data of the thermocouple is known, the thermal conductivity coefficient used by the positive problem model is checked or corrected according to the difference value, then the positive problem model is solved by combining with the boundary condition, the difference value between the calculated temperature and the measured temperature at the thermocouple is compared again, finally the difference value between the calculated temperature and the measured temperature of the thermocouple obtained by calculation of the adjusted positive problem model is within 10 ℃, so that the check of the thermal conductivity coefficient distribution data is completed, and a more accurate positive problem model can be obtained by utilizing the checked thermal conductivity coefficient distribution data, thereby obtaining more accurate first temperature field data.
On the other hand, as the modeling object of the erosion model is the blast furnace after casting repair, the thickness distribution of the residual lining and the casting material at different positions is different, and the material and the heat conductivity coefficient of the residual lining and the casting material are large in difference, so that the calculation accuracy of the inverse problem is influenced. In order to improve the accuracy of the inverse problem calculation result, the specific scheme is as follows:
after the checking of the thermal conductivity distribution data is completed, the modeling method further includes:
s521: based on the adjusted positive problem model, respectively thinning the thicknesses of the residual lining and the castable layer at the bottom of the hearth for N times to obtain N thinned positive problem models, wherein N is more than or equal to 2 and is an integer;
s522: solving the N thinned positive problem models to obtain corresponding N pieces of second temperature field data;
s523: according to the N pieces of second temperature field data, the calculated temperature of each thermocouple after N times of thinning is obtained;
s524: fitting according to the calculated temperature of each thermocouple after N times of thinning, and obtaining a fitting equation of the calculated temperature of each thermocouple and the residual thickness of the refractory;
alternatively, the value of N may be 4 to 6, preferably 5.
Taking n=5 as an example, an alternative thinning scheme is:
Thinning the castable layer on the side wall of the hearth by one third, and thinning the castable layer on the bottom of the hearth by one half to obtain a positive problem model after the first thinning;
thinning the castable layer on the side wall of the hearth by two thirds, and fully thinning the castable layer on the bottom of the hearth to obtain a positive problem model after the second thinning;
all casting material layers on the side wall of the hearth are thinned, and a layer of carbon bricks is thinned from the upper surface of the hearth, so that a positive problem model after the third thinning is obtained;
thinning the residual lining of the side wall of the hearth by one half, and thinning two layers of carbon bricks from the upper surface of the hearth to obtain a positive problem model after the fourth thinning;
and (3) thinning all residual linings on the side wall of the hearth, and thinning three layers of carbon bricks from the upper surface of the hearth to obtain a positive problem model after the fifth thinning.
Based on the thinning accounting in the process, a change trend equation of the calculated temperature of each thermocouple along with the residual thickness of the refractory material is obtained. In fitting the trend equation, optionally, for the thermocouple of each hearth side wall, a first equation may be fitted according to three temperatures calculated after three casting materials are thinned, and then a second equation may be fitted according to two temperatures calculated after two carbon rotations are thinned. The fitting method can adopt linear fitting or polynomial fitting; for example, for a linear fit, t=kx+c; wherein T is the temperature, and x is the residual thickness of the refractory. The coefficients k and c in the fitting equation are used as important parameters for subsequent anti-problem iterations.
Based on the trend of thinning of the refractory materials with different thickness and materials of the thermocouple calculated temperature, the step S6 specifically comprises:
s61: according to the first temperature field data, the position data and the real-time temperature data of the thermocouples and the fitting equation of the calculated temperature of each thermocouple and the residual thickness of the refractory, constructing an inverse problem model of the hearth and the bottom of the furnace in the finite element simulation software;
after constructing the inverse problem model, the modeling method further includes:
s71: obtaining basic parameters; the basic parameters comprise the positions and the number of the thermocouples, the number, elevation and angle of the cross section and the longitudinal section of the blast furnace determined according to the positions of the thermocouples, the thickness distribution of the residual lining, the thickness distribution of the castable layer, the heat conductivity distribution and the size of the cooling wall of the blast furnace;
specifically, the angles of the cross section and the vertical section are determined by determining the radial direction, the height direction of the hearth and the interfaces of different angles according to the position of the thermocouple.
S72: performing grid division on the inverse problem model;
specifically, grid division is performed based on interfaces, and the hearth and bottom entity of the inverse problem model can be divided into 80-120 ten thousand grids; preferably 100 tens of thousands.
