CN117460854A

CN117460854A - Method for estimating state of sintering process, method for guiding operation, method for producing sintered ore, device for estimating state of sintering process, operation guiding device, sintering operation guiding system, sintering operation guiding server, and terminal device

Info

Publication number: CN117460854A
Application number: CN202280040534.XA
Authority: CN
Inventors: 桥本佳也; 安原宏; 岩见友司; 广泽寿幸
Original assignee: JFE Steel Corp
Current assignee: JFE Steel Corp
Priority date: 2021-07-12
Filing date: 2022-07-04
Publication date: 2024-01-26
Also published as: KR20240013811A; WO2023286653A1; JPWO2023286653A1; JP2024050752A; EP4345178A1

Abstract

The method for estimating the state of the sintering process comprises the following steps: a process variable calculation step (S1) of calculating an observable process variable using a physical model that takes into account chemical reactions and heat conduction phenomena in the sintering process; a deviation degree calculation step (S2) for calculating a deviation degree between the calculated estimated value and the actual result value of the process variable; a model parameter adjustment step (S3) for correcting unknown parameters of the physical model so as to reduce the calculated degree of deviation; and a feature data calculation step (S4) for calculating feature data of the sintering process based on the corrected physical model.

Description

Method for estimating state of sintering process, method for guiding operation, method for producing sintered ore, device for estimating state of sintering process, operation guiding device, sintering operation guiding system, sintering operation guiding server, and terminal device

Technical Field

The present disclosure relates to a state estimating method of a sintering process, an operation guiding method, a manufacturing method of a sintered ore, a state estimating device of a sintering process, an operation guiding device, a sintering operation guiding system, a sintering operation guiding server, and a terminal device.

Background

In the iron industry, quality degradation of iron ore due to long-term production is generated. Therefore, the proportion of fine powder ore having a high powder rate after ore dressing in a mining area is increasing, and importance of a sintering process for manufacturing sintered ore by agglomerating fine powder ore before charging in a blast furnace is increasing. In order to ensure ventilation of the blast furnace, sintered ore having a particle size smaller than a predetermined particle size is not charged into the blast furnace, but is burned again as return ore by a sintering machine. The improvement of the yield, which is the ratio of the predetermined particle size or more, is directly related to the productivity of the sintering machine, and the improvement of the yield is strongly demanded.

Fig. 1 is a diagram showing an outline of a sintering process. A sintering material (pseudo particles) obtained by mixing and granulating fine ore, coke breeze, limestone, and the like is charged into a buffer hopper on the input side of the sintering machine. The sintering material is melted by the combustion heat of the coke breeze in the sintering machine, and the pseudo particles are melted with each other and cooled by air sucked from the upper part and discharged. The heating curve in the series of heating and cooling processes has a great influence on the product yield. The heating profile is the temperature distribution of the sintered material in the equipment longitudinal direction and the thickness direction of the sintering machine. In particular, retention time (high temperature holding time) of 1200 ℃ or higher, for example, for ensuring ore melting has a large influence on yield. Therefore, the feature data such as the heating curve affecting the yield is estimated with high accuracy, and the feature amount such as the high temperature holding time is calculated from the feature data. Further, by showing the appropriate raw coke ratio, tray speed, and other guiding operation amounts for controlling the feature amount to a predetermined value, the yield can be improved.

Here, patent document 1 discloses a method of controlling the position of BTP (Burn through point, firing point) to be constant as a conventional control method of a heating curve. In the technique of patent document 1, a position in the machine longitudinal direction where the temperature of the exhaust gas measured by a wind box at the lower part of the sintering machine becomes the highest is referred to as BTP.

Patent document 1: japanese patent laid-open No. 2006-307259

Here, it may be difficult to control the high temperature holding time described above only by controlling the position of the BTP to be constant. For example, even if the BTP position is constant, the high temperature holding time is shortened as the tray speed increases. As described above, in the conventional control method of the heating profile, there is a possibility that the high temperature holding time varies.

Disclosure of Invention

An object of the present disclosure, which has been made to solve the above problems, is to provide a state estimating method of a sintering process and a state estimating device of a sintering process, which can estimate the state of the sintering process with high accuracy. Further, an operation guidance method, a method for manufacturing a sintered ore, an operation guidance device, a sintering operation guidance system, a sintering operation guidance server, and a terminal device, which are capable of displaying guidance for improving the yield based on the state of the sintering process estimated with high accuracy, are provided.

The method for estimating the state of a sintering process according to one embodiment of the present disclosure includes:

a process variable calculation step of calculating an observable process variable using a physical model in which chemical reaction and heat conduction phenomena in the sintering process are taken into consideration;

a deviation degree calculating step of calculating a deviation degree between the calculated estimated value and actual result value of the process variable;

a model parameter adjustment step of correcting an unknown parameter of the physical model so as to reduce the calculated degree of deviation; and

and calculating characteristic data of the sintering process based on the corrected physical model.

