CN114688883A - Electrode depth measurement system and method for electrode for submerged arc furnace - Google Patents
Electrode depth measurement system and method for electrode for submerged arc furnace Download PDFInfo
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- CN114688883A CN114688883A CN202011608990.9A CN202011608990A CN114688883A CN 114688883 A CN114688883 A CN 114688883A CN 202011608990 A CN202011608990 A CN 202011608990A CN 114688883 A CN114688883 A CN 114688883A
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Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D11/00—Arrangement of elements for electric heating in or on furnaces
- F27D11/08—Heating by electric discharge, e.g. arc discharge
- F27D11/10—Disposition of electrodes
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K11/00—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00
- G01K11/22—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00 using measurement of acoustic effects
- G01K11/24—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00 using measurement of acoustic effects of the velocity of propagation of sound
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Vertical, Hearth, Or Arc Furnaces (AREA)
Abstract
The invention provides an electrode depth measurement system and method of an electrode for a submerged arc furnace, which comprises a protection tube, a sensing rod, an energy transducer and an operation control device, wherein the protection tube is connected with the sensing rod; the sensing rod is arranged in the protective tube, the protective tube and the sensing rod are embedded and run through the electrode for the submerged arc furnace together, the electrode can be consumed synchronously along with the submerged arc furnace, and inert gas, nitrogen, carbon dioxide or mixed gas thereof is introduced into the protective tube; the transducer is positioned on the upper end face and/or the side face of the sensing rod and is used for transmitting and/or receiving ultrasonic guided waves; and the operation control device is electrically connected and in signal connection with the transducer and is used for acquiring the transmission time and speed of the ultrasonic guided waves along the sensing rod through the transducer and calculating the length of the sensing rod and the depth of the electrode for the submerged arc furnace in the submerged arc furnace. The electrode depth measurement system can effectively and accurately obtain the depth of the electrode in the furnace without stopping production and stopping the furnace or human intervention, and achieves the purposes of optimizing process operation, saving electric energy, improving product quality and reducing safety risk.
Description
Technical Field
The invention relates to the technical field of electrode depth measurement systems and methods, in particular to an electrode depth measurement system and method for an electrode for an ore-smelting furnace.
Background
The temperature in an industrial ore-smelting furnace is usually very high, for example, the ore-smelting furnace is an industrial electric furnace with huge power consumption, and a huge crucible with the diameter of more than ten meters and the depth of six-seven meters is equipment for smelting ore-smelting hot furnace burden by applying work through electrode current to produce. The working characteristics are that the carbonaceous or magnesium refractory material is used as the lining of the ore-smelting furnace, the electrode paste is used to roast the electrode to make the self-roasting electrode, the alternating current or the direct current is respectively led into the ore-smelting furnace by three or six electrodes, the electrodes are inserted into the ore-smelting furnace to carry out the submerged arc operation, the current generates the electric arc at the lower end of the electrodes through the ore-smelting furnace between the electrodes and the electrodes, and the ore-smelting furnace is melted at high temperature under the combined action of the electric arc and the current to generate various compounds. The compounds mainly comprise calcium carbide, industrial silicon and ferroalloy, and the raw materials are the most basic raw materials of chemical industry, steel and electrons.
The outer layer of the self-baking electrode is a cylinder with the diameter of 1-1.2 m and made of a steel plate with the thickness of 1-2 mm, solid block-shaped electrode paste (mixture of anthracite, coke, asphalt and tar) is filled in the cylinder, the electrode paste is gradually softened at high temperature along with the production, the melted electrode paste can be softened, volatilized and sintered at higher temperature, and finally the electrode paste is baked into a cylindrical graphitized conductive electrode. The lower end part of the roasted electrode is inserted into the ore heating furnace charge, the roasted electrode is continuously consumed under high temperature and chemical reaction, so that electrode paste is continuously added from the upper part of the electrode cylinder to be roasted into a new electrode, and the production process is continuously carried out, so that block-shaped electrode paste is frequently added from the upper end part of the electrode cylinder to be roasted into a new electrode to supplement the consumed electrode. The lower end part of the self-baking electrode is inserted into the high-temperature ore-smelting furnace charge and plays a role in transmitting electric energy in the working process. Since the self-baking electrode is continuously consumed and added, and the lower end part of the self-baking electrode is inserted into high-temperature ore-smelting furnace charge, the length of the self-baking electrode is difficult to measure, and the depth of the self-baking electrode inserted into the ore-smelting furnace cannot be known.
The depth of insertion of the electrode into the submerged arc furnace is very important for the smelting process. The smelting process requires that the power center and the geometric center of the three-phase electrode are coincident and the insertion depth is reasonable, so that good smelting efficiency and low energy consumption can be obtained, the unreasonable depth position of the electrode also causes a raw material layer during roasting, the product quality is influenced, and accidents such as equipment damage, casualties and the like caused by material spraying are easily caused, so that the acquisition of the insertion depth of the electrode is very important for smelting in the submerged arc furnace.
The current industrial electrode depth measuring method in the submerged arc furnace comprises the following steps:
(1) accumulation method: the electrode length was estimated from the electrode paste added daily and the rate of consumption. The current electrode length H0 is obtained by estimating the daily electrode consumption H1 according to historical experience, estimating the electrode generation amount H2 according to the daily electrode paste addition amount, and further calculating the current electrode length H0-H1+ H2. The method is simple, but the daily consumption is greatly influenced by the smelting operation process, and the daily consumption is accumulated along with time, so that the error is large, and the function of guiding the depth of the electrode is lost.
(2) A weighing method comprises the following steps: the length of the electrode is estimated according to the weight of the electrode, see patent CN201621187815.6 (the patent name is a device for automatically measuring the length of the electrode of a heat accumulating type closed calcium carbide furnace). This method ignores the difference in density of the electrode at different sections and the difference in viscosity of the melted ore-heated charge, making it impossible to estimate the depth of insertion of the electrode by buoyancy.
(3) A probe method: inserting a contact electrode into the ore smelting furnace by using an iron drill, inserting and probing the end face of the detection electrode for multiple times, and further calculating the insertion depth of the electrode by applying the Pythagorean theorem, namely H2 is D2+ L2. The method is simple and effective, but is limited by the experience of operators and the need of stopping the submerged arc furnace when measuring, the use is very inconvenient, and particularly for the ferroalloy submerged arc furnace and the industrial silicon submerged arc furnace, the insertion of iron brazes is seriously influenced by hard submerged arc furnace burden, and the insertion depth of electrodes cannot be detected.
(4) Magnetic induction method: the method is characterized in that a plurality of magnetic field inductors are arranged on the periphery of the submerged arc furnace body, the magnetic field condition is obtained according to magnetic inductor signals, and then the insertion depth of the electrodes is estimated according to the current in the three-phase electrodes, and the method is disclosed in patent application CN 201710071904.7. The method ignores the influence of the complex flow direction and the phase sequence of the current in the submerged arc furnace, particularly the direction of the current in the submerged arc furnace is unpredictable under abnormal submerged arc furnace conditions, the direction of a magnetic field generated by the current is unpredictable, and the measurement accuracy is seriously influenced.
(5) Operating resistance estimation depth method: the operating resistance is calculated by measuring the voltage and the current of the electrode, and the depth of the electrode in the submerged arc furnace is further estimated by simulation, see patent CN201610490475.2 of the invention. The method seems to simulate the depth of the electrode into the submerged arc furnace, and in fact, due to the complex submerged arc furnace conditions in the submerged arc furnace, the simulation model is only made under the condition of fixing the proportion of the submerged arc furnace burden under the normal working condition, and because the submerged arc furnace burden is continuously adjusted and changed, the submerged arc furnace is in the abnormal working condition for a lot of time, the simulation is not effective at all, and the applicability is extremely poor.
The methods can not meet the requirements of easiness, accuracy and effectiveness of depth measurement of the electrode in the submerged arc furnace, so that the energy consumption and the product quality in the submerged arc furnace are not controlled in industrial production, equipment damage and production accidents occur frequently, and immeasurable economic and social benefit loss is caused.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention aims to provide an electrode depth measuring system and method for an electrode for a submerged arc furnace, which can effectively and accurately obtain the depth of the electrode in the submerged arc furnace without stopping production and stopping the submerged arc furnace or manually intervening, so as to provide data basis for controlling the electrode, achieve the purposes of optimizing process operation, saving electric energy, improving product quality and reducing safety risk, and can generate great social and economic benefits so as to overcome the defects in the prior art.