S73: constructing an objective function of the difference between the detected temperature and the calculated temperature of the thermocouple;
s74: according to the basic parameters and the detection temperature of the thermocouple at the current moment, carrying out iterative computation on the inverse problem model after grid division according to the principle of minimum objective function, and obtaining inverse problem computation result data; the inverse problem calculation result data comprises the modified erosion boundary and the residual thickness distribution of the refractory at the hearth bottom.
Specifically, writing a fitting equation into an anti-problem code for modeling, then carrying out erosion calculation by combining basic parameters and real-time thermocouple temperature data, and carrying out iterative calculation by continuously correcting an erosion boundary, and finally obtaining that the calculated temperature at the thermocouple is the same as the current detected temperature, so that the erosion boundary at the moment is accurate.
Optionally, in order to accelerate the iteration speed, seidel iteration can be selected; in order to increase the convergence rate, under-relaxation can be applied, the basic idea is to use the k iteration value x of the original iteration (k) From x (k) The resulting next step Seidel iteration valueForms a new iterative format: />Wherein the real parameter omega becomes a relaxation factor, generally 0-1,/for >Is composed of x (m) The resulting Seidel iterates.
The thinning accounting is carried out, and a fitting equation of the calculated temperature of the thermocouple and the residual thickness of the refractory material is used as an important parameter for modeling the inverse problem, because for the cast and repaired blast furnace, the thicknesses of a casting material layer and a residual lining at different positions of the hearth and the bottom of the furnace are different, namely the material and the heat conductivity coefficient are distributed differently, so that the thermocouples at different positions are inevitably different along with the temperature trend of the residual thickness of the different refractory materials, and therefore, the temperature trend of each thermocouple under the residual thickness of the different refractory materials is considered, a more accurate inverse problem model can be established, and the solving precision of the inverse problem model is improved.
Optionally, after step S74, the modeling method further includes:
s8: and graphically displaying the inverse problem calculation result data.
Alternatively, the residual thickness of the refractory material corresponding to different positions and thermocouple sections can be displayed as required during graphical display.
In general, according to the modeling method provided by the embodiment, after a period of time of furnace opening, the thermal conductivity coefficient of the refractory material is checked according to the difference between the measured temperature of the thermocouple and the calculated temperature of the thermocouple in the first temperature field, so that the modeling precision of the positive problem model and the negative problem model can be improved; and then, by combining thinning accounting of the alignment problem model, solving the temperature trend of each thermocouple under different residual thicknesses of the refractory material, and combining a temperature trend equation, establishing an inverse problem model, so that iterative calculation of the inverse problem model is faster and more accurate.
Based on the same inventive concept as the previous embodiment, in yet another alternative embodiment, as shown in fig. 3, there is provided an erosion model modeling system after casting repair of a blast furnace hearth, comprising:
the acquisition module 10 is used for acquiring thickness data and materials of residual linings at the bottom of the blast furnace hearth before casting repair and thickness data and materials of a casting material layer at the bottom of the blast furnace hearth after casting repair;
a determining module 20, configured to determine a thickness distribution of the residual liner, a thickness distribution of the castable layer, and a thermal conductivity distribution of the residual liner and the castable layer according to the thickness data and the material of the residual liner and the thickness data and the material of the castable layer;
the positive problem modeling module 30 is configured to construct a positive problem model of the hearth and the bottom of the furnace in finite element simulation software by using a heat transfer differential equation according to the thickness distribution of the residual liner, the thickness distribution of the castable layer and the heat conductivity distribution;
a positive problem solving module 40, configured to solve a positive problem model of the hearth and the bottom of the hearth in combination with boundary conditions, to obtain first temperature field data;
the inverse problem modeling module 50 is configured to obtain position data and real-time temperature data of a thermocouple of the blast furnace, and construct an inverse problem model of the hearth bottom in the finite element simulation software according to the first temperature field data, the position data and the real-time temperature data of the thermocouple.
Optionally, the determining module 20 is specifically configured to:
intercepting a first preset layer number in the height range of the side wall of the hearth; determining the thickness distribution of the residual lining and the thickness distribution of the castable layer of each hearth side wall in the radial direction according to the thickness data of the residual lining and the thickness data of the castable layer;
intercepting a second preset layer number in the height range of the furnace bottom; determining the thickness distribution of the residual lining or the thickness distribution of the castable layer of each layer of furnace bottom in the height direction according to the thickness data of the residual lining and the thickness data of the castable layer;
and determining the heat conductivity coefficient distribution of the residual lining and the castable layer according to the thickness distribution of the residual lining of each hearth side wall in the radial direction and the thickness distribution of the castable layer, the thickness distribution of the residual lining of each hearth in the height direction or the thickness distribution of the castable layer.
