CN117213263A - Online detection method for air leakage rate of annular cooler - Google Patents
Online detection method for air leakage rate of annular cooler Download PDFInfo
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- CN117213263A CN117213263A CN202311263854.4A CN202311263854A CN117213263A CN 117213263 A CN117213263 A CN 117213263A CN 202311263854 A CN202311263854 A CN 202311263854A CN 117213263 A CN117213263 A CN 117213263A
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Abstract
The invention provides a method for detecting the air leakage rate of a ring cooler, which utilizes infrared imaging equipment to determine the relationship between the infrared imaging temperature difference of equipment in different areas of the ring cooler and the air leakage rate of the ring cooler by combining big data analysis and correction theoretical change rules through the phenomenon of different colors and different depths of temperature, and finally obtains real-time air leakage data of the ring cooler.
Description
Technical Field
The invention relates to the technical field of production processes of main furnace pellets for blast furnace ironmaking, in particular to an online detection method for the air leakage rate of a circular cooler applied to the process.
Background
The circular cooler is a large-scale device for cooling materials, and mainly adopts the working principle that high-temperature materials are loaded through a trolley, the trolley runs on an annular track, an air box is arranged at the lower part of the trolley, air is blown into the trolley, and the high-temperature materials are cooled through air. A plurality of blowers are arranged around the outer side of the circular ring of the circular cooler according to the air quantity demand, so as to provide air sources for the cooling process. The small granular materials to be cooled are uniformly distributed in a thick material layer form on the annular cooler, and in order to ensure the sufficient cooling of the materials, an air box is arranged below the trolley and connected with an air blower, and external air is brought into the high-temperature material layer through the air blower. Due to the sealing structure of the annular cooler and the maintenance problem of long-term use, the air leakage phenomenon can be generated in the cooling production process, so that insufficient cooling and waste of energy of the blower are caused, and even production accidents of burning the conveying belt due to the fact that the discharging temperature of the annular cooler is too high can be generated under the condition of serious air leakage. The circular cooler and the attached bellows, air pipe, valve and the like have complex structures and work at high temperature, so that the detection of the air leakage rate is always lack of effective means.
At present, a calorimeter method, a sound method, a flow method and the like (hereinafter collectively referred to as a traditional means) are generally adopted for detecting air leakage of the annular cooler, but the prior art at least has the following problems: 1. although the total air leakage rate can be measured by a calorimeter method and a flow method, no effective detection means and no effective judgment analysis method are available for judging specific air leakage, air leakage amount and degradation trend, and meanwhile, the difference of results caused by different specific heat capacity and material properties is larger along with the change of materials. 2. Although the sound method overcomes the problems, the production site is generally noisy, and the result is affected by an erroneous sound signal. Therefore, development of a new method for detecting air leakage is required.
Disclosure of Invention
According to the technical problem, the relationship between the infrared imaging temperature difference of equipment in different areas of the annular cooler and the air leakage rate of the annular cooler is determined by utilizing the infrared imaging equipment and through the phenomenon of different colors and different shades of temperature and combining with big data analysis to correct theoretical change rules, and finally the real-time air leakage data of the annular cooler is obtained.
The invention not only can measure the air leakage rate of the system, and the result is not influenced by external noise, but also can judge specific places of air leakage, leakage quantity and degradation trend, and can provide powerful support for daily maintenance work.
The invention adopts the following technical means:
an online detection method for the air leakage rate of a circular cooler comprises the following steps:
step one, determining scanning points by the existing traditional means, setting infrared thermal imaging equipment at the scanning points, monitoring in real time, and recording temperature potential field video and photos;
step two, judging the air leakage point through the recorded video and photo of the temperature potential field in the step one;
the decision rule is as follows:
a. in a thermal imaging shooting picture, a dark point lower than the average temperature by 20 ℃ is a suspicious air leakage point;
b. in a thermal imaging shooting picture, dark spots surrounded by temperature differences larger than 150 ℃ are suspicious air leakage points;
c. the surface temperature of the annular cooler and the temperature difference of each part are respectively compared with historical data, and points with the reduced value of more than 20 ℃ or the temperature difference of more than 20 ℃ are suspicious air leakage points;
step three, the calculation method of the air leakage rate comprises the following steps:
wherein eta At present Is the air leakage rate of the instant circular cooler; n is n 2 The number of the detected real air leakage points; n is n Repair 2 Is a correction parameter formed according to the detected size and temperature difference of the air leakage point; n is n Total 2 Is the total number of points detected; η (eta) 1 The reference air leakage rate is obtained by detecting air leakage of the annular cooler through the traditional means; n is n Total 1 The total point position number of infrared thermal imaging detection when the ring cooler is subjected to air leakage detection by the traditional means; n is n 1 The number of the real air leakage points detected when the air leakage detection is carried out on the annular cooler by the traditional means; n is n Repair 1 Is the true one detected when the air leakage of the ring cooler is detected by the traditional meansAnd correcting parameters of the number of the real air leakage points, and adjusting according to the air leakage area and the temperature difference.
