CN114234880A - Online monitoring method for lining thickness of torpedo tank refractory material - Google Patents
Online monitoring method for lining thickness of torpedo tank refractory material Download PDFInfo
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
- G01B21/08—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness
- G01B21/085—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness using thermal means
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Abstract
The invention relates to an online monitoring method for the thickness of a lining of a torpedo ladle refractory material, which comprises the following steps: step 1: determining the positions of 16 temperature measuring points of the torpedo ladle lining; step 2: establishing an electromotive force loop; and step 3: determining upper and lower limits of current; and 4, step 4: tracking temperature values of 8 detection points of a lower loop; step 5, estimating the analog value of the thickness of the torpedo ladle refractory: step 6: correcting and perfecting by using a current value real-time graph and a trend graph; according to the technical scheme, a current loop is established through tracking and detecting the temperature of the shell of the torpedo tank, the change of current is monitored, the thickness of the lining is calculated out, when the thickness is lower than a safe operation value and the current exceeds an upper limit value, an alarm is given by a system, the torpedo tank is guided to be offline for maintenance, and the purpose of safe operation is achieved.
Description
Technical Field
The invention relates to a monitoring method, in particular to an online monitoring method for the thickness of a lining of a torpedo ladle refractory material, and belongs to the technical field of torpedo ladle monitoring.
Background
At present, the lining heat preservation structure of the torpedo tank car mainly comprises a permanent layer, a pouring material and a heat preservation layer, plays roles of containing molten iron and preserving heat, the permanent layer is mostly clay bricks or paraffin bricks, the technical scheme and the construction scheme are mature, the temperature of the molten iron is as high as 1500 ℃ in the molten iron conveying process, and the molten iron contains various erosion components, the lining is seriously washed, if the lining is seriously washed, the molten iron burns through the shell of the torpedo tank, the molten iron overflows, the railway is burnt, the damage of the whole iron and steel transportation system is caused, the blast furnace stops blowing, the converter stops production, and the serious economic loss is generated for the whole-process iron and steel plant. However, the difficulty of identifying the thickness is caused because the torpedo tank is high in temperature, namely an empty tank, the temperature is also 1000 ℃, the working condition of the current thermodetector cannot be met, and the thickness measurement becomes a difficult problem in the industry. Therefore, a new solution to solve the above technical problems is urgently needed.
Disclosure of Invention
The invention provides an online monitoring method for the thickness of a lining of a torpedo tank refractory material, aiming at the problems in the prior art, the technical scheme can establish a current loop through tracking and detecting the temperature of the shell of the torpedo tank, monitor the change of current, and simultaneously calculate the thickness of the lining, when the thickness is lower than a safe operation value and the current exceeds an upper limit value, a system gives an alarm to guide the torpedo tank to be offline for maintenance, thereby achieving the aim of safe operation.
In order to achieve the purpose, the technical scheme of the invention is that the method for monitoring the thickness of the lining of the torpedo tank refractory material on line is characterized by comprising the following steps:
step 1: determining the positions of 16 temperature measuring points of the torpedo ladle lining;
step 2: establishing an electromotive force loop;
and step 3: determining upper and lower limits of current;
and 4, step 4: tracking temperature values of 8 detection points of a lower loop;
step 5, estimating the analog value of the thickness of the torpedo ladle refractory:
step 6: and correcting and perfecting by using a current value real-time graph and a trend graph.