In order to achieve the purpose, the invention provides an electrode depth measurement system of an electrode for an ore-smelting furnace, which comprises a protection tube, a sensing rod, a transducer and an operation control device; the sensing rod is placed in a protection pipe, the protection pipe and the sensing rod are embedded and run through the electrode for the submerged arc furnace, the protection pipe and the sensing rod can be consumed synchronously along with the electrode for the submerged arc furnace, and inert gas, nitrogen, carbon dioxide or mixed gas of the inert gas, the nitrogen and the carbon dioxide are introduced into the protection pipe; the transducer is positioned on the upper end face and/or the side face of the sensing rod and is used for transmitting and/or receiving ultrasonic guided waves, and the ultrasonic guided waves are reflected on the end face of the sensing rod and transmitted along the sensing rod; the operation control device is electrically connected and in signal connection with the transducer and is used for obtaining the receiving time t and the speed v of the ultrasonic guided wave transmitted along the sensing rod through the transducer, calculating the total length H of the sensing rod according to the receiving time t of the ultrasonic guided wave and the speed v of the ultrasonic guided wave, and subtracting the length H of the electrode for the submerged arc furnace outside the submerged arc furnace from the total length H of the sensing rod to determine the depth D of the electrode for the submerged arc furnace in the submerged arc furnace.
Through the technical scheme, the sensing rod is reasonably arranged in the electrode for the submerged arc furnace, the characteristic that ultrasonic guided waves are reflected on the end face of the sensing rod is utilized, the length of the sensing rod is obtained by measuring the transmission time of reflected waves at the end part of the guided waves, and the sensing rod can be consumed along with the consumption of the electrode, namely, the length of the sensing rod is consistent with the length of the electrode, so that the length of the electrode and the depth of the electrode in the submerged arc furnace can be synchronously obtained, the defects of the measuring method for the depth of the electrode in the submerged arc furnace in the prior art, such as poor accuracy, the need of stopping production of the submerged arc furnace, incapability of continuous measurement, influence measurement of working conditions and submerged arc furnace burden, the need of manual intervention and the like are avoided, unexpected effects are obtained, the submerged arc furnace can be effectively and accurately obtained without stopping production of the submerged arc furnace or manual intervention, and data basis is provided for controlling the electrode, the purposes of optimizing process operation, saving electric energy, improving product quality and reducing safety risk are achieved.
As a further description of the electrode depth measurement system of the electrode for the submerged arc furnace according to the present invention, preferably, the electrode for the submerged arc furnace includes a self-baking electrode, a graphite electrode, and a carbon electrode.
As a further description of the electrode depth measurement system of the electrode for the submerged arc furnace, preferably, the transducer is an electromagnetic ultrasonic transducer and/or a magnetostrictive transducer and/or a piezoelectric transducer.
As a further description of the electrode depth measurement system of the electrode for the submerged arc furnace, it is preferable that the melting point of the protection tube is above 2000 ℃, and the protection tube is made of one or more of a metal material, graphite and/or a ceramic material; the metal material is selected from one or more of tungsten, molybdenum, rhenium, iridium, lanthanum and/or a mixture; the ceramic material is one or more of alumina, zirconia, magnesia, silicon carbide, molybdenum silicide, molybdenum carbide, titanium carbide monomer or mixture thereof, zirconia or alumina aerogel and/or aerogel fiber.
Through the technical scheme, through a plurality of times of experimental researches of the inventor, the selected material of the protection tube has the advantage of synchronous consumption with the electrode for the submerged arc furnace, so that the length of the sensing rod arranged in the protection tube is ensured, the close correlation between the length of the electrode for the submerged arc furnace and the depth of the electrode in the submerged arc furnace is ensured, and the accuracy of the electrode depth measurement is further ensured. Furthermore, the metal material can be used for preventing the protection tube from being broken by the ball-shaped electrode paste, and can also be used for preventing the paste-shaped electrode paste from corroding the protection tube, and the graphite material can be used for supporting the lower end part of the protection tube, so that the protection tube can be kept smooth at high temperature, and the metal tube molten material can be prevented from blocking the protection tube. The ceramic material can be used for preventing the sensing rod from generating chemical reaction with graphite at high temperature, so as to achieve the purpose of early fusing. The protection tube is regular and/or irregular tubular, and comprises one or more of but not limited to square tubes, round tubes, oval tubes, polygonal tubes and irregular tubes.
As a further description of the electrode depth measurement system of the electrode for the submerged arc furnace, preferably, the melting point of the sensing rod is above 2000 ℃, and the material of the sensing rod is one or more of a metal material, graphite and/or a ceramic material; the metal material is selected from one or more of tungsten, molybdenum, rhenium, iridium, lanthanum and/or a mixture; the ceramic material is selected from one or more of monomers and/or mixtures of aluminum oxide, zirconium oxide, magnesium oxide, silicon carbide and molybdenum silicide.
Through the technical scheme, through a plurality of times of experimental researches of the inventor, the material of the selected sensing rod can ensure that the sensing rod has good ultrasonic guided wave transmission and reflection performance, and on one hand, the problem that the sensing rod is difficult to form reflected waves due to absorption of ultrasonic guided waves because the sensing rod is melted in the electrode for the submerged arc furnace is avoided; on the other hand, the sensing rod is made of a high-temperature easily-oxidized material, so that the part of the sensing rod, which exceeds the electrode end head, can be oxidized by furnace gas at high temperature, the sensing rod and the electrode for the submerged arc furnace are consumed together, the purpose of indicating the position of the electrode is achieved, and the accuracy of measuring the depth of the electrode in the submerged arc furnace is ensured.
As a further description of the electrode depth measurement system of the electrode for the submerged arc furnace according to the present invention, preferably, the melting point of the sensing rod is 2200 ℃ or higher, and the material of the sensing rod is one or more of graphite, alumina, zirconia, magnesia, tungsten, and molybdenum, which are single or mixed.
By adopting the technical scheme, the sensing rod with the melting point of more than 2000 ℃, preferably 2200 ℃ is placed in the through hole, and when the sensing rod passes through the middle hole of the electrode and reaches the position of the interface of the lower end face of the electrode and the cavity, the protruding part is rapidly melted and oxidized. When the electrode is gradually consumed, the sensing rod can be synchronously consumed along with the electrode in the submerged arc furnace, the length of the sensing rod represents the length of the electrode, and the depth of the electrode inserted into the furnace can be calculated by measuring the length of the sensing rod and the depth outside the furnace of the electrode.
As a further description of the electrode depth measurement system of the electrode for the submerged arc furnace, preferably, a groove or a protrusion is arranged on the sensing rod at intervals of Δ L for reflecting the ultrasonic guided wave; the groove or protrusion closest to the lower end surface of the sensing rod is an nth groove or protrusion, the distance from the groove or protrusion to the lower end surface of the sensing rod is S, and S < delta L; the ultrasonic guided waves are transmitted along the sensing rod, and each groove generates a reflected wave; the total length H of the sensing rod is as follows:
(1) the distance from the top end of the sensing rod to the lowest end groove or protrusion is as follows: n × Δ L;
(2) the nth groove or protrusion of the sensing rod is distanced from the lower section of the sensing rod
Total length of the sensing rod
Wherein, the first and the second end of the pipe are connected with each other,
the lower end average speed of the ultrasonic guided wave is obtained; ts is the receiving time of the reflected wave of the lower end surface of the sensing rod; tn is the receiving time of the reflection wave of the nth groove or protrusion;
(3) the depth D of the electrode for the submerged arc furnace in the submerged arc furnace is H-H;
the distance from the lower end part of the electrode for the submerged arc furnace to the furnace bottom is as follows: d is L-D;
wherein H is the total length of the sensing rod; h is the length of the electrode outside the submerged arc furnace, and the length is obtained through measurement; l is the total depth of the submerged arc furnace; s, H, DeltaL, h, D, D, L units are all meter (m); ts and tn are both seconds(s);
the unit is meter/second (m/s).
As a further description of the electrode depth measurement system of the electrode for the submerged arc furnace, preferably, the operation control device comprises an operation control module, the operation control module is electrically connected and signal-connected with the high-power ultrasonic excitation module, the high-power ultrasonic excitation module is electrically connected and signal-connected with the sensor matching circuit, the sensor matching circuit is respectively electrically connected and signal-connected with the transducer and the band-pass filter circuit, the band-pass filter circuit is electrically connected and signal-connected with the gain adjustment circuit, the gain adjustment circuit is electrically connected and signal-connected with the digital acquisition circuit, the digital acquisition circuit is electrically connected and signal-connected with the operation control module, and the operation control module is signal-connected with the human-computer interaction module through the communication module; the operation control module sends a trigger instruction to the high-power ultrasonic excitation module, the high-power ultrasonic excitation module generates a trigger signal, the trigger signal acts on the transducer through the sensor matching circuit so that the transducer generates an ultrasonic guided wave signal, the ultrasonic guided wave signal is transmitted and reflected on the surface of the sensing rod, the transducer receives a reflected wave and converts the reflected wave into an electric signal, the electric signal is transmitted to the band-pass filter circuit through the sensor matching circuit and then transmitted to the digital acquisition circuit through the gain adjustment circuit for filtering and amplification, finally the digital acquisition circuit uploads the ultrasonic guided wave reflection data to the operation control module, the operation control module processes the ultrasonic guided wave reflection data, time and/or distance parameters are calculated, and a data processing result is transmitted to the human-computer interaction module through the communication module; the human-computer interaction module can reversely adjust preset parameters in the operation control module through a feedback mechanism so as to improve the data processing precision.