Further, the method comprises the steps of,
and a suspicious air leakage point confirmation step is added between the second step and the third step, wherein the step comprises the following steps: after the suspicious air leakage point is found, shooting with higher resolution at a shorter distance, and determining whether the suspicious air leakage point is a real air leakage point or not by utilizing the second rule to perform a confirmation judgment work again, wherein the real air leakage point is used for recording the air leakage area and the temperature difference.
Further, the method comprises the steps of,
the obtained equipment temperature potential field data, including the temperature raw data (including temperature difference data) of the suspected air leakage area (air leakage area), is used for database archiving and is used for comparison as historical data in the next air leakage detection, and is used for correcting the judgment condition of the air leakage point and optimizing two correction parameters n Repair 1 、n Repair 2 。
Further, the method comprises the steps of,
the infrared thermal imaging equipment is a plurality of thermal imagers arranged at a plurality of positions inside and outside the annular cooler, the thermal imagers are internally provided with communication modules, and data are output through a wired or wireless mode.
According to the invention, by utilizing the infrared imaging equipment and through the phenomenon of different colors and different shades of temperature, the theoretical change rule is corrected by combining big data analysis, the relation between the infrared imaging temperature difference of equipment in different areas of the annular cooler and the air leakage rate of the annular cooler is determined, and finally the real-time air leakage data of the annular cooler are obtained.
Compared with the prior art, the invention has the following advantages:
1) The infrared thermal imaging is used as a detection means, and the deviation is corrected by combining big data, so that the detection work of the air leakage condition of the real-time annular cooler in a noisy environment is realized, and the method is high in practicability, rapid, accurate, flexible and efficient.
2) Most of the positions of easy air leakage are thinned and damaged due to abrasion and corrosion and the like, the abrasion and corrosion conditions of the baffle can be predicted by infrared detection through comparison of the existing detection temperature data and basic data, judgment of degradation trend is achieved, more powerful pre-judgment effect is provided for maintenance operation, and maintenance effect is enhanced.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings may be obtained according to the drawings without inventive effort to a person skilled in the art.
FIG. 1 is a flow chart of the present invention.
Detailed Description
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments.
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. The following description of at least one exemplary embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.
The relative arrangement of the components and steps, numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless it is specifically stated otherwise. Meanwhile, it should be clear that the dimensions of the respective parts shown in the drawings are not drawn in actual scale for convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail, but are intended to be part of the specification where appropriate. In all examples shown and discussed herein, any specific values should be construed as merely illustrative, and not a limitation. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further discussion thereof is necessary in subsequent figures.
In the description of the present invention, it should be understood that the azimuth or positional relationships indicated by the azimuth terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal", and "top, bottom", etc., are generally based on the azimuth or positional relationships shown in the drawings, merely to facilitate description of the present invention and simplify the description, and these azimuth terms do not indicate and imply that the apparatus or elements referred to must have a specific azimuth or be constructed and operated in a specific azimuth, and thus should not be construed as limiting the scope of protection of the present invention: the orientation word "inner and outer" refers to inner and outer relative to the contour of the respective component itself.
Spatially relative terms, such as "above … …," "above … …," "upper surface at … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial location relative to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "above" or "over" other devices or structures would then be oriented "below" or "beneath" the other devices or structures. Thus, the exemplary term "above … …" may include both orientations of "above … …" and "below … …". The device may also be positioned in other different ways (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
In addition, the terms "first", "second", etc. are used to define the components, and are only for convenience of distinguishing the corresponding components, and the terms have no special meaning unless otherwise stated, and therefore should not be construed as limiting the scope of the present invention.
Example 1
As shown in fig. 1, the invention provides an on-line detection method for the air leakage rate of a circular cooler,
step one, carrying out air leakage detection on the annular cooler by a traditional means, recording the air leakage rate eta, the air leakage points n, installing a plurality of infrared thermal imaging equipment parallel networks inside and outside the annular cooler to realize real-time monitoring, and recording the temperature potential field video and the photos for further analysis and recording.
And step two, according to the recorded video and photo analysis judgment of the temperature potential field in the step one, judging rules comprise.
a. In the thermal imaging shooting picture, dark points lower than the average temperature by 20 ℃ are suspicious air leakage points.
b. In a thermal imaging shooting picture, dark spots surrounded by temperature differences larger than 150 ℃ are suspicious air leakage points.
c. And comparing the surface temperature of the annular cooler and the temperature difference of each part with historical data, wherein the point with the reduced value of more than 20 ℃ or the temperature difference of more than 20 ℃ is the suspicious air leakage point.