As a modification of the present invention, the step 1: determining the positions of 16 temperature measuring points of the torpedo ladle lining, which comprises the following steps:
according to the characteristics that the lining of the torpedo tank is eroded and corroded by molten iron and the material resistance, two loop lines are arranged according to the position of 250 tons of molten iron canned by 320 tons of torpedos according to the tank capacity, the lower 20cm of the molten iron liquid level and the lower 20cm of the bottom of the torpedo tank are taken as references, 4 points are uniformly distributed on each loop line in consideration of relative reliability of data and daily maintenance requirements, 16 temperature measuring points are mainly monitored, the upper loop line is also a red dot area shown in the drawing, 8, 4 are respectively arranged on the front side and the back side of the torpedo tank and are taken as a slag line area, the area is less in direct impact with the molten iron, the erosion of the material resistance lining is less, the thickness is not changed, and the area is taken as a reference value for thickness comparison; the corresponding next ring line is in one-to-one correspondence with the 8 detection points of the previous ring line, is positioned in an impact area where the torpedo ladle is charged with molten iron, is seriously impacted by the molten iron, the thickness of refractory materials is gradually reduced, the later risk of the furnace life of the first generation of torpedo ladle is large, and the possibility of being punctured by the molten iron exists, namely, 8 key monitoring areas are arranged on the front side and the back side of the torpedo ladle, and 4 detection points are arranged on each side.
As an improvement of the present invention, step 2: establishing an electromotive force loop, which comprises the following specific steps: after 16 temperature detection points are determined, thermocouples are embedded, the thermocouples are connected with a potential difference meter through a lead to form a loop, the temperature difference of the upper corresponding point and the lower corresponding point is formed due to the difference of the temperatures of the upper corresponding point and the lower corresponding point, the difference of the temperatures is fed back by the magnitude of the current, the temperature difference of the two thermocouples fed back by the greater current is also large under the same molten iron temperature, the difference of the thicknesses fed back indirectly is enlarged, 8 circuits are formed, 8 current signals are connected into an industrial control system of the torpedo car, and the change of the current is monitored in real time.
As a modification of the present invention, the step 3: determining the upper and lower limits of the current as follows: the upper limit value is as follows: in the later stage of the first generation furnace age, the thickness of the lower loop line is the thinnest part, the temperature is high, the corresponding temperature difference is the largest, the current is the largest, and the lower loop line is determined as the upper limit value. Lower limit value: at the initial stage of the first generation of furnace life, the thicknesses of the upper and lower ring lines are basically consistent, the corresponding temperature difference is minimum, the current is minimum, and the lower limit value is determined.
As a modification of the present invention, step 4: tracking the temperature values of 8 detection points of the lower loop line, specifically as follows:
the online torpedo ladle temperature detection system can detect out the temperature of the whole surface of torpedo ladle shell to can record, store the temperature, the characteristics can play the warning effect, find the temperature of every shell point easily, but can not reflect with the masonry thickness of inside resistant material, and the temperature is high promptly and also not representing the risk big, and the temperature is low also can not represent the risk little. Therefore, the temperature measurement system counts the approximate data intervals of 8 monitoring points, mainly focuses on 220 and 300 ℃, and can be basically classified as a safety interval; 300-320 ℃ is a temperature interval with risk, appears for 10 days continuously (namely 40 times of temperature measurement), and needs to be processed and observed off line; 320-350 ℃ is a higher risk temperature interval, appears for 5 consecutive days (namely 20 times of temperature measurement), and needs to be processed and observed off line; and (5) performing off-line treatment at the temperature higher than 350 ℃.
As an improvement of the present invention, in the step 5, the analog value of the thickness of the torpedo ladle refractory is estimated, specifically as follows: and (3) estimating the simulated value of the thickness of the torpedo ladle refractory: according to the temperature of the next loop, the current thickness is roughly calculated through the heat conductivity coefficient of the refractory material.
1) Determining the temperature of the empty tank and the full tank;
2) setting the temperature of the inner lining when the tank is empty;
3) determining the temperature of molten iron, wherein the temperature T1 of the molten iron is taken from the temperature of the blast furnace during tapping;
4) the torpedo ladle passes through a temperature online detection system to measure the temperature T2;
5) calculating the temperature difference T3 between the molten iron and the shell, namely T2-T1;
6) deducing the thickness of the lining according to a thermal calculation formula; (δ 1 × λ 1+ δ 2 × λ 2+ δ 3 × λ 3+ …) ═ T3 ═ T2-T1, that is, δ 1 in the innermost layer (T2-T1- δ 2 × λ 2- δ 3- λ 3- …)/λ 1 ═ is recorded;
lambda is the thermal conductivity of the lining brick, W/(m.DEG C);
δ — thickness of the lining;
the correction coefficient is corrected according to the correction value in a period of operation;
7) and feeding back data, wherein when the measured temperature value is obtained, the system immediately obtains a corresponding thickness value according to the function relation, the thickness value is compared with the standard value, if the thickness value is smaller than the standard value, the monitoring picture immediately gives an alarm, and certain measures are taken to reduce the risk of continuous operation.