As a further description of the electrode depth measurement system of the electrode for the submerged arc furnace, preferably, the human-computer interaction module comprises a remote human-computer interaction module and/or an on-site human-computer interaction module; the remote human-computer interaction module is positioned at the far end of the electrode depth measurement system, and the local human-computer interaction module is positioned at the near end of the electrode depth measurement system.
As a further description of the electrode depth measurement system of the electrode for the submerged arc furnace, preferably, the electrode depth measurement system further comprises a protective gas generator, a gas pressure regulating device and/or a one-way valve, wherein the protective gas generator is connected with the gas pressure regulating device, the gas pressure regulating device is connected with the one-way valve, and the one-way valve extends into the protective pipe; the protective gas generator generates protective gas, the pressure of the protective gas is changed through the gas pressure adjusting device, and the protective gas is sent to the periphery of the sensing rod through the one-way valve so as to protect the sensing rod from being oxidized at high temperature. In order to achieve another object of the present invention, the present invention further provides a submerged arc furnace inner electrode depth measurement method using the electrode depth measurement system for the submerged arc furnace inner electrode, wherein the submerged arc furnace inner electrode depth measurement method comprises the following steps:
step S1): arranging a groove or a protrusion on the sensing rod at intervals of delta L, wherein the groove or the protrusion closest to the lower end surface of the sensing rod is an nth groove or protrusion, the distance from the groove or the protrusion to the lower end surface of the sensing rod is S, and S is less than delta L;
step S2): acquiring the total length H of the sensing rod through the operation control device; wherein, the distance from the top end of the sensing rod to the lowest end of the groove or the protrusion is as follows: n × Δ L; the nth groove or protrusion of the sensing rod is away from the lower end face of the sensing rod
The total length of the sensing rod
The lower end average speed of the ultrasonic guided wave is obtained; ts is the receiving time of the ultrasonic guided wave reflected by the lower end face of the sensing rod; tn is the receiving time of the nth groove or protrusion for reflecting the ultrasonic guided wave;
step S3): measuring to obtain the length H of the electrode for the submerged arc furnace outside the submerged arc furnace, wherein the depth D of the electrode for the submerged arc furnace in the submerged arc furnace is H-H; the distance from the lower end part of the electrode for the submerged arc furnace to the furnace bottom is as follows: d is L-D, L is the total depth of the submerged arc furnace; wherein S, H, delta L, h, D, D and L are all meters (m); ts and tn are both seconds(s);
the unit is meter/second (m/s).
Through the technical scheme, in the operating environment of the submerged arc furnace, the temperature of the electrode is gradually increased along with the increase of the depth of the electrode in the furnace. Meanwhile, the transmission speed of the ultrasonic guided waves on the sensing rod is obviously changed along with the increase of the temperature. Because the transmission speed of the ultrasonic guided wave is not constant, in order to improve the measurement accuracy of the length of the sensing rod, the sensing rod is segmented, the number of grooves or protrusions and the average speed of the lower end of the ultrasonic guided wave are respectively obtained, and the measurement accuracy is improved along with the reduction of the delta L. The longitudinal section of the groove or the protrusion is selected from one or more of a triangle, a circle or a fan, a square, a polygon and/or an irregular shape; wherein Δ L/total sensing rod length H may be greater than 1/30, or Δ L/total sensing rod length H may be greater than 1/20. The value of Δ L depends on the length of the ultrasonic pulse, and when Δ L/total length of the sensing rod is too small, the ultrasonic guided wave signals reflected by different grooves easily overlap, so that the reflected signals of the grooves are difficult to distinguish. The control of the size of the delta L is beneficial to realizing the statistics of the reflection number of the ultrasonic guided waves, and then the number of grooves or protrusions on the sensing rod after oxidation consumption is obtained.
The invention has the following beneficial effects: the electrode depth measuring system of the electrode for the submerged arc furnace obtains the length of the sensing rod by reasonably arranging the sensing rod in the electrode for the submerged arc furnace and utilizing the characteristic that the ultrasonic guided wave has reflection on the end surface, the groove or the protrusion of the sensing rod, obtains the length of the sensing rod by measuring the transmission time of the reflected wave at the end part of the guided wave, and simultaneously utilizes the consumption of the sensing rod along with the consumption of the electrode, namely the length of the sensing rod is kept consistent with the length of the electrode, so that the length of the electrode and the depth of the electrode in the submerged arc furnace can be synchronously obtained, the defects of the measuring method for the depth of the electrode in the submerged arc furnace in the prior art, such as poor precision, need to stop the production and stop the submerged arc furnace, incapability of continuous measurement, influence measurement of working conditions and submerged arc furnace burden, need of manual intervention and the like, unexpected effects are obtained, and the depth of the electrode in the submerged arc furnace can be effectively and accurately obtained without stopping the production and stopping the submerged arc furnace or manual intervention, therefore, data basis is provided for the control electrode, the purposes of optimizing process operation, saving electric energy, improving product quality and reducing safety risk are achieved, and great social and economic benefits can be generated.
Drawings
FIG. 1 is a schematic diagram of the temperature curve of the electrode for the submerged arc furnace of the present invention.
Fig. 2 is a side view of the electrode depth measuring system of the electrode for the submerged arc furnace in the submerged arc furnace.
Fig. 3 is a top view of the electrode depth measuring system of the electrode for the submerged arc furnace in the submerged arc furnace.
Fig. 4 is a schematic view of the shape of the protective tube and sensing rod of the present invention.
FIG. 5 is a diagram of the placement of a transducer of the present invention.
FIG. 6 is a diagram of the groove placement and calculation scheme of the present invention.
Fig. 7 is a schematic structural diagram of an electrode depth measurement system of the electrode for the submerged arc furnace.
Detailed Description
To further understand the structure, characteristics and other objects of the present invention, the following detailed description is given with reference to the accompanying preferred embodiments, which are only used to illustrate the technical solutions of the present invention and are not to limit the present invention.
The high temperature in the ore smelting furnace is generally a huge industrial electric ore smelting furnace, for example, the ore smelting furnace is a device for conveying energy to the ore smelting furnace by means of three self-baking electrodes so as to smelt ore smelting charge materials. As shown in fig. 2 and fig. 3, fig. 3 is a sectional view taken along the direction of a-a of fig. 2, and three electrodes are uniformly arranged in the submerged arc furnace in a shape like a Chinese character 'ji', wherein the submerged arc furnace comprises an electrode 201 for the submerged arc furnace, a submerged arc furnace body 202 and a submerged arc furnace charge 203. The electrode is embedded into the ore-smelting furnace charge to release the electric arc for smelting the ore-smelting furnace charge.
As shown in fig. 2-5, the invention provides an electrode depth measurement system of an electrode for a submerged arc furnace, which comprises an electrode 201 for the submerged arc furnace, a protection tube 101, a sensing rod 102, a transducer 103 and an operation control device; the sensing rod 102 is placed in the protection pipe 101, the protection pipe 101 and the sensing rod 102 are embedded and run through the electrode 201 for the submerged arc furnace, the protection pipe 101 and the sensing rod 102 can be consumed synchronously along with the electrode 201 for the submerged arc furnace, and inert gas, nitrogen, carbon dioxide or mixed gas of the inert gas, the nitrogen and the carbon dioxide are introduced into the protection pipe 101; the inert gas includes but is not limited to one or more of helium, neon, argon, krypton, xenon, radon; transducer 103 is located on the upper end and/or side of sensing shaft 102, as shown in FIG. 5, FIG. 5 is an enlarged view at I of FIG. 2, FIG. 5, I-1, shows transducer 103 located on the upper end of sensing shaft 102, FIG. 5, I-2, shows transducer 103 located on the side of sensing shaft 102, transducer 103 being used to transmit and/or receive guided ultrasonic waves that are reflected at the end of sensing shaft 102 and transmitted along sensing shaft 102; the operation control device is electrically connected and in signal connection with the transducer 103, and is used for acquiring the receiving time and speed of the ultrasonic guided waves transmitted along the sensing rod 102 through the transducer 103, calculating the length of the sensing rod 102, and calculating the depth of the electrode 201 for the submerged arc furnace in the submerged arc furnace based on the length of the sensing rod 102. Specifically, the total length H of the sensing rod is calculated according to the receiving time t of the ultrasonic guided wave and the velocity v of the ultrasonic guided wave, and the total length H of the sensing rod is subtracted by the length H of the electrode for the submerged arc furnace outside the submerged arc furnace to determine the depth D of the electrode for the submerged arc furnace in the submerged arc furnace. Preferably, the electrode 201 for the submerged arc furnace includes a self-baking electrode, a graphite electrode, and a carbon electrode.