Optionally, the obtaining module 10 is further configured to: after the blast furnace is opened for a preset time, obtaining the measured temperature of each thermocouple in the bottom and the side wall of the hearth of the blast furnace;
the positive problem modeling module 30 is also configured to:
determining the calculated temperature corresponding to each thermocouple according to the first temperature field data;
According to the difference value between the calculated temperature and the actually measured temperature of each thermocouple, the distribution of the heat conductivity coefficients of the residual lining and the castable layer is adjusted, and an adjusted positive problem model is obtained;
optionally, the modeling system further includes a thinning module 60 and an inverse problem solving module 70, where the thinning module 60 is specifically configured to:
based on the adjusted positive problem model, respectively thinning the thicknesses of the residual lining and the castable layer at the bottom of the hearth for N times to obtain N thinned positive problem models, wherein N is more than or equal to 2 and is an integer;
solving the N thinned positive problem models to obtain corresponding N pieces of second temperature field data;
according to the N pieces of second temperature field data, the calculated temperature of each thermocouple after N times of thinning is obtained;
fitting according to the calculated temperature of each thermocouple after N times of thinning, and obtaining a fitting equation of the calculated temperature of each thermocouple and the residual thickness of the refractory;
the inverse problem modeling module 50 is specifically configured to:
according to the first temperature field data, the position data and the real-time temperature data of the thermocouples and the fitting equation of the calculated temperature of each thermocouple and the residual thickness of the refractory, constructing an inverse problem model of the hearth and the bottom of the furnace in the finite element simulation software;
The inverse problem solving module 70 is specifically configured to:
obtaining basic parameters; the basic parameters comprise the positions and the number of the thermocouples, the number, elevation and angle of the cross section and the longitudinal section of the blast furnace determined according to the positions of the thermocouples, the thickness distribution of the residual lining, the thickness distribution of the castable layer, the heat conductivity distribution and the size of the cooling wall of the blast furnace;
performing grid division on the inverse problem model;
constructing an objective function of the difference between the detected temperature and the calculated temperature of the thermocouple;
according to the basic parameters and the detection temperature of the thermocouple at the current moment, carrying out iterative computation on the inverse problem model after grid division according to the principle of minimum objective function, and obtaining inverse problem computation result data; the inverse problem calculation result data comprises the modified erosion boundary and the residual thickness distribution of the refractory at the hearth bottom.
Alternatively, the thinning scheme used by the thinning module 60 is:
thinning the castable layer on the side wall of the hearth by one third, and thinning the castable layer on the bottom of the hearth by one half to obtain a positive problem model after the first thinning;
thinning the castable layer on the side wall of the hearth by two thirds, and fully thinning the castable layer on the bottom of the hearth to obtain a positive problem model after the second thinning;
All casting material layers on the side wall of the hearth are thinned, and a layer of carbon bricks is thinned from the upper surface of the hearth, so that a positive problem model after the third thinning is obtained;
thinning the residual lining of the side wall of the hearth by one half, and thinning two layers of carbon bricks from the upper surface of the hearth to obtain a positive problem model after the fourth thinning;
and (3) thinning all residual linings on the side wall of the hearth, and thinning three layers of carbon bricks from the upper surface of the hearth to obtain a positive problem model after the fifth thinning.
Optionally, the modeling system further includes a graphical presentation module 80, and the graphical presentation module 80 is configured to:
and graphically displaying the inverse problem calculation result data.