As a modification of the present invention, step 6: and correcting and perfecting by using a current value real-time graph and a trend graph, which specifically comprises the following steps: by using the real-time current value graph and the trend graph, an operator can intuitively obtain the corrosion condition of the lower loop, can judge specific approximate parts, estimate a temperature value, theoretically analyze the thickness of the lining of the torpedo ladle, compare the thickness with the actual corrosion thickness, and continuously correct an algorithm to enable the thickness and the actual corrosion thickness to be continuously close to each other, so that firstly, monitoring is provided for daily operation, and safe operation in the later period of the furnace life is ensured; secondly, the service cycle of the torpedo ladle refractory can be prolonged, and the torpedo ladle refractory runs more economically; and thirdly, the improvement of a local masonry process and material selection can be further explored, so that the service life of the torpedo ladle refractory is continuously prolonged.
Compared with the prior art, the method has the advantages that the temperature of the shell of the torpedo tank is detected, the temperature system is detected on line, a large database is used, the temperature ranges of 16 important parts of the torpedo tank are obtained, the thermoelectromotive force loop is established, and 8 current curve graphs are established; meanwhile, the thickness of the outermost liner is calculated according to the heat conductivity coefficient of the material, a functional relation between the temperature and the thickness is established, when the current is used for alarming and the thickness is lower than a standard value of the technical requirement, attention is paid to the function, the torpedo tank is taken off line for maintenance, the accident that molten iron burns through the shell is effectively avoided, and safe operation is guaranteed. Compared with the condition that the temperature and the refractory thickness of the outer shell of the torpedo tank are not related to the prior art, a set of monitoring and supervising system which is relatively easy to operate, convenient to monitor and effective is established, meanwhile, the system can be continuously improved and promoted, and the system has certain popularization value in the industry.
Drawings
FIG. 1 is a schematic view of the overall structure of a torpedo;
FIG. 2 is a schematic diagram of an electromotive force circuit;
in the figure: 1 is a pot mouth, 2 is molten iron, 3 is a surface of a pot shell, and 4 is a surface of a refractory lining.
The specific implementation mode is as follows:
for the purpose of enhancing an understanding of the present invention, the present embodiment will be described in detail below with reference to the accompanying drawings.
Example 1: referring to fig. 1 and 2, an online monitoring method for the thickness of a torpedo ladle refractory material lining comprises the following steps:
step 1: determining the positions of 16 temperature measuring points of the torpedo ladle lining;
step 2: establishing an electromotive force loop;
and step 3: determining upper and lower limits of current;
and 4, step 4: tracking temperature values of 8 detection points of a lower loop;
step 5, estimating the analog value of the thickness of the torpedo ladle refractory:
step 6: and correcting and perfecting by using a current value real-time graph and a trend graph.
The step 1: determining the positions of 16 temperature measuring points of the torpedo ladle lining, which comprises the following steps:
according to the characteristics that the lining of the torpedo tank is eroded and corroded by molten iron and the material resistance, two loop lines are arranged according to the position of 250 tons of molten iron canned by 320 tons of torpedos according to the tank capacity, the lower 20cm of the molten iron liquid level and the lower 20cm of the bottom of the torpedo tank are taken as references, 4 points are uniformly distributed on each loop line in consideration of relative reliability of data and daily maintenance requirements, 16 temperature measuring points are mainly monitored, the upper loop line is also a red dot area shown in the drawing, 8, 4 are respectively arranged on the front side and the back side of the torpedo tank and are taken as a slag line area, the area is less in direct impact with the molten iron, the erosion of the material resistance lining is less, the thickness is not changed, and the area is taken as a reference value for thickness comparison; the corresponding next ring line is in one-to-one correspondence with the 8 detection points of the previous ring line, is positioned in an impact area where the torpedo ladle is charged with molten iron, is seriously impacted by the molten iron, the thickness of refractory materials is gradually reduced, the later risk of the furnace life of the first generation of torpedo ladle is large, and the possibility of being punctured by the molten iron exists, namely, 8 key monitoring areas are arranged on the front side and the back side of the torpedo ladle, and 4 detection points are arranged on each side.