The sensing rod is placed in a narrow space formed inside the electrode for the submerged arc furnace, and due to the fact that electromagnetic waves, sound waves and ultrasonic waves are all transmitted in a fan shape, echoes cannot be obtained through the narrow space. Meanwhile, because the lower end part of the electrode is high in temperature and has a cavity, the infrared ray and the laser cannot effectively acquire the reflected light wave, and the length of the space cannot be acquired. Therefore, a wave capable of being transmitted in a narrow space is sought, and the spatial length is obtained by echo time. The guided wave has the capability of transmitting along the surface of an object, and the transmission path and space of the guided wave depend on the shape of the conductor, so that the purpose of acquiring echo signals through a narrow space is achieved. The waveguide electromagnetic guided wave and the ultrasonic guided wave, wherein the electromagnetic guided wave needs to reflect electromagnetic waves by means of substances with different dielectric constants of peripheral media, and because the dielectric constant of a carbon material is far larger than that of a cavity at the lower end part of an electrode, an echo cannot be obtained at the junction of carbon and the cavity.
The ultrasonic guided wave has the capability of transmitting along the surface of the sensing rod, and is generally used for detecting defects such as corrosion, cracks and the like of a pipeline in the prior art. The invention utilizes the characteristic that ultrasonic guided waves are reflected on the end surface, the groove or the protrusion of the sensing rod, obtains the length of the sensing rod by measuring the transmission time of reflected waves at the end part of the guided waves, and simultaneously obtains the length of the electrode and the depth of the electrode in the submerged arc furnace synchronously by utilizing the consumption of the sensing rod along with the consumption of the electrode, namely the length of the sensing rod is consistent with the length of the electrode.
Since the ultrasonic guided waves interfere with the end of the sensing rod if being in close contact with other objects in the transmission process along the sensing rod, which leads to misjudgment of the length of the sensing rod, the sensing rod can be protected by using a protection tube. The protective tube also has the functions of preventing the electrode paste and other objects from wrapping the sensing rod and preventing the ultrasonic wave from being absorbed and not receiving echo signals; meanwhile, the protective tube can be used for transmitting protective gas, so that the sensing rod is prevented from being oxidized by other substances at high temperature in advance and being consumed. The protective gas selected by the invention has the capability of not generating chemical reaction with the sensing rod in a high-temperature environment, and simultaneously protects the sensing rod in the protective tube from being isolated from air and submerged arc furnace gas and not oxidized. In the invention, the lower end part of the sensing rod is positioned in the cavity of the ore-smelting furnace burden, the cross section of the cavity is far larger than that of the protection tube, the protective gas loses the high-temperature protection effect on the sensing rod, the substances quickly oxidize the sensing rod at high temperature, so that the lower end surface of the sensing rod is flush with the lower end surface of the protection tube, and the materials of the protection tube, such as metal, graphite, ceramic and the like, react with the high-temperature gas in the cavity, so that the protection tube is flush with the lower end surface of the electrode, thereby ensuring the realization of the electrode depth measurement. Because the effect of the furnace gas can lead to the early oxidation of the sensing rod, the inert gas or the nitrogen is introduced into the through hole, the influence of high-temperature oxidation on the measurement precision can be prevented, the temperature in the through hole can be further reduced, the temperature difference between the through hole and the cavity is increased, and the measurement precision is improved. Meanwhile, the protective gas is introduced into the protective tube, so that whether the protective tube is in a smooth state can be indicated, and the pressure of the protective gas in the protective tube is increased if the end head is melted; and also has the function of blowing off the end head which is temporarily blocked.
In addition, a groove or protrusion is provided on the sensing rod 102 at intervals Δ L for reflecting the ultrasonic guided waves, as shown in FIG. 6; the groove or protrusion closest to the lower end surface of sensing rod 102 is the nth groove or protrusion, which is located a distance S from the lower end surface of sensing rod 102, S < Δ L; the ultrasonic guided waves propagate along the sensing rod 102, and each groove or protrusion generates a reflected wave.
The total length H of the sensing rod is:
(1) the distance from the top end of the sensing rod to the lowest end groove or protrusion is: n × Δ L;
(2) the nth groove or protrusion of the sensing rod is spaced from the lower section of the sensing rod
Total length of sensing rod
Wherein the content of the first and second substances,
the lower end average speed of the ultrasonic guided wave is obtained;
ts is the receiving time of the reflected wave of the lower end surface of the sensing rod; tn is the receiving time of the reflection wave of the nth groove or protrusion;
(3) the depth D of the electrode in the submerged arc furnace is H-H;
the distance from the lower end part of the electrode 201 for the submerged arc furnace to the furnace bottom is as follows: D-L-D;
wherein H is the total length of the sensing rod; h is the length of the electrode outside the submerged arc furnace, and L is the total depth of the submerged arc furnace obtained through measurement; s, H, Delta L, h, D, D, L units are all meter (m); ts and tn are both seconds(s);
the unit is meter/second (m/s).
In the operating environment of the submerged arc furnace, the temperature of the electrode is gradually increased along with the increase of the depth of the electrode in the furnace. Meanwhile, the transmission speed of the ultrasonic guided waves on the sensing rod is obviously changed along with the increase of the temperature. Because the transmission speed of the ultrasonic guided wave is not constant, in order to improve the measurement accuracy of the length of the sensing rod, the sensing rod is segmented, the number of grooves or protrusions and the average speed of the lower end of the ultrasonic guided wave are respectively obtained, and the measurement accuracy is improved along with the reduction of the delta L. The longitudinal section of the groove or the protrusion is selected from one or more of a triangle, a circle or a fan, a square, a polygon and/or an irregular shape; wherein Δ L/total sensor rod length H may be greater than 1/30, or Δ L/total sensor rod length H may be greater than 1/20. The value of Δ L depends on the length of the ultrasonic pulse, and when Δ L/total length of the sensor rod is too small, the ultrasonic guided wave signals reflected by different grooves easily overlap, making it difficult to distinguish the reflected signals of the grooves. The control of the size of the delta L is beneficial to realizing the statistics of the reflection number of the ultrasonic guided waves, and then the number of grooves or protrusions on the sensing rod after oxidation consumption is obtained.
The temperature in the submerged arc furnace is very high, for example, the temperature of the end part of an electrode of the submerged arc furnace is as high as 1600-2200 ℃, the electrode is also buried in submerged arc furnace burden, any sensor cannot survive in the environment, and moreover, the electrode is made of graphitized carbon material and has the length of about 15-20 meters, and any electromagnetic wave, sound wave, light wave and terahertz wave cannot penetrate through the electrode. The outside of the electrode is protected by the ore-smelting furnace charge, the ore-smelting furnace brick and the ore-smelting furnace body steel plate, even if X rays, alpha rays, beta rays, gamma rays and neutron rays are adopted, the penetration can be realized only by carrying out electron acceleration, the cost is about 500 plus 1000 ten thousand, the cost is not acceptable in economy, and meanwhile, the ray pollution is brought. The system for measuring the electrode depth by utilizing the ultrasonic guided wave can penetrate through a thick and heavy electrode to reach the end part of the electrode, can send a wave signal for detection to the end part of the electrode, and can obtain an echo signal. Therefore, the length of the electrode is measured, and the depth of the electrode in the submerged arc furnace is further measured.