The operation guidance method of one embodiment of the present disclosure includes:

a high temperature holding time calculation step of calculating a high temperature holding time of the sintered material using the heating curve calculated by the state estimation method of the sintering process, wherein the characteristic data is the heating curve of the sintered material in the longitudinal direction of the sintering machine; and

a guiding operation amount prompting step of prompting a guiding operation amount including at least one of a raw coke ratio and a tray speed so as to maintain the high temperature maintaining time above a predetermined value.

The method for manufacturing a sintered ore according to one embodiment of the present disclosure manufactures a sintered ore using the instruction operation amount presented by the above-described operation instruction method.

The state estimating device for a sintering process according to one embodiment of the present disclosure includes:

a storage unit for storing a physical model in which chemical reaction and heat conduction phenomena during sintering are considered;

a process variable calculation unit configured to calculate an observable process variable using the physical model;

a deviation degree calculating unit that calculates a deviation degree between the calculated estimated value and actual result value of the process variable;

a model parameter adjustment unit configured to correct an unknown parameter of the physical model so that the calculated degree of deviation becomes smaller; and

and a feature data calculation unit that calculates feature data of the sintering process based on the corrected physical model.

An operation guidance device according to an embodiment of the present disclosure includes:

a high temperature holding time calculation unit for calculating a high temperature holding time of the sintered material using the heating curve calculated by the state estimation device in the sintering process, wherein the characteristic data is the heating curve of the sintered material in the longitudinal direction of the sintering machine; and

a guiding operation amount prompting unit for prompting a guiding operation amount including at least one of a raw coke ratio and a tray speed so as to maintain the high temperature maintaining time at a predetermined value or more.

The sintering operation guidance system of one embodiment of the present disclosure is provided with a sintering operation guidance server and a terminal device,

the sintering operation guidance server includes:

a actual performance value acquisition unit that acquires an actual performance value indicating an operation state of the sintering process;

a storage unit for storing a physical model in which chemical reaction and heat conduction phenomena in the sintering process are considered;

a model parameter adjustment unit configured to correct an unknown parameter of the physical model so that the calculated degree of deviation becomes smaller;

a feature data calculation unit that calculates feature data of the sintering process based on the corrected physical model;

a high temperature holding time calculation unit that calculates a high temperature holding time of the sintered material using a heating curve, wherein the characteristic data is the heating curve of the sintered material in the longitudinal direction of the sintering machine; and

a guiding operation amount prompting unit for prompting a guiding operation amount including at least one of a raw coke ratio and a tray speed so as to maintain the high temperature maintaining time at a predetermined value or more,

the terminal device is provided with:

a guidance operation amount acquisition unit configured to acquire the guidance operation amount presented by the sintering operation guidance server; and

and a display unit for displaying the acquired instruction operation amount.

The sintering operation guidance server according to one embodiment of the present disclosure includes:

The terminal device according to one embodiment of the present disclosure is a terminal device that forms a sintering operation guidance system together with a sintering operation guidance server, and includes:

a guidance operation amount acquisition unit that acquires the guidance operation amount presented by the sintering operation guidance server; and

a display unit for displaying the acquired instruction operation amount,

the sintering operation guidance server corrects unknown parameters of a physical model in such a manner that the degree of deviation between an estimated value and an actual value of a process variable calculated by using the physical model in consideration of a chemical reaction and a heat conduction phenomenon during sintering is reduced,

the guiding operation amount is an operation amount including at least one of a raw coke ratio and a tray speed so as to maintain a high temperature holding time of the sintered material at a predetermined value or more based on a heating curve calculated using the physical model in which the unknown parameter is corrected.

According to the present disclosure, a state estimating method of a sintering process and a state estimating device of a sintering process capable of estimating a state of a sintering process with high accuracy can be provided. Further, according to the present disclosure, it is possible to provide an operation guidance method, a sintered ore manufacturing method, an operation guidance device, a sintering operation guidance system, a sintering operation guidance server, and a terminal device, which can display guidance for improving the yield based on a state of a sintering process estimated with high accuracy.

Drawings

Fig. 1 is a diagram showing an outline of a sintering process.

Fig. 2 is a diagram showing input/output information of a physical model used in the present disclosure.

Fig. 3 is a diagram showing an example of a main process variable calculated by a physical model in which correction of an unknown parameter is not performed.

Fig. 4 is a graph showing a response of a process variable when an unknown parameter is changed stepwise.

Fig. 5 is a diagram showing an example of a main process variable calculated by a physical model for performing correction of an unknown parameter.

Fig. 6 is a diagram showing an example of transition of unknown parameters.