Step 2: establishing an electromotive force loop, which comprises the following specific steps: after 16 temperature detection points are determined, thermocouples are pre-embedded and connected with a potential difference meter by a lead to form a loop, because the temperatures of the upper corresponding point and the lower corresponding point are different, current is formed, the difference of the temperatures is fed back by the magnitude of the current, the temperature difference of the two thermocouples fed back by the greater current is also greater under the same molten iron temperature, and the difference of the thicknesses fed back indirectly is increased. 8 circuits are formed, 8 current signals are connected into an industrial control system of the torpedo car, and the change of the current is monitored in real time.
The step 3: determining the upper and lower limits of the current as follows: the upper limit value is as follows: in the later stage of the first generation furnace age, the thickness of the lower loop line is the thinnest part, the temperature is high, the corresponding temperature difference is the largest, the current is the largest, and the lower loop line is determined as the upper limit value.
Lower limit value: at the initial stage of the first generation of furnace life, the thicknesses of the upper and lower ring lines are basically consistent, the corresponding temperature difference is minimum, the current is minimum, and the lower limit value is determined.
The step 4: tracking the temperature values of 8 detection points of the lower loop line, specifically as follows:
the online torpedo ladle temperature detection system can detect out the temperature of the whole surface of torpedo ladle shell to can record, store the temperature, the characteristics can play the warning effect, find the temperature of every shell point easily, but can not reflect with the masonry thickness of inside resistant material, and the temperature is high promptly and also not representing the risk big, and the temperature is low also can not represent the risk little. Therefore, the temperature measurement system counts the approximate data intervals of 8 monitoring points, mainly focuses on 220 and 300 ℃, and can be basically classified as a safety interval; 300-320 ℃ is a temperature interval with risk, appears for 10 days continuously (namely 40 times of temperature measurement), and needs to be processed and observed off line; 320-350 ℃ is a higher risk temperature interval, appears for 5 consecutive days (namely 20 times of temperature measurement), and needs to be processed and observed off line; and (5) performing off-line treatment at the temperature higher than 350 ℃.
The step 5 of estimating the analog value of the thickness of the torpedo ladle refractory specifically comprises the following steps: and (3) estimating the simulated value of the thickness of the torpedo ladle refractory: according to the temperature of the next loop, the current thickness is roughly calculated through the heat conductivity coefficient of the refractory material.
1) Determining the temperature of the empty tank and the full tank;
2) setting the temperature of the inner lining when the tank is empty;
3) determining the temperature of molten iron, wherein the temperature T1 of the molten iron is taken from the temperature of the blast furnace during tapping;
4) the torpedo ladle passes through a temperature online detection system to measure the temperature T2;
5) calculating the temperature difference T3 between the molten iron and the shell, namely T2-T1;
6) deducing the thickness of the lining according to a thermal calculation formula; (δ 1 × λ 1+ δ 2 × λ 2+ δ 3 × λ 3+ …) ═ T3 ═ T2-T1, that is, δ 1 in the innermost layer (T2-T1- δ 2 × λ 2- δ 3- λ 3- …)/λ 1 ═ is recorded;
lambda is the thermal conductivity of the lining brick, W/(m.DEG C);
δ — thickness of the lining;
the correction coefficient is corrected according to the correction value in a period of operation;
7) and feeding back data, wherein when the measured temperature value is obtained, the system immediately obtains a corresponding thickness value according to the function relation, the thickness value is compared with the standard value, if the thickness value is smaller than the standard value, the monitoring picture immediately gives an alarm, and certain measures are taken to reduce the risk of continuous operation.