Through one or more embodiments of the present invention, the present invention has the following benefits or advantages:
the invention provides a modeling method of an erosion model after casting repair of a blast furnace hearth, which comprises the steps of measuring thickness data of a residual lining at the bottom of the hearth of the blast furnace before casting repair, and measuring thickness data of a castable layer at the bottom of the hearth after casting repair; according to the thickness data before and after casting, determining thickness distribution data of the residual lining and the casting material layer; the residual lining and the castable layer are different in material and therefore different in heat conductivity coefficient, so that the heat conductivity coefficient distribution of the hearth bottom of the repaired hearth is determined according to the material and thickness distribution of the residual lining and the material and thickness distribution of the castable layer; thus, according to the thickness distribution and the heat conductivity coefficient distribution of the residual lining and the castable layer, the accurate structure of the hearth and the bottom of the blast furnace hearth after casting repair can be obtained; and then, a positive problem model is built by utilizing a heat transfer differential equation, a first temperature field is obtained by solving the positive problem model, and then, an inverse problem model is built by adopting a method of inverse problem of heat transfer according to the solved first temperature field and the position and real-time temperature of a thermocouple in a hearth of a blast furnace hearth, so that the problem that an accurate hearth and hearth erosion model is difficult to build due to uneven distribution of lining of the hearth and the hearth after casting and repairing of the blast furnace is effectively solved, and effective guarantee is provided for safe and long-life operation of the blast furnace.
While the preferred embodiments of the present application have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. It is therefore intended that the following claims be interpreted as including the preferred embodiments and all such alterations and modifications as fall within the scope of the application.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present application without departing from the spirit or scope of the application. Thus, if such modifications and variations of the present application fall within the scope of the claims and the equivalents thereof, the present application is intended to cover such modifications and variations.
Claims (10)
1. A modeling method of an erosion model after casting repair of a blast furnace hearth, which is characterized by comprising the following steps:
acquiring thickness data and materials of a residual lining at the bottom of a blast furnace hearth before casting repair;
acquiring thickness data and materials of a castable layer at the bottom of the blast furnace hearth after casting repair;
determining thickness distribution of the residual lining, thickness distribution of the castable layer and heat conductivity coefficient distribution of the residual lining and the castable layer according to the thickness data and the material of the residual lining and the thickness data and the material of the castable layer;
According to the thickness distribution of the residual lining, the thickness distribution of the castable layer and the heat conductivity coefficient distribution, constructing a positive problem model of the hearth and the bottom of the furnace in finite element simulation software by utilizing a heat transfer differential equation;
solving a positive problem model of the hearth bottom of the hearth by combining boundary conditions to obtain first temperature field data;
and acquiring position data and real-time temperature data of a thermocouple of the blast furnace, and constructing an inverse problem model of the hearth and the bottom of the furnace in the finite element simulation software according to the first temperature field data, the position data and the real-time temperature data of the thermocouple.
2. The modeling method of claim 1, wherein determining the thickness distribution of the residual liner, the thickness distribution of the castable layer, and the thermal conductivity distribution of the residual liner and the castable layer based on the thickness data and the material of the residual liner, the thickness data and the material of the castable layer, specifically comprises:
intercepting a first preset layer number in the height range of the side wall of the hearth; determining the thickness distribution of the residual lining and the thickness distribution of the castable layer of each hearth side wall in the radial direction according to the thickness data of the residual lining and the thickness data of the castable layer;
Intercepting a second preset layer number in the height range of the furnace bottom; determining the thickness distribution of the residual lining or the thickness distribution of the castable layer of each layer of furnace bottom in the height direction according to the thickness data of the residual lining and the thickness data of the castable layer;
and determining the heat conductivity coefficient distribution of the residual lining and the castable layer according to the thickness distribution of the residual lining of each hearth side wall in the radial direction and the thickness distribution of the castable layer, the thickness distribution of the residual lining of each hearth in the height direction or the thickness distribution of the castable layer.
3. The modeling method of claim 2, wherein the first predetermined number of layers is 10 layers and the second predetermined number of layers is 6 layers.
4. The modeling method of claim 1, wherein after said solving a positive problem model of the hearth bottom in combination with boundary conditions to obtain first temperature field data, the modeling method further comprises:
after the blast furnace is opened for a preset time, obtaining the measured temperature of each thermocouple in the bottom and the side wall of the hearth of the blast furnace;
determining the calculated temperature corresponding to each thermocouple according to the first temperature field data;
And adjusting the distribution of the heat conductivity coefficients of the residual lining and the castable layer according to the difference value between the calculated temperature and the actually measured temperature of each thermocouple, so as to obtain an adjusted positive problem model.
