JP2009068765A - Profile measuring method of refractory in coke oven, and wear amount measuring method of refractory - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a profile measuring method of a refractory in a coke oven and a wear amount measuring method of the refractory capable of measuring the wear amount of the refractory on an oven wall and an oven bottom in the coke oven with easy method. <P>SOLUTION: In this profile measuring method of the refractory in the coke oven 1 provided with the refractory on its oven wall and oven bottom, an image of the refractory including a reference point positioned near the refractory is picked up in a red heat state of the refractory after the cokes are pushed out, a plurality of images different in photographing angles to the same object are picked up, and the image data is acquired to calculate the profile of the refractory. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for measuring a profile of a refractory installed on a furnace wall and a bottom of a coke oven, and a method for measuring the amount of wear of the refractory.

Along with the recent increase in steel production, stable supply of coke used as a reducing material is essential for high brewing ratio operation in a blast furnace. Coke is produced by carbonizing coal using a coke oven. A coke carbonization chamber for carbonizing coal in a coke oven is constructed of a refractory material such as a refractory brick.
Many of these coke ovens have been operating for a long period of 25 years or more, and the refractories on the furnace wall and the bottom of the furnace are worn due to the action of the furnace age and mechanical external force. Troubles such as clogging and non-sticking due to spillage are likely to occur.
For stable operation of the coke oven, it is necessary to repair the worn refractory material before these problems occur.
Therefore, it is important to manage the wear of the refractory so as to correctly grasp the wear state of the refractory.

The general refractory wear management method currently used for coke ovens is the method of visually checking the wear state of refractories on the furnace wall and bottom after coke extrusion and managing them. Yes.
In particular, for the furnace wall, the evaporated carbon generated during carbonization adheres to the furnace wall and the furnace wall refractory cannot be observed directly. The amount of wear is visually controlled after
However, such a visual management method has a considerably low management accuracy.

  As a method for inspecting the wear state of the refractory in the furnace using a device, a method has been proposed in which a camera is inserted into the furnace, the furnace wall is photographed, and the photographed image data is analyzed ( Patent Document 1).

In addition, regarding management of the amount of wear of a refractory lined in a converter, which is not a refractory of a coke oven, for example, Patent Document 2 captures two refractory images with different shooting angles, and these images A refractory management method is disclosed in which the damage state of a refractory is grasped in a three-dimensional manner.
Further, for example, in Patent Document 3, in the observation of Patent Document 2, an observation (management) method for detecting a damage state of a refractory as a phase difference by photographing the surface of the refractory while irradiating light from two points. Is disclosed.
JP-A-8-218071 JP-A-62-238993 JP 63-55444 A

In a coke oven, since the refractory brick breaks due to thermal contraction when the temperature in the carbonization chamber decreases, it is necessary to keep the temperature at 700 to 800 ° C. or higher at all times.
For this reason, the method of photographing the furnace wall by inserting a camera into the carbonization chamber as in the case of Patent Document 1 requires a cooling means for protecting the apparatus from heat, making the apparatus complicated and expensive. There is a problem of conversion. In addition, since the apparatus is inserted into the furnace and photographed, the camera must be moved in a narrow space called a carbonization chamber, and there is a problem that measurement takes time.

Patent Documents 2 and 3 do not target a coke oven, and the techniques described in these documents cannot be directly applied to a coke oven, and have the following problems.
Each of Patent Documents 2 and 3 can only grasp the damage state of the refractory in the furnace before the refractory repair, and cannot quantitatively grasp the wear amount (wear depth) of the refractory. If the wear amount (wear depth) of the refractory cannot be quantitatively grasped, the fire resistance in the furnace to reliably avoid troubles such as clogging and hold-down caused by the wear amount (wear depth) Goods cannot be managed properly.

  The present invention has been made to solve such a problem, and provides a method for measuring a profile of a refractory in a coke oven and a refractory capable of measuring the amount of wear of the refractory on the furnace wall and bottom of the coke oven by a simple method. The object is to obtain a method for measuring the amount of wear of objects.

The inventor studied the following points in order to solve the above problems.
The coke oven carbonization chamber has a furnace height of about 6 m, a kiln width of about 0.45 m, a furnace length of about 16 m, a high height and a large depth, whereas the distance between the furnace walls is It is a very narrow space that is short.
(A) How should the profile of the wall forming such a narrow space be measured?

(B) Also, in order to quantitatively measure the amount of refractory wear in a coke oven, the state before the repair where the refractory was worn and the state after the repair after the refractory was repaired It is necessary to obtain a refractory profile. However, there is a lapse of time between the state after the repair and the state before the repair, and it is not realistic to always install the camera at the same position. From this, how should we grasp the same location of the imaging target before and after repair?
(C) In this regard, it is conceivable to provide a reference point that does not change in position before and after the repair. However, when the refractory object to be imaged is in a red hot state, it becomes a reference point for photographing. It is necessary to consider that the difference in luminance is large, but what should this point be?
The inventor has intensively studied various problems to be solved and found a solution to complete the present invention. Specifically, the inventor has the following configuration.