Preferably, as shown in fig. 7, the operation control device includes an operation control module 110, the operation control module 110 is electrically connected and signal-connected with a high-power ultrasonic excitation module 105, the high-power ultrasonic excitation module 105 is electrically connected and signal-connected with a sensor matching circuit 104, the sensor matching circuit 104 is respectively electrically connected and signal-connected with a transducer 103 and a band-pass filter circuit 107, the band-pass filter circuit 107 is electrically connected and signal-connected with a gain adjustment circuit 108, the gain adjustment circuit 108 is electrically connected and signal-connected with a digital acquisition circuit 109, the digital acquisition circuit 109 is electrically connected and signal-connected with the operation control module 110, and the operation control module 110 is signal-connected with a human-computer interaction module through a communication module 111; wherein, the operation control module 110 sends a trigger instruction to the high-power ultrasonic excitation module 105, the high-power ultrasonic excitation module 105 generates a trigger signal, the trigger signal acts on the transducer 103 through the sensor matching circuit 104, so that the transducer 103 generates ultrasonic guided wave signals which are transmitted and reflected on the surface of the sensing rod 102, the transducer 103 receives reflected waves and converts the reflected waves into electric signals, the electric signals are transmitted to the band-pass filter circuit 107 through the sensor matching circuit 104 and then transmitted to the digital acquisition circuit 109 through the gain adjusting circuit 108 for filtering and amplification, finally the digital acquisition circuit 109 uploads ultrasonic guided wave reflection data to the operation control module 110, the operation control module 110 processes the ultrasonic guided wave reflection data, time and/or distance parameters are calculated, and data processing results are transmitted to the man-machine interaction module through the communication module 111; the human-computer interaction module may also reversely adjust preset parameters in the operation control module 110, including the terminal sound velocity, through a feedback mechanism, so as to improve the data processing precision. The man-machine interaction module can adjust operation definite values in the operation control module, such as data of delta L length, average sound velocity of the lower end part of the sensing rod and measurement period, and the operation result is influenced.
The human-computer interaction module comprises a remote human-computer interaction module 112 and/or an on-site human-computer interaction module 113; the remote human-computer interaction module 112 is located at the far end of the electrode depth measurement system, and the in-situ human-computer interaction module 113 is located at the near end of the electrode depth measurement system.
Preferably, as shown in fig. 7, the electrode depth measurement system further includes a shielding gas generator 114, a gas pressure regulating device 115 and/or a one-way valve 116, the shielding gas generator 114 is connected to the gas pressure regulating device 115, the gas pressure regulating device 115 is connected to the one-way valve 116, and the one-way valve 116 extends into the protection tube 101; wherein, the protective gas generator 114 generates protective gas, which is pressure-converted by the gas pressure regulator 115 and sent to the outer circumference of the sensor rod 102 through the check valve 116, so as to protect the sensor rod 102 from being oxidized at high temperature.
Preferably, the transducer 103 is an electromagnetic ultrasonic transducer and/or a magnetostrictive transducer and/or a piezoelectric transducer.
Preferably, the melting point of the protection tube 101 is above 2000 ℃, and the protection tube 101 is made of one or more of metal material, graphite and/or ceramic material; the metal material is selected from one or more of tungsten, molybdenum, rhenium, iridium, lanthanum and/or a mixture; the ceramic material is one or more of alumina, zirconia, magnesia, silicon carbide, molybdenum silicide, molybdenum carbide, titanium carbide monomer or mixture thereof, zirconia or alumina aerogel and/or aerogel fiber.
Through a plurality of times of experimental researches of the inventor, the selected material of the protection tube has the advantage of synchronous consumption with the electrode for the submerged arc furnace, so that the length of the sensing rod arranged in the protection tube is ensured, the close correlation between the length of the electrode for the submerged arc furnace and the depth of the electrode in the submerged arc furnace is ensured, and the accuracy of the electrode depth measurement is further ensured. Furthermore, the metal material can be used for preventing the protection tube from being broken by the ball-shaped electrode paste, and meanwhile, the graphite material can be used for supporting the lower end part of the protection tube, so that the protection tube can be kept smooth at high temperature, and the metal tube melt can be prevented from blocking the protection tube. The ceramic material can be used for preventing the sensing rod from generating chemical reaction with graphite at high temperature, so as to achieve the purpose of early fusing. The protection tube is in a regular and/or irregular tubular shape, including but not limited to one or more of a square tube, a round tube, an oval tube, a polygonal tube, and an irregular-shaped tube, as shown in fig. 4, fig. 4 is an enlarged view of fig. 3 at ii, fig. 4 ii-1 shows an example where the protection tube 101 is a round tube, and fig. 4 ii-2 shows an example where the protection tube 101 is a square tube.
Preferably, the melting point of sensing rod 102 is above 2000 ℃, and sensing rod 102 is made of one or more of a metal material, graphite, and/or a ceramic material; the metal material is selected from one or more of tungsten, molybdenum, rhenium, iridium, lanthanum and/or a mixture; the ceramic material is selected from one or more of monomers and/or mixtures of alumina, zirconia, magnesia, silicon carbide, molybdenum silicide. Preferably, the melting point of the sensing rod 102 is 2200 ℃ or higher, and the material of the sensing rod 102 is one or more of graphite, alumina, zirconia, magnesia, tungsten, molybdenum, and/or a mixture thereof.
Through a plurality of times of experimental researches of an inventor, the material of the selected sensing rod can ensure that the sensing rod has good ultrasonic guided wave transmission and reflection performance, and on one hand, the problem that the sensing rod is difficult to form reflected waves due to absorption of ultrasonic guided waves caused by melting in an electrode for a submerged arc furnace is avoided; on the other hand, the sensing rod is made of a high-temperature easily-oxidized material, so that the part of the sensing rod, which exceeds the electrode end head, can be oxidized by furnace gas at high temperature, the sensing rod and the electrode for the submerged arc furnace are consumed together, the purpose of indicating the position of the electrode is achieved, and the accuracy of measuring the depth of the electrode in the submerged arc furnace is ensured.
When the electrode of the submerged arc furnace works, the electrode can be arranged at the end of the electrode under the action of electric arc and gas in the furnace
The cavity is formed, the size of the cavity is related to the variety and the furnace condition to be smelted, extremely high temperature and a large amount of gas are generated in the cavity due to arc discharge, the internal temperature of the electrode tip is about 2000-3000 ℃, the temperature is far lower than the temperature of the cavity, the lower end face of the electrode is at an arc starting position, the temperature in the cavity rises sharply, the temperature is estimated to be 4000-10000 ℃, the schematic diagram of the electrode temperature curve is shown in figure 1, and the horizontal axis in figure 1 represents the temperature curve of the electrode H from the top end to the bottom end to the cavity. As can be seen from fig. 1, the position of the end of the extraction electrode is the position of the gas interface between the extraction electrode and the cavity.
According to the invention, a through hole is pre-buried from the inside of the electrode, and through research of the inventor, a sensing rod (shown in figure 2) with the melting point of more than 2000 ℃, preferably 2200 ℃ is placed in the through hole, and after the sensing rod passes through the middle hole of the electrode, the sensing rod reaches the position of the interface between the lower end face of the electrode and the cavity, and the protruding part is rapidly melted and oxidized. When the electrode is gradually consumed, the sensing rod can be synchronously consumed along with the electrode in the submerged arc furnace, the length of the sensing rod represents the length of the electrode, and the depth of the electrode inserted into the furnace can be calculated by measuring the length of the sensing rod and the depth outside the furnace of the electrode.
The electrode depth measurement system of the electrode for the submerged arc furnace can be used for measuring the depth of the electrode in the electric arc submerged arc furnace and/or the resistance submerged arc furnace for smelting ores and carbonaceous reducing agents; preferably, the electrode depth measurement is performed in an iron alloy ore heating furnace, a calcium carbide ore heating furnace, a yellow phosphorus ore heating furnace, a silicon-calcium ore heating furnace, a silicon carbide ore heating furnace and/or an industrial silicon ore heating furnace. In the use process of the submerged arc furnace, the depth of the electrode inserted into the submerged arc furnace is very important for the smelting process. The smelting process requires that the power center and the geometric center of the three-phase electrode coincide and the insertion depth is reasonable, so that good smelting efficiency and low energy consumption can be obtained, the unreasonable depth position of the electrode also causes a raw material layer during roasting, the product quality is influenced, and accidents such as equipment damage and casualties caused by material spraying are easy to cause, so that the accurate acquisition of the insertion depth of the electrode is very necessary for the safe and efficient production of the smelting industry of the submerged arc furnace.
The invention also provides an electrode depth measurement method in the submerged arc furnace, which is realized by the electrode depth measurement system of the electrode for the submerged arc furnace, and comprises the following steps:
step S1): one groove or protrusion is placed on sensor rod 102 every Δ L, the groove or protrusion closest to the lower end surface of sensor rod 102 being the nth groove or protrusion, which is located at a distance S from the lower end surface of sensor rod 102, where S < Δ L; as shown in fig. 6.
Step S2): the overall length H of the sensor rod 102 is obtained by the arithmetic control unit.