5. The modeling method of claim 4, further comprising:
based on the adjusted positive problem model, respectively thinning the thicknesses of the residual lining and the castable layer at the bottom of the hearth for N times to obtain N thinned positive problem models, wherein N is more than or equal to 2 and is an integer;
solving the N thinned positive problem models to obtain corresponding N pieces of second temperature field data;
according to the N pieces of second temperature field data, the calculated temperature of each thermocouple after N times of thinning is obtained;
fitting according to the calculated temperature of each thermocouple after N times of thinning, and obtaining a fitting equation of the calculated temperature of each thermocouple and the residual thickness of the refractory;
the method for constructing the inverse problem model of the hearth bottom in the finite element simulation software according to the first temperature field data, the position data of the thermocouple and the real-time temperature data specifically comprises the following steps:
according to the first temperature field data, the position data and the real-time temperature data of the thermocouples and the fitting equation of the calculated temperature of each thermocouple and the residual thickness of the refractory, constructing an inverse problem model of the hearth and the bottom of the furnace in the finite element simulation software;
After constructing the inverse problem model of the hearth bottom in the finite element simulation software, the modeling method further includes:
obtaining basic parameters; the basic parameters comprise the positions and the number of the thermocouples, the number, elevation and angle of the cross section and the longitudinal section of the blast furnace determined according to the positions of the thermocouples, the thickness distribution of the residual lining, the thickness distribution of the castable layer, the heat conductivity distribution and the size of the cooling wall of the blast furnace;
performing grid division on the inverse problem model;
constructing an objective function of the difference between the detected temperature and the calculated temperature of the thermocouple;
according to the basic parameters and the detection temperature of the thermocouple at the current moment, carrying out iterative computation on the inverse problem model after grid division according to the principle of minimum objective function, and obtaining inverse problem computation result data; the inverse problem calculation result data comprises the modified erosion boundary and the residual thickness distribution of the refractory at the hearth bottom.
6. The modeling method according to claim 5, wherein the thicknesses of the residual lining and the castable layer at the hearth bottom are thinned N times based on the adjusted positive problem model, respectively, to obtain N thinned positive problem models, specifically comprising:
Thinning the castable layer on the side wall of the hearth by one third, and thinning the castable layer on the bottom of the hearth by one half to obtain a positive problem model after the first thinning;
thinning the castable layer on the side wall of the hearth by two thirds, and fully thinning the castable layer on the bottom of the hearth to obtain a positive problem model after the second thinning;
all casting material layers on the side wall of the hearth are thinned, and a layer of carbon bricks is thinned from the upper surface of the hearth, so that a positive problem model after the third thinning is obtained;
thinning the residual lining of the side wall of the hearth by one half, and thinning two layers of carbon bricks from the upper surface of the hearth to obtain a positive problem model after the fourth thinning;
and (3) thinning all residual linings on the side wall of the hearth, and thinning three layers of carbon bricks from the upper surface of the hearth to obtain a positive problem model after the fifth thinning.
7. The modeling method of claim 5, wherein after said obtaining inverse problem calculation result data, the modeling method further comprises:
and graphically displaying the inverse problem calculation result data.
8. The modeling method of claim 5, wherein meshing the inverse problem model comprises:
And dividing the hearth and bottom entity of the inverse problem model into 80-120 ten thousand grids.
9. The modeling method of claim 1, wherein prior to said obtaining thickness data and material of the remaining lining of the hearth of the blast furnace hearth before casting repair, said modeling method further comprises:
and cleaning the adhesive and ineffective brick lining on the residual lining at the bottom of the blast furnace hearth.
10. A blast furnace hearth casting repaired erosion model modeling system, the modeling system comprising:
the device comprises an acquisition module, a casting repair module and a casting repair module, wherein the acquisition module is used for acquiring thickness data and materials of a residual lining at the bottom of a blast furnace hearth before casting repair and thickness data and materials of a casting material layer at the bottom of the blast furnace hearth after casting repair;
the determining module is used for determining thickness distribution of the residual lining, thickness distribution of the casting material layer and heat conductivity coefficient distribution of the residual lining and the casting material layer according to the thickness data and the material of the residual lining and the thickness data and the material of the casting material layer;
the positive problem modeling module is used for constructing a positive problem model of the hearth and the bottom of the furnace in finite element simulation software by utilizing a heat transfer differential equation according to the thickness distribution of the residual lining, the thickness distribution of the castable layer and the heat conductivity coefficient distribution;
The positive problem solving module is used for solving a positive problem model of the hearth and the bottom of the hearth in combination with boundary conditions to obtain first temperature field data;
the inverse problem modeling module is used for acquiring position data and real-time temperature data of the thermocouple of the blast furnace, and constructing an inverse problem model of the hearth bottom in the finite element simulation software according to the first temperature field data, the position data and the real-time temperature data of the thermocouple.
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