Fig. 7 is a diagram showing a configuration example of a state estimating device and an operation guiding device for a sintering process according to an embodiment.

Fig. 8 is a flowchart showing a method for estimating the state of a sintering process according to an embodiment.

Fig. 9 is a flowchart showing an operation guidance method of an embodiment.

Fig. 10 is a diagram showing a configuration example of a sintering operation guidance system according to an embodiment.

Detailed Description

A state estimating method, an operation guidance method, a manufacturing method of a sintered ore, a state estimating device, an operation guidance device, a sintering operation guidance system, a sintering operation guidance server, and a terminal device of one embodiment of the present disclosure will be described below with reference to the accompanying drawings. The physical model used in the present disclosure is a model which is configured by partial differential equations and is capable of calculating the state in the sintering machine, taking into consideration physical phenomena such as combustion of coke breeze, thermal decomposition of limestone, and evaporation of water, as in the method described in reference 1 (Yamaoka et al isij International, vol.45, no.4, pp.522). In the present embodiment, the physical model is a two-dimensional unsteady state model capable of calculating a temperature distribution (heating curve) of the sintered material and a distribution of the exhaust gas composition in the equipment longitudinal direction and the thickness direction of the sintering machine. Further, the position of the BTP can be known from the calculated heating curve. Hereinafter, the "position of BTP" may be simply referred to as BTP.

As shown in fig. 2, among the input variables given to the physical model, the tray speed, the exhaust gas flow rate, the raw material bulk density, the raw material moisture ratio, the raw material limestone ratio, and the raw material coke ratio are mainly changed with time. These input variables may be operating variables or running factors of the sintering machine. The pallet speed is a speed at which the sintering material loaded on the pallet of the sintering machine illustrated in fig. 1 is moved. The exhaust gas flow rate is a flow rate per unit time of the exhaust gas of the sintering machine, and is adjusted by, for example, an exhaust fan. The bulk density of the raw material is calculated from the layer thickness, the width of the sintering machine, and the like. The raw material moisture proportion, the raw material limestone proportion and the raw material coke proportion are the moisture, limestone and coke proportions in the sintering raw material respectively. Here, coke is a main coagulated material, and the raw coke ratio is sometimes referred to as a coagulated material ratio.

In addition, the main output variables of the physical model are BTP and exhaust gas composition. The exhaust gas composition includes O ₂ 、CO ₂ The ratio of CO. Here, the output variable may also include the temperature under the sintering bed. The output variable, which varies from moment to moment, is calculated using a physical model. The calculated time interval (the time between "t+1" and "t" of the expression of the physical model to be described laterThe difference) is not particularly limited, but is 5 minutes as an example.

The physical model can be represented by the following formula (1) and formula (2).

[ number 1]

x(t+1)＝f(x(t)，u(t) (1)

y(t)＝C(x(t) (2)

Here, u (t) is the input variable described above, and is a variable that can be manipulated by an operator who performs the operation of the sintering machine. x (t) is a state variable calculated within the physical model. The state variables are, for example, the heating curve in the sintering machine, the reactivity of the coke, CO and CO ₂ Etc. and the ratio of the gas components. y (t) is the output variable (process variable) and is BTP or O in the exhaust gas composition ₂ Proportion of CO ₂ Ratio, partial burn rate. Y (t) is a main process variable and can be determined as follows.

[ number 2]

y(t)＝[y ₁ (t)，y ₂ (t)，y ₃ (t)，y ₄ (t)] ^T ≡[BTP(t)，X _O2 (t)，X _CO2 (t)，γ _CO (t)] ^T

Here, the partial burn rate is the CO in the exhaust gas divided by (CO+CO) ₂ ) And the obtained value (i.e. CO/(CO+CO) ₂ )). The increase in the partial combustion rate means that the coke gasification reaction (c+co) is an endothermic reaction ₂ 2 CO) activation, meaning that the average temperature level during sintering rises. Here, in addition to this, the main process variables may include the temperature under the sintering bed, and the like.

The BTP and exhaust composition can be calculated directly using a physical model as in the prior art. Fig. 3 is a diagram showing an example of a main process variable for 30 hours calculated directly using a physical model. In fig. 3, the values calculated using the physical model (estimated values) are shown by solid lines, and actual result values measured in the actual equipment (sintering machine of the actual machine) are shown by broken lines. Here, BTP is represented by a distance [ m ] from the position of the buffer hopper in the moving direction of the tray.

For each major process variable, an average estimation error was calculated, with a BTP of 2.4914[ m ]]、O ₂ The ratio is 0.0086, CO ₂ The ratio was 0.0086 and the partial burn rate was 0.0169. Here, the average estimation error is calculated as follows: the sum of all the steps is obtained for a value obtained by squaring the degree of deviation between the estimated value and the actual result value, and the square root of the value obtained by dividing the sum by the number of steps is obtained. If the physical model calculation is performed for a long time in this way, there is a problem that an error (estimation error) of the estimated value is generated which cannot be ignored in the conventional method. In the example of fig. 3, data of 30 hours is used, but in order to further control the sintering process by calculating the long period of time in years, it is necessary to reduce the estimation error.