Wherein the distance from the top end of the sensing rod 102 to the lowest end of the groove or protrusion is: n × Δ L; the nth groove or protrusion of the sensor rod 102 is spaced from the lower end surface of the sensor rod 102
The overall length of the sensor rod 102
The lower end average speed of the ultrasonic guided wave is obtained; ts is the receiving time of the reflected ultrasonic guided waves at the lower end surface of the sensing rod 102; and tn is the receiving time of the nth groove or protrusion for reflecting the ultrasonic guided wave.
Step S3): and measuring to obtain the length H of the electrode 201 for the submerged arc furnace outside the submerged arc furnace, wherein the depth D of the electrode 201 for the submerged arc furnace in the submerged arc furnace is H-H, and the distance from the lower end part of the electrode 201 for the submerged arc furnace to the furnace bottom is as follows: and D is L-D, and L is the total depth of the submerged arc furnace.
The units of S, H, Delta L, h, D, D and L are all meters (m); ts and tn are both seconds(s);
the unit is meter/second (m/s).
Example 1
The invention discloses an electrode depth measurement system of an electrode for a submerged arc furnace, which comprises the following steps:
the electrode depth measurement system comprises a protection tube 101, a sensing rod 102, a transducer 103, a sensor matching circuit 104, a high-power ultrasonic excitation module 105, a storage module 106, a band-pass filter circuit 107, a gain adjusting circuit 108, a digital acquisition circuit 109, an operation control module 110, a communication module 111, a remote human-computer interaction module 112, an on-site human-computer interaction module 113, a protective gas generator 114, a gas pressure adjusting device 115 and a one-way valve 116.
The protection tube 101 is pre-buried and penetrates through the electrode 201 for the submerged arc furnace, the electrode 201 for the submerged arc furnace is a self-baking electrode, and the protection tube 101 is made of graphite and is a square tube with the side length of 30 mm; the sensing rod 102 is made of tungsten, and has a cross section with a length-diameter ratio of 2.5 mm to 2: 1, an oval column shape, which is placed in the protection tube 101; transducer 103 is mounted on the side end face of sensor shaft 102 as shown in figure 5, I-2.
The remote human-computer interaction module 112 and the local human-computer interaction module 113 transmit a data acquisition command to the operation control module 111 through the communication module 111, software in the operation control module 110 sends a signal to the high-power ultrasonic excitation module 105 to generate a trigger signal, the trigger signal acts on the transducer 103 through the sensor matching circuit 104, the transducer 103 converts an electric signal into an ultrasonic signal, the ultrasonic signal is transmitted to the lower end face through the sensing rod 102 to generate a reflection echo, the transducer 103 converts the reflection echo into an electric signal and transmits the electric signal to the sensor matching circuit 104 to the band-pass filter circuit 107, the electric signal is transmitted to the digital acquisition circuit 109 through the gain adjustment circuit 108 to be filtered and amplified, and the storage module 106 uploads the data to the operation control module 110.
The operation control module 110 processes the ultrasonic guided wave reflection data to calculate data such as time, distance and the like, for example, the receiving time t of the ultrasonic guided wave and the like, and obtains the total length of the sensing rod according to a formula, that is, t × v/2, in combination with the ultrasonic guided wave velocity v; and according to the custom data H measured by the pull rope distance meter, obtaining the depth of the electrode in the submerged arc furnace by using the formula of electrode depth D ═ H-H.
The calculation control module directly transmits the calculated time and distance, including data such as the length of the sensing rod and the depth of the electrode in the submerged arc furnace, to the remote man-machine interaction module 112 through the communication module 111 or to the local man-machine interaction module 113 through the communication module 111.
The human-computer interaction module (the remote human-computer interaction module 112 and the local human-computer interaction module 113) can transmit the set fixed value to the operation control module, so that customization in the operation control module is changed, and the software in the operation control module can calculate data such as time, distance and the like conveniently.
Example 2
The invention relates to another embodiment of an electrode depth measurement system of an electrode for an ore-smelting furnace, which comprises the following steps:
the electrode depth measurement system comprises a protection tube 101, a sensing rod 102, a transducer 103, a sensor matching circuit 104, a high-power ultrasonic excitation module 105, a storage module 106, a band-pass filter circuit 107, a gain adjusting circuit 108, a digital acquisition circuit 109, an operation control module 110, a communication module 111, a remote human-computer interaction module 112, an on-site human-computer interaction module 113, a protective gas generator 114, a gas pressure adjusting device 115 and a one-way valve 116. The protection pipe 101 is pre-buried and penetrated in an electrode 201 for the submerged arc furnace, and the electrode 201 for the submerged arc furnace is a self-baking electrode and is a circular pipe with the diameter of 30 mm. This protection tube 101 is two-layer structure, and the skin is graphite material, and the inlayer is zirconia aerogel. The sensing rod 102 is made of molybdenum lanthanum alloy, has a cylindrical cross section with the diameter of 1.5 mm, and is placed in the protection tube 101; a groove for reflecting ultrasonic guided waves is formed every 100cm on the sensor rod 102, the longitudinal section of the groove is semicircular, and a transducer 103 is mounted on the upper end face of the sensor rod 102, as shown in FIG. 5I-1.
The shielding gas generator 114 generates a shielding gas, such as helium, which does not chemically react with the sensor rod in a high-temperature environment (hereinafter referred to as shielding gas). After the pressure of the protective gas is changed by the gas adjusting device 115, the protective gas is sent to the protective tube 101 through the one-way valve 116 to protect the sensor rod 102 at high temperature, while the ventilation pressure is kept at 1.05 atmosphere.
The remote human-computer interaction module 112 and the local human-computer interaction module 113 transmit a data acquisition command to the operation control module 111 through the communication module 111, software in the operation control module 110 sends a signal through the high-power ultrasonic excitation module 105 to enable the signal to generate a trigger signal, the trigger signal acts on the transducer 103 through the sensor matching circuit 104, the transducer 103 converts an electric signal into an ultrasonic signal, the ultrasonic signal is transmitted to the lower end face through the sensing rod 102 to generate a reflection echo, the transducer 103 converts the reflection echo into an electric signal and transmits the electric signal to the band-pass filter circuit 107, the electric signal is transmitted to the digital acquisition circuit 109 through the gain adjustment circuit 108 to be filtered and amplified, and then the data are uploaded to the operation control module 110; the operation control module 110 processes the ultrasonic guided wave reflection data to calculate data such as time and distance, for example:
and obtaining the groove closest to the lower end surface of the sensor as the nth groove according to the quantity of the reflected waves and the average speed of the ultrasonic guided waves. Acquiring the receiving time ts of the reflected wave of the lower end surface of the sensing rod and the receiving time tn of the reflected wave of the nth groove;
using the formula:
the total length of the sensor rod H4, H5, H6 is obtained.
And according to the custom data H measured by the laser range finder, obtaining the depth of the electrode in the submerged arc furnace by using the formula of electrode depth D ═ H-H.
The calculation control module directly transmits the calculated time and distance, including data such as the length of the sensing rod and the depth of the electrode in the submerged arc furnace, to the remote man-machine interaction module 112 through the communication module 111 or to the local man-machine interaction module 113 through the communication module 111.
The human-computer interaction module (the remote human-computer interaction module 112 and the local human-computer interaction module 113) can transmit the set fixed value to the operation control module, so that customization in the operation control module is changed, and the software in the operation control module can calculate data such as time, distance and the like conveniently.
Example 3
In a calcium carbide ore-smelting furnace with the temperature of about 1800-2200 ℃ and the capacity of 33000kVA scale, different test methods are adopted for self-baking electrodes, and the measurement results of the electrode depth are compared.
the self-baking electrode 1 was estimated from the electrode paste added daily and the rate of consumption by the accumulation method. The depth of the self-baked electrode in the submerged arc furnace was estimated on days 7, 14 and 21, respectively, to obtain electrode depths of about 1.3m, 0.9m and 0.6 m.
The invention provides an embodiment of an electrode depth measurement system and method of an electrode for a submerged arc furnace, which comprises the following steps:
a through protective tube is pre-embedded in the self-baking electrode 1, the outer layer of the protective tube is made of graphite, and the inner layer of the protective tube is an alumina coating. The protection tube is in a regular and/or irregular tubular shape, including but not limited to one or more of a square tube, a round tube, an oval tube, a polygonal tube and an irregular tube, and in the embodiment, the protection tube is a regular round tube with an inner diameter of 30 mm. The sensing rod is made of molybdenum, and is a circular solid column with the cross section diameter of 2mm and is placed in the protective tube; the transducer is a magnetostrictive transducer and is arranged on the upper end surface of the sensing rod.