Step 6: and correcting and perfecting by using a current value real-time graph and a trend graph, which specifically comprises the following steps: by using the real-time current value graph and the trend graph, an operator can intuitively obtain the corrosion condition of the lower loop, can judge specific approximate positions, estimate a temperature value, theoretically analyze the thickness of the lining of the torpedo ladle, compare the thickness with the actual corrosion thickness, and then continuously correct the algorithm to enable the thickness and the actual corrosion thickness to be continuously close to each other, so that the monitoring is provided for daily operation, and the safe operation in the later period of the furnace life is ensured; secondly, the service cycle of the torpedo ladle refractory can be prolonged, and the torpedo ladle refractory runs more economically; and thirdly, the improvement of a local masonry process and material selection can be further explored, so that the service life of the torpedo ladle refractory is continuously prolonged.
It should be noted that the above-mentioned embodiments are not intended to limit the scope of the present invention, and all equivalent modifications and substitutions based on the above-mentioned technical solutions are within the scope of the present invention as defined in the claims.
Claims (7)
1. An online monitoring method for the thickness of a torpedo tank refractory material lining is characterized by comprising the following steps:
step 1: determining the positions of 16 temperature measuring points of the torpedo ladle lining;
step 2: establishing an electromotive force loop;
and step 3: determining upper and lower limits of current;
and 4, step 4: tracking temperature values of 8 detection points of a lower loop;
step 5, estimating the analog value of the thickness of the torpedo ladle refractory:
step 6: and correcting and perfecting by using a current value real-time graph and a trend graph.
2. The method of claim 1, wherein the step 1: determining the positions of 16 temperature measuring points of the torpedo ladle lining, which comprises the following steps:
according to the characteristics that an inner lining of a torpedo tank is washed and eroded by molten iron and resistant materials, 250 tons of molten iron are filled in the torpedo tank according to the tank capacity of 320 tons of torpedos, two loop lines are arranged by taking the next 20cm of the molten iron liquid level and the bottom 20cm of the torpedo tank as references, 4 points are uniformly distributed on each loop line, 16 temperature measuring points are counted for important monitoring, 4 points on each side of the front side and the back side of the torpedo tank are respectively taken as slag line areas and used as reference values for thickness comparison, the corresponding next loop line corresponds to 8 detection points on the previous loop line one by one, the torpedo tank is located in an impact area for molten iron mixing, the torpedo tank is seriously impacted by the molten iron, the thickness of the resistant materials is gradually reduced, the later-stage risk of the furnace age of a generation of the torpedo tank is large, the possibility of being punctured by the molten iron exists, namely 8 important monitoring areas are also arranged on the front side and the back side of the torpedo tank, and the back side of each side of the torpedo tank are respectively 4.
3. The method of claim 2, wherein the step 2: establishing an electromotive force loop, which comprises the following specific steps: after 16 temperature detection points are determined, thermocouples are pre-embedded, the thermocouples are connected with a potential difference meter through a lead to form a loop, current is formed due to the difference of the temperatures of the upper corresponding point and the lower corresponding point, the difference of the temperatures is fed back by the magnitude of the current, 8 circuits are formed, 8 current signals are accessed into an industrial control system of the torpedo car, and the change of the current is monitored in real time.
4. The method of claim 3, wherein the step 3: determining the upper and lower limits of the current as follows: the upper limit value is as follows: in the later stage of the first generation furnace age, the thickness of the lower loop is the thinnest part, the temperature is high, the corresponding temperature difference is the largest, the current is the largest, and the lower loop is determined as an upper limit value;
lower limit value: at the initial stage of the first generation of furnace life, the thicknesses of the upper and lower ring lines are basically consistent, the corresponding temperature difference is minimum, the current is minimum, and the lower limit value is determined.