In order to reduce the estimation error, it is effective to successively adjust parameters, boundary conditions, and the like of the reaction rate of the physical model so that the estimated value matches the actual result value. Therefore, it is preferable to calculate the parameters after including the variable elements in the physical model as one or more unknown parameters. In the present embodiment, 3 parameters, that is, a correction parameter of an exhaust gas flow rate, a correction parameter of a raw material bulk density, and a correction parameter of a raw material coke ratio, are selected as unknown parameters for reasons described below. In addition to this, it is also conceivable to use as the unknown parameters the fluctuation factors such as the raw material moisture ratio, the carbon combustion rate, the coke gasification reaction rate, and the like. For example, the combustion speed of carbon depends on the temperature of the solid and the oxygen concentration in the gas, but the scaling factor in these relations can be used as an unknown parameter. The unknown parameters need to be selected based on the raw materials used for the subject process, the equipment configuration, etc.

The reason for selecting the unknown parameters (3 correction parameters) in the present embodiment will be described below.

In the sintering machine, air is sucked from the upper part of the sintering bed, and CO is measured at the lower part of the sintering bed ₂ Exhaust gas flow rate of CO, etc. The measured exhaust gas flow rate includes a flow rate of a gas called "air leakage" that passes through other voids without passing through the sintered bed (air leakage flow rate). The air leakage flow is difficult to actually measure and difficult to directly input into a physical model. Therefore, it is considered appropriate to correct the exhaust gas flow rate of the physical model so as to match the actual value of the main process variable。

The bulk density of the raw material input into the physical model is set to ρ [ kg/m ] ³ ]ρ is calculated by the following equation (3).

[ number 3]

Here, V [ kg/min ] is the actual cutting speed of the raw material. Hm is the layer thickness of the raw material. W m is the width of the sintering machine. PS [ m/min ] is a value calculated from the tray speed. Here, the cutting speed of the raw material is a value measured by a cutting device upstream of the sintering machine. That is, the loading rate of the raw material actually loaded into the sintering machine was not measured. Therefore, it is difficult to accurately estimate the bulk density of the raw material in the sintering machine. Therefore, it is considered that it is appropriate to correct the bulk density of the raw material.

Regarding the raw coke ratio, unlike the coagulated material (coke) charged into the sintering machine, the operation of mixing a raw material containing carbon such as blast furnace dust into fine ore in advance in the raw material site has an influence. Since the variation in the mixing ratio is large, it is considered that it is appropriate to correct the raw coke ratio (the coagulant ratio).

Here, fig. 4 is a graph showing a response of a process variable when an unknown parameter is changed stepwise. Fig. 4 is obtained by stepwise changing the above-described 3 correction parameters after a certain constant operation condition is continuously given to the physical model and a steady state is reached.

First, when the exhaust gas flow rate is increased by 10%, BTP is shortened, O ₂ The proportion is increased, CO ₂ The ratio is reduced and the partial burn rate is hardly changed. When the bulk density of the raw material is increased by 10%, BTP is prolonged, O ₂ Reduced ratio of CO ₂ The ratio is increased and the partial burn rate is hardly changed. When the coke content of the raw material was increased by 10%, BTP was hardly changed, O ₂ Reduced ratio of CO ₂ The proportion is slightly increased, and the partial combustion rate is increased.

Using the unknown parameters obtained as aboveStep response of the number is subjected to parameter correction by the following steps (a) to (f) to make BTP, O ₂ Proportion of CO ₂ The proportion and the partial combustion rate are consistent. The algorithm described below is called MHE (Moving Horizon Estimation: rolling time domain estimation), but other methods of estimating the state such as a particle filter and a kalman filter may be used.

First, as step (a), the state variables and main process variables of the past step a are calculated by the following equations (4) and (5).

[ number 4]

x(t-k+1)＝f(x(t-k)，u(t-k)) (4)

y(t-k+1)＝c(x(t-k+1)) (5)

Here, k varies between a and 1. In addition, the input variables use actual performance values.

As step (b), x (t-a+1) is saved to be used as an initial condition for iterative calculation.

As step (c), the degree of deviation is calculated by the following equation (6).

[ number 5]

e(t)＝y _act (t)-y _cal (t) (6)

Here, y _act Is a performance value. In addition, y _cal Is an estimated value.