The protective tube is internally communicated with protective gas nitrogen, the ventilation pressure is 1.05 atmospheric pressure, the protective gas can protect the sensing rod from being oxidized in the protective tube at high temperature, and simultaneously, the lower end face of the sensing rod is not protected along with the overflow of the protective gas on the lower end face of the sensing rod, so that the sensing rod is consumed due to oxidation and keeps the same length with a self-baking electrode.
Transmitting ultrasonic guided waves by using the transducers on the 7 th day, the 14 th day and the 21 st day respectively, so that the ultrasonic guided waves are transmitted along the sensing rod, the transmission speed of the ultrasonic guided waves is 5625m/s, the ultrasonic guided waves reach the bottom of the sensing rod and then are reflected, and the transducers receive the reflected waves and convert the reflected waves into electric pulse signals; obtaining the receiving time of the ultrasonic guided wave of 7.11ms, 6.90ms and 6.76ms, and obtaining the total length H of the sensing rod of 20m, 19.4m and 19m according to 1/2 of the product of the receiving time t of the ultrasonic guided wave and the velocity v of the ultrasonic guided wave; the length H of the electrode outside the submerged arc furnace is 18.75m, 18.28m and 18.00m measured by an infrared distance meter, and the depth H of the electrode inside the submerged arc furnace is 1.25m, 1.12m and 1.00m obtained by subtracting the length H of the electrode outside the submerged arc furnace from the total length H of the sensing rod.
And on the 7 th day, the 14 th day and the 21 st day respectively, after measuring the depth of the electrode by using the ultrasonic guided wave, stopping the submerged arc furnace, lifting the electrode to the lower end surface, exposing the submerged arc furnace material, and measuring the actual electrode lengths by using laser, wherein the actual electrode lengths are respectively 19.95m, 19.46m and 19.06 m. The actual depth of the electrode in the submerged arc furnace is 1.20m, 1.18m and 1.06m by combining the lengths h of the electrode outside the submerged arc furnace, which are respectively measured.
As can be seen from the following table 1, the method for measuring the electrode depth by using the ultrasonic guided wave has the accuracy of about 95 percent, is far higher than that of an accumulation method used in the prior art, can improve the product quality, can replace a shutdown submerged arc furnace, and has extremely high social and economic values.
TABLE 1
Example 4
In a calcium carbide ore-smelting furnace with the temperature of about 1800-2200 ℃ and the capacity of 33000kVA scale, different test methods are adopted for self-baking electrodes, and the measurement results of the electrode depth are compared.
for the self-baking electrode 2, a probe method is adopted, an iron drill rod is inserted into a touch electrode in the ore-smelting furnace, the end face of the electrode is detected by multiple times of insertion, and then the insertion depth of the electrode is calculated by applying the pythagorean theorem. The depth of the self-baking electrode in the ore furnace is calculated and measured on the 8 th day, the 16 th day and the 24 th day respectively, and the data of the electrode depth is obtained to be 1.2m, 1.0m and 0.9 m.
The invention provides another embodiment of the electrode depth measurement system and the method for the electrode for the submerged arc furnace, which comprises the following steps:
a through protection pipe is pre-buried in the self-baking electrode 2, and the protection pipe is a regular square pipe with the side length of 50 mm. The protective tube is made of graphite material. The sensing rod is made of tungsten-rhenium alloy, a rectangular solid column with the cross section of 5 mm and the width of 0.5 mm is placed in the protective tube, and the length of the column is 19 m; the transducer is a piezoelectric transducer and is arranged on the side end face of the sensing rod.
A groove is arranged on the sensing rod every 120cm and used for reflecting ultrasonic guided waves, the longitudinal section of the groove is in an equilateral triangle shape, and the transducer is arranged on the upper end face of the sensing rod. Meanwhile, due to the consumption of the self-baking electrode, the protective tubes and the sensing rods in the submerged arc furnace, the protective tubes and the sensing rods with the length of 1.2m are supplemented timely when the self-baking electrode is prepared by supplementing the electrode paste every day, and are connected with the embedded protective tubes and sensing rods through threads or welding.
The protective tube is filled with protective gas argon, and the ventilation pressure is 1.05 atmospheric pressure. The protective gas can protect the sensing rod from being oxidized in the protective tube at high temperature, and simultaneously, the lower end face of the sensing rod is not protected along with the overflow of the protective gas on the lower end face of the sensing rod, so that the sensing rod and the self-baking electrode are maintained to be in the same length due to the consumption of the protective gas caused by oxidation.
On the 8 th day, the 16 th day and the 24 th day, the transducer emits ultrasonic guided waves, the ultrasonic guided waves are transmitted along the sensing rod, after secondary and above reflected waves are filtered, the number of the received primary reflected waves is calculated to be 19, 18 and 19 respectively, and the number of the reflected waves of the lower end surface is subtracted to be 1, so that the grooves closest to the lower end surface of the sensing rod are the 18 th, 17 th and 18 th grooves. It can be seen that the grooves closest to the lower end face of the sensor rod are at distances of 21.6m, 20.4m, 21.6m from the upper end face of the sensor rod.
After simulation calculation, the average speed of the ultrasonic guided waves is measured at 3786m/s, and the receiving time of reflected waves of the lower end surface of the sensor rod is obtained at 11.83ms, 11.25ms and 11.57ms, and the receiving time of reflected waves of 18 th, 17 th and 18 th grooves at 8 th, 16 th and 24 th days is obtained at 11.41ms, 10.78ms and 11.41 ms.
Using the formula:
the total lengths of the sensing rods are respectively 22.40m, 21.29m and 21.90 m;
using a laser range finder to obtain the lengths h of the electrodes outside the ore-smelting furnace to be 21.12m, 20.11m and 20.75m respectively;
d ═ H-H; the depth of the electrode in the ore furnace is 1.28m, 1.18m and 1.15 m.
And on the 8 th day, the 16 th day and the 24 th day respectively, after the depth of the electrode is measured by using the ultrasonic guided wave, the submerged arc furnace is stopped, the electrode is lifted to the lower end surface, the submerged arc furnace material is exposed, and the actual electrode lengths are measured by using laser, wherein the actual electrode lengths are 22.42m, 21.32m and 21.87m respectively. The actual depth of the electrode in the submerged arc furnace is 1.30m, 1.21m and 1.12m by combining the lengths h of the electrode outside the submerged arc furnace, which are respectively measured.
As can be seen from the following table 2, the method for measuring the electrode depth by using the ultrasonic guided wave has the accuracy of more than 97 percent, is far higher than the probe method used in the prior art, can improve the product quality, can replace a shutdown submerged arc furnace, and has extremely high social and economic values.
TABLE 2
It should be noted that the above summary and the detailed description are intended to demonstrate the practical application of the technical solutions provided by the present invention, and should not be construed as limiting the scope of the present invention. Various modifications, equivalent substitutions, or improvements may be made by those skilled in the art within the spirit and principles of the invention. The scope of the invention is defined by the appended claims.
Claims (11)
1. An electrode depth measurement system of an electrode for a submerged arc furnace is characterized by comprising a protection tube (101), a sensing rod (102), an energy converter (103) and an operation control device; wherein, the first and the second end of the pipe are connected with each other,
the sensing rod (102) is placed in the protection pipe (101), the protection pipe (101) and the sensing rod (102) are embedded and run through the electrode (201) for the submerged arc furnace together, the protection pipe (101) and the sensing rod (102) can be consumed synchronously along with the electrode (201) for the submerged arc furnace, and inert gas, nitrogen, carbon dioxide or mixed gas of the inert gas, the nitrogen and the carbon dioxide are introduced into the protection pipe (101);
the transducer (103) is positioned on the upper end face and/or the side face of the sensing rod (102) and is used for transmitting and/or receiving ultrasonic guided waves, and the ultrasonic guided waves are reflected on the end face of the sensing rod (102) and transmitted along the sensing rod (102);
the operation control device is electrically connected and in signal connection with the transducer (103) and is used for acquiring receiving time t and speed v of ultrasonic guided waves transmitted along the sensing rod (102) through the transducer (103), calculating the total length H of the sensing rod according to the receiving time t of the ultrasonic guided waves and the speed v of the ultrasonic guided waves, and determining the depth D of the electrode for the submerged arc furnace in the submerged arc furnace by subtracting the length H of the electrode for the submerged arc furnace outside the submerged arc furnace from the total length H of the sensing rod.
2. The electrode depth measurement system of claim 1, wherein the submerged arc furnace electrode (201) comprises a self-baking electrode, a graphite electrode, and a carbon electrode.
3. The electrode sounding system according to claim 1, characterized in that the transducer (103) is an electromagnetic ultrasound transducer and/or a magnetostrictive transducer and/or a piezoelectric transducer.