In the middle step, after the suspicious air leakage point is found, shooting with higher resolution at a shorter distance, and determining whether the suspicious air leakage point is the real air leakage point or not by utilizing the second rule to perform a confirmation judgment work again, wherein the air leakage area and the temperature difference are recorded if the suspicious air leakage point is the real air leakage point.
And thirdly, calculating according to a technical scheme air leakage rate formula.
The calculation method of the air leakage rate comprises the following steps:
wherein eta At present Is the air leakage rate of the instant circular cooler; n is n 2 The number of the detected real air leakage points; n is n Repair 2 Is a correction parameter formed according to the detected size and temperature difference of the air leakage point; n is n Total 2 Is the total number of points detected; η (eta) 1 The reference air leakage rate is obtained by detecting air leakage of the annular cooler through the traditional means; n is n Total 1 The total point position number of infrared thermal imaging detection when the ring cooler is subjected to air leakage detection by the traditional means; n is n 1 The number of the real air leakage points detected when the air leakage detection is carried out on the annular cooler by the traditional means; n is n Repair 1 The real air leakage point quantity correction parameters detected when the air leakage detection is carried out on the annular cooler through the traditional means are adjusted according to the air leakage area and the temperature difference.
And fourthly, overhauling and plugging on site according to the data, reducing the air leakage rate, improving the cooling capacity and reducing the electricity consumption.
TABLE 1 reference data for synchronous detection of conventional methods and the methods of this patent
| Numbering device | Air leakage rate eta 1 | Real air leakage point n 1 | Correction parameter n of air leakage point Repair 1 | Corresponding thermal imaging scanning total points n Total 1 |
| Datum | 38.2％ | 13 | 6 | 214 |
TABLE 2 air leakage Rate data detected by the method of this patent
Taking 200 ten thousand ton of annual output grate-rotary kiln-annular cooler as an example, the cooling capacity is insufficient due to the fact that the annular cooler leaks air in summer, the yield is further reduced, the cooling capacity is detected and maintained in real time according to the yield of 5000t/d, and the processing cost is calculated by 100 yuan/ton.
TABLE 3 instant maintenance and leakage blocking after detecting air leakage by the method of this patent
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (4)
1. An on-line detection method for the air leakage rate of a circular cooler is characterized in that,
the method comprises the following steps:
determining scanning points by the existing traditional means, setting infrared thermal imaging equipment at the scanning points, performing real-time monitoring, and recording temperature potential field video and photos;
step two, judging the air leakage point through the recorded video and photo of the temperature potential field in the step one;
the decision rule is as follows:
a. in a thermal imaging shooting picture, a dark point lower than the average temperature by 20 ℃ is a suspicious air leakage point;
b. in a thermal imaging shooting picture, dark spots surrounded by temperature differences larger than 150 ℃ are suspicious air leakage points;
c. the surface temperature of the annular cooler and the temperature difference of each part are respectively compared with historical data, and points with the reduced value of more than 20 ℃ or the temperature difference of more than 20 ℃ are suspicious air leakage points;
step three, the calculation method of the air leakage rate comprises the following steps:
wherein eta At present Is the air leakage rate of the instant circular cooler; n is n 2 The number of the detected real air leakage points; n is n Repair 2 Is a correction parameter formed according to the detected size and temperature difference of the air leakage point; n is n Total 2 Is the total number of points detected; η (eta) 1 The reference air leakage rate is obtained by detecting air leakage of the annular cooler through the traditional means; n is n Total 1 The total point position number of infrared thermal imaging detection when the ring cooler is subjected to air leakage detection by the traditional means; n is n 1 The number of the real air leakage points detected when the air leakage detection is carried out on the annular cooler by the traditional means; n is n Repair 1 The real air leakage point quantity correction parameters detected when the air leakage detection is carried out on the annular cooler through the traditional means are adjusted according to the air leakage area and the temperature difference.
2. The on-line detection method for air leakage rate of circular cooler according to claim 1, wherein,
and a suspicious air leakage point confirmation step is added between the second step and the third step, wherein the step comprises the following steps: after the suspicious air leakage point is found, shooting with higher resolution at a shorter distance, and determining whether the suspicious air leakage point is a real air leakage point or not by utilizing the second rule to perform a confirmation judgment work again, wherein the real air leakage point is used for recording the air leakage area and the temperature difference.
3. The online detection method for the air leakage rate of the circular cooler according to claim 1 or 2 is characterized in that,
the obtained equipment temperature potential field data, including the temperature original data of the suspected air leakage area, are used for database archiving and are used for comparison as historical data when the air leakage is detected next time, and are used for correcting the judging condition of the air leakage point and optimizing two correction parameters n Repair 1 、n Repair 2 。
4. The on-line detection method for air leakage rate of circular cooler according to claim 3, wherein,
the infrared thermal imaging equipment is a plurality of thermal imagers arranged at a plurality of positions inside and outside the annular cooler, the thermal imagers are internally provided with communication modules, and data are output through a wired or wireless mode.
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