As step (d), as shown in the following equation (7), correction amounts Δα, Δβ, and Δγ of the unknown parameters are obtained so as to minimize the overlap deviation and an evaluation function obtained by the step response of the main process variable for each of the above-described unknown parameters. The unknown parameters α, β, and γ in the formula (7) correspond to the correction parameters of the exhaust gas flow rate, the correction parameters of the raw material bulk density, and the correction parameters of the raw material coke ratio, respectively. A smaller evaluation function corresponds to a smaller degree of deviation. Here, a term for preventing the unknown parameter from being greatly dissociated from "1" is added to the evaluation function (see fig. 6).

[ number 6]

Here, q determines the primary process variable. In the present embodiment, q=1, 2, 3, and 4 means BTP and O, respectively ₂ Proportion of CO ₂ Ratio, partial burn rate. In addition, R _q ^p (s) means the value of p for the response in the step response of q as the primary process variable, i.e. in s, relative to the unknown parameter.

As step (e), the unknown parameters are corrected as in the following equations (8) to (10).

[ number 7]

α＝α+Δα (8)

β＝β+Δβ (9)

γ＝γ+Δγ (10)

As step (f), t of the time step is updated to t+1, and the process returns to step (a). In this way, the unknown parameters are corrected by successive arithmetic processing.

In the present embodiment, correction of unknown parameters of the physical model is performed using MHE. Fig. 5 is a diagram showing an example of a main process variable calculated by a physical model for performing correction of an unknown parameter. Fig. 6 is a diagram showing an example of transition of the unknown parameters corresponding to fig. 5. For each major process variable, an average estimation error was calculated, with a BTP of 0.9961[ m ]]，O ₂ At a ratio of 0.0044, CO ₂ The ratio was 0.0047 and the partial burn rate was 0.0064. That is, it is known that by correcting the unknown parameter using MHE, the estimation error becomes smaller than in the case of fig. 3.

Here, the a of the formula (7) may be determined so that, for example, a time required from the inlet side to the outlet side of the sintering can be evaluated, and specifically, may be about 30 minutes to 60 minutes. In the example of fig. 5, the time step width is 5 minutes, a is 8, and the time is 40 minutes.

The state estimating device (described in detail later) of the sintering process according to the present embodiment can estimate the BTP and the exhaust gas composition with high accuracy by correcting the unknown parameters described above. Further, by performing highly accurate estimation using such a physical model, the estimation accuracy can be improved also in relation to calculation of the high temperature holding time of the sintered material. The high temperature holding time is a time when the temperature of the sintered material is held at a threshold value (1200 ℃ as an example) or more that affects the improvement of the yield.

When the calculated high temperature holding time of the sintered material is lower than a predetermined value (3 minutes as an example), the operation guidance device of the present embodiment (described in detail later) can guide the operation in such a manner that the high temperature holding time can be ensured by increasing the raw coke ratio and thereby increasing the temperature. The operation guidance device may guide the tray in such a manner that the tray speed is reduced to ensure the high-temperature holding time. The operation guidance device presents information (guidance operation amount) for guiding to an appropriate operation to the operator, thereby expecting an effect of improving the yield.

Fig. 7 is a diagram showing a configuration example of the state estimating device 10 and the operation guiding device 20 in the sintering process according to the embodiment. As shown in fig. 7, the state estimating device 10 for the sintering process includes a storage unit 11, a process variable calculation unit 12, a degree of deviation calculation unit 13, a model parameter adjustment unit 14, and a feature data calculation unit 15. The operation guidance device 20 includes a storage unit 21, a high-temperature holding time calculation unit 22, and a guidance operation amount presentation unit 23. The state estimating device 10 for the sintering process acquires actual result values (also referred to as measured values) which are various measured values from sensors and the like provided in the sintering machine, and performs calculation using the above-described physical model. The operation guidance device 20 obtains the characteristic data of the sintering process calculated by the state estimation device 10 of the sintering process, obtains a guidance operation amount, and displays guidance for the operation of the sintering machine on the display unit 30. In the present embodiment, the characteristic data is a heating curve of the sintered material in the longitudinal direction of the sintering machine equipment. When the high temperature holding time of the sintered material is lower than a predetermined value (3 minutes as an example), the operation guidance device 20 displays a guidance operation amount on the display unit 30 as a guidance for enabling the high temperature holding time to be ensured. The pilot operation amount may be an operation amount (adjustment amount) for ensuring at least one of the raw coke ratio and the tray speed required for the high temperature holding time. The display unit 30 may be a display device such as a liquid crystal display (Liquid Crystal Display) or an Organic Electro-Luminescence Panel.

First, the constituent elements of the state estimating device 10 in the sintering process will be described. The storage unit 11 stores a physical model in which chemical reactions and heat conduction phenomena during sintering are considered. The storage unit 11 stores programs and data related to the state estimation of the sintering process. The storage unit 11 may include any storage device such as a semiconductor storage device, an optical storage device, and a magnetic storage device. The semiconductor memory device may include, for example, a semiconductor memory. The storage section 11 may include various storage devices.