4. The electrode depth sounding system according to claim 1, wherein the melting point of the protection tube (101) is above 2000 ℃, and the protection tube (101) is made of one or more of a metal material, graphite and/or a ceramic material; the metal material is selected from one or more of tungsten, molybdenum, rhenium, iridium, lanthanum and/or a mixture; the ceramic material is one or more of alumina, zirconia, magnesia, silicon carbide, molybdenum silicide, molybdenum carbide, titanium carbide monomer or mixture thereof, zirconia or alumina aerogel and/or aerogel fiber.
5. The electrode depth measurement system of claim 1, wherein the melting point of the sensing rod (102) is above 2000 ℃, and the material of the sensing rod (102) is one or more of a metal material, graphite and/or a ceramic material; the metal material is selected from one or more of tungsten, molybdenum, rhenium, iridium, lanthanum and/or a mixture; the ceramic material is selected from one or more of monomers and/or mixtures of alumina, zirconia, magnesia, silicon carbide, molybdenum silicide.
6. The electrode depth measurement system of claim 5, wherein the melting point of the sensing rod (102) is above 2200 ℃, and the sensing rod (102) is made of one or more of graphite, alumina, zirconia, magnesia, tungsten, molybdenum, and/or a mixture thereof.
7. The electrode depth measurement system of claim 1, wherein the sensor rod (102) is provided with a groove or protrusion at intervals of Δ L for reflecting the guided ultrasonic waves; the groove or protrusion closest to the lower end surface of the sensor rod (102) is the nth groove or protrusion at a distance S from the lower end surface of the sensor rod (102), S < Δ L; the guided ultrasonic waves being transmitted along the sensing rod (102), each of the grooves generating reflected waves;
the total length H of the sensing rod is as follows:
(1) the distance from the top end of the sensing rod to the lowest end groove or protrusion is as follows: n × Δ L;
(2) the nth groove or protrusion of the sensing rod is spaced from the lower section of the sensing rod
Total length of the sensing rod
Wherein, the first and the second end of the pipe are connected with each other,
the lower end average speed of the ultrasonic guided wave is obtained; ts is the receiving time of the reflected wave of the lower end surface of the sensing rod; tn is the receiving time of the reflection wave of the nth groove or protrusion;
(3) the depth D of the electrode for the submerged arc furnace in the submerged arc furnace is H-H;
the distance from the lower end part of the electrode (201) for the submerged arc furnace to the furnace bottom is as follows: d is L-D;
wherein H is the total length of the sensing rod; h is the length of the electrode for the submerged arc furnace outside the submerged arc furnace, and the length is obtained through measurement; l is the total depth of the submerged arc furnace; s, H, Delta L, h, D, D, L units are all meter (m); ts and tn are both seconds(s);
the unit is meter/second (m/s).
8. The electrode sounding system according to claim 1, wherein the operation control device comprises an operation control module (110), the operation control module (110) is electrically and signal-connected with the high-power ultrasonic excitation module (105), the high-power ultrasonic excitation module (105) is electrically and signal-connected with the sensor matching circuit (104), the sensor matching circuit (104) is respectively electrically and signal-connected with the transducer (103) and the band-pass filter circuit (107), the band-pass filter circuit (107) is electrically and signal-connected with the gain adjustment circuit (108), the gain adjustment circuit (108) is electrically and signal-connected with the digital acquisition circuit (109), the digital acquisition circuit (109) is electrically and signal-connected with the operation control module (110), and the operation control module (110) is signal-connected with the human-computer interaction module through the communication module (111); wherein the content of the first and second substances,
the operation control module (110) sends a trigger instruction to the high-power ultrasonic excitation module (105), the high-power ultrasonic excitation module (105) generates a trigger signal, the trigger signal acts on the transducer (103) through the sensor matching circuit (104) so that the transducer (103) generates an ultrasonic guided wave signal, the ultrasonic guided wave signal is transmitted and reflected on the surface of the sensing rod (102), and the transducer (103) receives a reflected wave and converts the reflected wave into an electric signal; the ultrasonic guided wave reflection data is transmitted to a band-pass filter circuit (107) through a sensor matching circuit (104), then transmitted to a digital acquisition circuit (109) through a gain adjustment circuit (108) for filtering and amplification, and finally the digital acquisition circuit (109) uploads the ultrasonic guided wave reflection data to an operation control module (110); the operation control module (110) processes the ultrasonic guided wave reflection data, calculates time and/or distance parameters, and transmits a data processing result to the man-machine interaction module through the communication module (111); the human-computer interaction module can also reversely adjust preset parameters in the operation control module (110) through a feedback mechanism so as to improve the data processing precision.
9. The electrode sounding system of claim 8, wherein the human-machine interaction module comprises a remote human-machine interaction module (112) and/or an in-situ human-machine interaction module (113); the remote human-computer interaction module (112) is located at the far end of the electrode depth measurement system, and the in-situ human-computer interaction module (113) is located at the near end of the electrode depth measurement system.
10. The electrode depth measurement system according to any one of claims 1 to 9, further comprising a shielding gas generator (114), a gas pressure regulating device (115) and/or a one-way valve (116); the protective gas generator (114) is connected with a gas pressure regulating device (115), the gas pressure regulating device (115) is connected with a one-way valve (116), and the one-way valve (116) extends into the protective pipe (101); wherein, the protective gas generator (114) generates protective gas, the pressure of the protective gas is changed by the gas pressure adjusting device (115), and the protective gas is sent to the periphery of the sensing rod (102) through the one-way valve (116) so as to protect the sensing rod (102) from being oxidized at high temperature.
11. A method for measuring electrode depth in a submerged arc furnace using the electrode depth measuring system according to any one of claims 1 to 10, wherein the method for measuring electrode depth in a submerged arc furnace comprises the steps of:
step S1): providing a groove or protrusion on the sensor rod (102) at intervals of Δ L, the groove or protrusion closest to the lower end surface of the sensor rod (102) being the nth groove or protrusion at a distance S from the lower end surface of the sensor rod (102), S < Δ L;
step S2): acquiring the total length H of the sensing rod (102) by the arithmetic control device;
wherein the distance from the top end of the sensing rod (102) to the lowest end of the groove or the protrusion is as follows: n × Δ L; the nth groove or protrusion of the sensor rod (102) is spaced from the lower end surface of the sensor rod (102)
The total length of the sensor rod (102)
The lower end average speed of the ultrasonic guided wave is obtained; ts is the receiving time of the ultrasonic guided wave reflected by the lower end surface of the sensing rod (102); tn is the receiving time of the nth groove or protrusion for reflecting the ultrasonic guided wave;
step S3): the length h of the electrode (201) for the submerged arc furnace outside the submerged arc furnace is obtained through measurement,
the depth D of the electrode (201) for the submerged arc furnace in the submerged arc furnace is H-H;
the distance from the lower end part of the electrode (201) for the submerged arc furnace to the furnace bottom is as follows: d is L-D, L is the total depth of the submerged arc furnace;
wherein S, H, delta L, h, D, D and L are all meters (m); ts and tn are both seconds(s);
the unit is meter/second (m/s).
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| CN115200774A (en) * | 2022-07-22 | 2022-10-18 | 北京超测智能系统有限公司 | Method and system for measuring or adjusting gas pressure in submerged arc furnace |
| CN115267764A (en) * | 2022-07-22 | 2022-11-01 | 北京超测智能系统有限公司 | Method and system for measuring electrode depth of submerged arc furnace |
| CN117213356A (en) * | 2023-11-09 | 2023-12-12 | 北京朗信智能科技有限公司 | Submerged arc furnace electrode position detection system and detection method |
| CN117782363A (en) * | 2024-02-27 | 2024-03-29 | 山东蓝孚高能物理技术股份有限公司 | Nondestructive measurement method and system for internal temperature of traveling wave electron accelerator |
| CN117782363B (en) * | 2024-02-27 | 2024-05-28 | 山东蓝孚高能物理技术股份有限公司 | Nondestructive measurement method and system for internal temperature of traveling wave electron accelerator |
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| CN115267764A (en) * | 2022-07-22 | 2022-11-01 | 北京超测智能系统有限公司 | Method and system for measuring electrode depth of submerged arc furnace |
| CN115200774B (en) * | 2022-07-22 | 2023-12-01 | 北京超测智能系统有限公司 | Method and system for measuring or adjusting gas pressure in submerged arc furnace |
| CN115267764B (en) * | 2022-07-22 | 2024-02-06 | 北京超测智能系统有限公司 | Method and system for measuring electrode depth of submerged arc furnace |
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