5. The method for on-line monitoring the thickness of the inner lining of the torpedo ladle refractory material according to claim 3 or 4, wherein the step 4: tracking the temperature values of 8 detection points of the lower loop line, specifically as follows:
the torpedo tank online temperature detection system can detect the temperature of the whole surface of the torpedo tank shell, record and store the temperature, and the temperature measurement system counts the approximate data intervals of 8 monitoring points, mainly focuses on the temperature of 220 plus-300 ℃, and is classified into a safety interval; the temperature of 300-320 ℃ is a temperature interval with risk, appears for 10 days continuously, and needs to be off-line for processing and observation; 320-350 ℃ is a higher risk temperature interval, appears for 5 consecutive days, and needs to be off-line for processing and observation; and (5) performing off-line treatment at the temperature higher than 350 ℃.
6. The method of claim 5, wherein the step 5 of estimating the simulated value of the thickness of the torpedo ladle refractory material comprises the following steps:
1) determining the temperature of the empty tank and the full tank;
2) setting the temperature of the inner lining when the tank is empty;
3) determining the temperature of molten iron, wherein the temperature T1 of the molten iron is taken from the temperature of the blast furnace during tapping;
4) the torpedo ladle passes through a temperature online detection system to measure the temperature T2;
5) calculating the temperature difference T3 between the molten iron and the shell, namely T2-T1;
6) deducing the thickness of the lining according to a thermal calculation formula; (δ 1 × λ 1+ δ 2 × λ 2+ δ 3 × λ 3+ …) ═ T3 ═ T2-T1, that is, δ 1 in the innermost layer (T2-T1- δ 2 × λ 2- δ 3- λ 3- …)/λ 1 ═ is recorded;
lambda is the thermal conductivity of the lining brick, W/(m.DEG C);
δ — thickness of the lining;
the correction coefficient is corrected according to the correction value in a period of operation;
7) and feeding back data, wherein when the measured temperature value is obtained, the system immediately obtains a corresponding thickness value according to the function relation, the thickness value is compared with the standard value, if the thickness value is smaller than the standard value, the monitoring picture immediately gives an alarm, and certain measures are taken to reduce the risk of continuous operation.
7. The method of claim 6, wherein the step 6: and correcting and perfecting by using a current value real-time graph and a trend graph, which specifically comprises the following steps:
by using the real-time current value graph and the trend graph, the corrosion condition of the lower loop can be intuitively obtained, specific approximate parts can be judged, the temperature value is estimated, the thickness of the lining of the torpedo tank is theoretically analyzed, the thickness is compared with the actual corrosion thickness, and the algorithm is continuously corrected, so that the current value graph and the trend graph are continuously close to each other.
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| CN206740688U (en) * | 2017-05-12 | 2017-12-12 | 安徽工业大学 | A kind of torpedo tank car inner wall corrosion mechanism for monitoring |
| CN110453034A (en) * | 2019-08-26 | 2019-11-15 | 北京北科神州亿立冶金材料研究所 | A kind of device and method of on-line real time monitoring converter lining erosion state |
| CN111004882A (en) * | 2019-12-18 | 2020-04-14 | 上海大学 | Method and device for measuring thickness of furnace wall of hearth of blast furnace on line |
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2020
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2000273519A (en) * | 1999-03-24 | 2000-10-03 | Kawasaki Steel Corp | Method for removing slag from torpedo car |
| JP2009035789A (en) * | 2007-08-03 | 2009-02-19 | Jfe Steel Kk | Method and apparatus for determining thickness of remaining refractory lining |
| CN101514896A (en) * | 2008-09-02 | 2009-08-26 | 中冶华天工程技术有限公司 | Convertor lining thickness online testing method and device thereof |
| CN206740688U (en) * | 2017-05-12 | 2017-12-12 | 安徽工业大学 | A kind of torpedo tank car inner wall corrosion mechanism for monitoring |
| CN110453034A (en) * | 2019-08-26 | 2019-11-15 | 北京北科神州亿立冶金材料研究所 | A kind of device and method of on-line real time monitoring converter lining erosion state |
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