The process variable calculation unit 12 calculates an observable process variable using a physical model. In the present embodiment, the process variable is BTP, O in the exhaust gas composition ₂ Proportion of CO ₂ Ratio, partial burn rate.

The deviation degree calculating unit 13 calculates a deviation degree between the estimated value of the calculated process variable and the actual performance value in the actual plant.

The model parameter adjustment unit 14 corrects the unknown parameters of the physical model so that the calculated degree of deviation becomes smaller.

The feature data calculation unit 15 calculates feature data of the sintering process based on the corrected physical model. As described above, in the present embodiment, the characteristic data is a heating curve of the sintered material in the longitudinal direction of the sintering machine equipment.

The process variable calculation unit 12, the degree of deviation calculation unit 13, and the model parameter adjustment unit 14 perform operations according to the steps (a) to (f) described above, and correct unknown parameters of the physical model. In the present embodiment, the unknown parameters are corrected by iterative calculation performed while updating time steps using the above-described evaluation function including the degree of deviation, the process variable, and the unknown parameters. The feature data calculation unit 15 calculates a heating curve using the corrected physical model, and outputs the heating curve as feature data to the operation guidance device 20.

Next, the constituent elements of the operation guidance device 20 will be described. The storage unit 21 stores programs and data related to the operation instruction. The storage unit 21 may include any storage device such as a semiconductor storage device, an optical storage device, and a magnetic storage device. The semiconductor memory device may include, for example, a semiconductor memory. The storage section 21 may include a plurality of kinds of storage devices.

The high temperature holding time calculation unit 22 calculates the high temperature holding time of the sintered material using the heating curve calculated by the state estimation device 10 of the sintering process.

If the calculated high temperature holding time of the sintered material is less than the predetermined value, the instruction operation amount presenting unit 23 presents the instruction operation amount to the display unit 30 so as to maintain the high temperature holding time at or above the predetermined value. In the present embodiment, the pilot operation amount includes at least one of a raw coke ratio and a tray speed. The pilot operation amount presentation unit 23 may display the increase in the raw coke ratio by 10% as the pilot operation amount on the display unit 30. The instruction operation amount presentation unit 23 may display the reduction of the tray speed by 5% as the instruction operation amount on the display unit 30, for example. Here, the pilot operation amount presentation unit 23 may cause the state estimating device 10 of the sintering process to calculate the amount of increase in the raw coke ratio and the amount of decrease in the tray speed using a physical model. That is, the instruction manipulation variable presenting unit 23 may cause the state estimating device 10 of the sintering process to perform simulation using the physical model to determine the presented instruction manipulation variable.

The operator can change the operating conditions of the sintering machine based on the instruction operation amount shown in the display unit 30. The operating instructions on such a sintering machine can be performed as part of the manufacturing method for manufacturing the sinter.

Here, the state estimating device 10 and the operation guiding device 20 of the sintering process may be separate devices or may be integrated devices. In the case of an integrated device, the storage section 11 and the storage section 21 may be realized by the same storage device.

The state estimating device 10 and the operation guiding device 20 of the sintering process may be realized by a computer such as a process computer that controls the operation of the sintering machine or the production of the sintered ore. The computer includes, for example, a memory, a hard disk drive (storage device), a CPU (processing device), and a display device such as a display. An Operating System (OS) and application programs for executing various processes can be stored in a hard disk drive, and read from the hard disk drive into a memory when executed by a CPU. The data during the processing is stored in the memory and, if necessary, in the HDD. The various functions are realized by organically cooperating hardware such as a CPU and a memory with an OS and a required application program. The storage unit 11 and the storage unit 21 may be realized by, for example, a storage device. The process variable calculation unit 12, the degree of deviation calculation unit 13, the model parameter adjustment unit 14, the feature data calculation unit 15, the high temperature holding time calculation unit 22, and the instruction operation amount presentation unit 23 may be realized by, for example, a CPU. The display unit 30 may be realized by a display device, for example.

Fig. 8 is a flowchart showing a method for estimating the state of a sintering process according to an embodiment. The state estimating device 10 of the sintering process outputs characteristic data of the sintering process according to the flowchart shown in fig. 8. The state estimating method shown in fig. 8 may be performed as a part of the manufacturing method of the sintered ore.

The process variable calculation unit 12 calculates a process variable using the physical model (step S1, process variable calculation step). The deviation degree calculating unit 13 calculates the deviation degree between the estimated value and the actual result value of the calculated process variable (step S2, deviation degree calculating step). The model parameter adjustment unit 14 corrects the unknown parameters of the physical model so that the degree of deviation becomes smaller (step S3, model parameter adjustment step). Then, the feature data calculation unit 15 calculates feature data based on the corrected physical model (step S4, feature data calculation step).

Fig. 9 is a flowchart showing an operation guidance method of an embodiment. The operation instruction device 20 prompts and instructs the operation amount according to the flowchart shown in fig. 9. The operation guidance method shown in fig. 9 may be performed as part of the manufacturing method of the sintered ore.

The high temperature holding time calculation unit 22 calculates the high temperature holding time of the sintered material using the heating curve calculated as the characteristic data (step S11, high temperature holding time calculation step). The instruction operation amount presentation unit 2 presents the instruction operation amount to the display unit 30 so as to maintain the high temperature holding time at or above a predetermined value (step S12, instruction operation amount presentation step).

Fig. 10 is a diagram showing the structure of a sintering operation guidance system according to an embodiment. The sintering operation guidance system may be constituted by the sintering operation guidance server 40 and the terminal device 50, as shown by the broken line in fig. 10, for example. The sintering operation guidance server 40 has the functions of the state estimating device 10 and the operation guidance device 20 for the sintering process, and may be realized by a computer, for example. The terminal device 50 functions at least as the display unit 30, and may be implemented by a portable terminal device such as a tablet computer or a computer. The sintering operation guidance server 40 and the terminal device 50 can transmit and receive data to and from each other via a network such as the internet, for example. The sintering operation guidance server 40 and the terminal device 50 may be located at the same place (for example, in the same factory), or may be physically separated from each other. The sintering operation guidance system is not limited to the above configuration, and may be configured to further include an operation data server 60 that collects operation data (actual result values and operation parameters indicating an operation state, as an example) of the sintering machine. The operation data server 60 can communicate with the sintering operation guidance server 40 and the terminal device 50 via a network, and the operation data server 60 can be implemented by a computer that manages the production of sintered ore, for example. The operation data server 60 may be located at the same site as the sintering operation guidance server 40 or the terminal device 50, or may be physically separated from each other. The following describes components and the like by taking a sintering operation guidance system including the sintering operation guidance server 40 and the terminal device 50 as an example.

The sintering operation guidance server 40 acquires actual result values indicating the operation state of the sintering process, performs calculation using the above-described physical model, and calculates the high-temperature holding time of the sintered material using the calculated heating curve as the characteristic data. In order to maintain the high-temperature holding time at or above the predetermined value, the sintering operation guidance server 40 displays a guidance operation amount including at least one of the raw coke ratio and the tray speed on the terminal device 50 functioning as the display unit 30. The sintering operation guidance server 40 includes the components of the state estimating device 10 and the components of the operation guidance device 20 in the sintering process described with reference to fig. 7. Specifically, the sintering operation guidance server 40 includes: a storage unit, a process variable calculation unit 12, a degree of deviation calculation unit 13, a model parameter adjustment unit 14, a feature data calculation unit 15, a high temperature holding time calculation unit 22, and a guide operation amount presentation unit 23. The storage unit stores a physical model in which chemical reactions and thermal conduction phenomena during the sintering process are considered, a program and data related to the state estimation of the sintering process, a program and data related to the operation guidance, and the like. The process variable calculation unit 12, the degree of deviation calculation unit 13, the model parameter adjustment unit 14, the feature data calculation unit 15, the high temperature holding time calculation unit 22, and the instruction operation amount presentation unit 23 are the same as those described above. The sintering operation guidance server 40 may further include a performance value acquisition unit that acquires a performance value indicating an operation state of the sintering process. The actual performance value obtaining unit may directly obtain the actual performance value from a sensor provided in the sintering machine, a sintering process computer, or the like, or may obtain the actual performance value via the operation data server 60.

The terminal device 50 constitutes a sintering operation guidance system together with the sintering operation guidance server 40, and displays the guidance operation amount. The terminal device 50 includes at least the display unit 30. The display unit 30 is the same as described above. The terminal device 50 may further include a guidance operation amount acquisition unit that acquires the guidance operation amount presented by the sintering operation guidance server 40.

As described above, the state estimating method and the state estimating device 10 for a sintering process according to the present embodiment can accurately estimate the state of the sintering process by the above-described configuration. The operation guidance method, the sintered ore manufacturing method, the operation guidance device 20, the sintering operation guidance system, the sintering operation guidance server 40, and the terminal device 50 according to the present embodiment can display guidance for improving the yield based on the state of the sintering process estimated with high accuracy. For example, the operator can change the operating conditions based on the indicated instruction operation amount, and can ensure the high-temperature holding time of the sintered material in advance, thereby improving the yield.

While embodiments of the present disclosure have been described with reference to the drawings and examples, it is noted that various modifications and changes will readily be made by those skilled in the art based on the present disclosure. Accordingly, it is noted that such variations or modifications are included within the scope of the present disclosure. For example, functions and the like included in each structural part, each step and the like can be rearranged in a logically non-contradictory manner, and a plurality of structural parts, steps and the like can be combined into one or divided. The embodiments of the present disclosure may be implemented as a program executed by a processor provided in an apparatus or a storage medium storing the program. It should be understood that they are also included within the scope of the present disclosure.

The configuration of the state estimating device 10 and the operation guiding device 20 of the sintering process shown in fig. 7 is an example. The state estimating device 10 and the operation guidance device 20 for the sintering process may not include all the components shown in fig. 7. The state estimating device 10 and the operation guidance device 20 for the sintering process may include components other than those shown in fig. 7. For example, the operation guidance device 20 may be further provided with a display unit 30.

In the above embodiment, the unknown parameters include 3 correction parameters, but may include at least one parameter. That is, the estimation error can be reduced by correcting at least one unknown parameter of the physical model.

Description of the reference numerals

10 … state estimating means for sintering process; 11 … storage; 12 … process variable calculation unit; 13 … deviation degree calculating section; 14 … model parameter adjusting part; 15 … feature data calculation unit; 20 … run instruction means; 21 … storage; 22 … high-temperature holding time calculation unit; 23 … to instruct an operation amount presenting section; 30 … display.

Claims

1. A method for estimating a state of a sintering process, comprising:

a deviation degree calculation step of calculating a deviation degree between the calculated estimated value and actual result value of the process variable;

2. The method for estimating a state of a sintering process according to claim 1, wherein,

the process variable includes at least one of BTP, exhaust gas composition, and temperature under the sinter bed.

3. The method for estimating the state of a sintering process according to claim 1 or 2, wherein,

the unknown parameters include at least one correction parameter of exhaust gas flow, feedstock bulk density, feedstock moisture ratio, feedstock char ratio, carbon burn rate, and char gasification reaction rate.

4. The method for estimating a state of a sintering process according to any one of claims 1 to 3, wherein,

the unknown parameter is corrected by iterative calculation performed while updating time steps using an evaluation function including the degree of deviation, the process variable, and the unknown parameter.

5. The method for estimating a state of a sintering process according to any one of claims 1 to 4, wherein,

the characteristic data is a heating curve of the sintered material in the longitudinal direction of the sintering machine equipment.

6. A method of operation guidance, comprising:

a high temperature holding time calculation step of calculating a high temperature holding time of a sintered material using the heating curve calculated by the state estimation method of the sintering process according to claim 5; and

a pilot operation amount prompting step of prompting a pilot operation amount including at least one of a raw coke ratio and a tray speed so as to maintain the high temperature holding time at a predetermined value or more.

7. A method for manufacturing a sintered ore is characterized in that,

a sintered ore is produced using the instructed manipulated variable prompted by the operation instruction method of claim 6.

8. A state estimating device for a sintering process is characterized by comprising:

a process variable calculation unit that calculates an observable process variable using the physical model;

a deviation degree calculation unit that calculates a deviation degree between the calculated estimated value and actual result value of the process variable;

9. An operation guidance device is characterized by comprising:

a high temperature holding time calculation unit that calculates a high temperature holding time of a sintered material using the heating curve calculated by the state estimation device of the sintering process according to claim 8, wherein the characteristic data is the heating curve of the sintered material in the longitudinal direction of the sintering machine; and

10. A sintering operation guidance system is characterized in that,

comprises a sintering operation instruction server and a terminal device,

the sintering operation guidance server is provided with:

a storage unit for storing a physical model in which chemical reaction and thermal conduction phenomena during the sintering process are considered;

a high temperature holding time calculation unit that calculates a high temperature holding time of a sintered material using a heating curve, wherein the characteristic data is the heating curve of the sintered material in the longitudinal direction of the sintering machine; and

a pilot operation amount presentation unit for presenting a pilot operation amount including at least one of a raw coke ratio and a tray speed so as to maintain the high temperature holding time at a predetermined value or more,

the terminal device is provided with:

and a display unit for displaying the acquired instruction operation amount.

11. A sintering operation guidance server is characterized by comprising:

12. A terminal device that constitutes a sintering operation guidance system together with a sintering operation guidance server, the terminal device comprising:

a display unit for displaying the acquired instruction operation amount,

the sintering operation guidance server corrects unknown parameters of a physical model in such a manner that the degree of deviation between an estimated value and an actual result value of a process variable calculated by using the physical model in consideration of a chemical reaction and a heat conduction phenomenon during sintering becomes smaller,

the guiding operation amount is an operation amount including at least one of a raw coke ratio and a tray speed so as to maintain a high temperature holding time of the sintered material at a predetermined value or more based on a heating curve of the sintered material in a longitudinal direction of the sintering machine calculated using the physical model in which the unknown parameter is corrected.