(1) A refractory profile measurement method in a coke oven according to the present invention is a refractory profile measurement method in a coke oven in which a refractory is installed on a furnace wall and a furnace bottom, and after extruding coke, In the state where the refractory is red hot, the refractory and the reference point arranged in the vicinity thereof are imaged, and the imaging is to capture a plurality of images with different photographing angles with respect to the same object. The image data is acquired and the profile of the refractory is calculated.

Since a plurality of images with different shooting angles are captured with respect to the same object, and the image data is acquired to calculate the profile of the refractory, a plurality of images with different shooting angles can be captured. As long as the profile can be calculated, it can be applied to a narrow space such as a carbonization chamber.
In addition, since the profile of the refractory is calculated from the image data including the reference point, it is possible to compare with the profile of the refractory that is not worn based on this reference point, thereby The amount of wear can be known quantitatively.
In addition, the profile of the state in which the refractory is not worn can be acquired from various things such as a design drawing of the coke oven, imaging data obtained by imaging the state of repairing the refractory, and the like. In this case, the relationship with the reference point in the pre-repair data acquisition process after the coke oven operation is clarified.

  In addition, imaging including the reference point means that when the reference point and the refractory are imaged simultaneously, the target of the reference point and the refractory are separately focused and imaged in multiple times. Includes both.

  The state in which the refractory is red-hot refers to a state in which the refractory appears visually red due to the high temperature after the coke is extruded, and in terms of surface temperature, it refers to a state of 700 ° C. or higher.

(2) Further, in the imaging described in (1) above, the first data captured in accordance with the brightness of the red refractory is combined with the second data captured in accordance with the brightness of the reference point. It includes a synthesis step of acquiring image data including both the refractory and the reference point.

(3) Moreover, the reference point described in the above (1) or (2) is a specific point on the iron skin of the kiln and a specific point on the joint of the refractory.

(4) A method for measuring the amount of wear of a refractory in a coke oven according to the present invention is a method for measuring the amount of wear of a refractory in a coke oven in which the refractory is installed on the furnace wall and the bottom of the furnace. A step of calculating a profile of the refractory in a state where the refractory is performed, and after extruding coke from the coke oven, the refractory is in a red-hot state and includes the refractory and a reference point disposed in the vicinity thereof. The imaging is for imaging a plurality of images with different imaging angles for the same object, obtaining the image data and calculating the profile of the refractory, and the profile of those profiles And a step of calculating an amount of wear of the refractory from the difference.

(5) In the above (4), the step of acquiring the refractory profile in a state where the refractory is repaired includes the refractory and a reference point arranged in the vicinity thereof. The imaging is to capture a plurality of images with different imaging angles with respect to the same object, and is a step of obtaining the image data and calculating the profile of the refractory. is there.

(6) Moreover, in the above-mentioned (4) or (5), the imaging in the state where the refractory is in red is the first data imaged in accordance with the luminance of the red refractory and the reference It includes a synthesis step of obtaining image data including both the refractory and the reference point by synthesizing the second data picked up in accordance with the luminance of the point.

  According to the present invention, since the profile of the refractory can be measured from outside the furnace after the coke is extruded, the refractory can be managed easily, surely and appropriately. As a result, it is possible to appropriately manage the refractory in the furnace in order to surely avoid troubles such as clogging and stoppage due to wear of the refractory, and to stably produce coke.

  FIG. 1 is a diagram for explaining a method for measuring the amount of wear of a refractory in a coke oven according to an embodiment of the present invention, and schematically shows a state in which the refractory on the furnace wall in the carbonization chamber 3 is photographed. Show. 2 is a cross-sectional view taken along line AA in FIG.

The carbonization chamber 3 of the coke oven 1 is a narrow space having a height and a depth, for example, having a height of about 6 m, a width of about 0.45 m, and a length (depth) of about 16 m.
The method for measuring the amount of wear of the refractory 5 in the present embodiment is to image the refractory 5 in such a narrow space with the camera 7 installed outside the furnace and obtain the amount of wear. Specifically, It consists of the following configurations.

In the method for measuring the amount of wear of the refractory 5 according to the present embodiment, the refractory 5 in the coke oven 1 is repaired and the refractory 5 is photographed including the reference point to acquire image data. A data acquisition step, a repair state profile calculation step of calculating a profile of the refractory 5 in the repair state based on the acquired repair state data, a coke extruded from the coke oven 1 and carbon adhering to the surface of the refractory 5 After burning, the refractory 5 is photographed including a reference point to obtain image data, and a pre-repair data acquisition step, and a profile of the refractory 5 in a pre-repair state based on the acquired pre-repair data. A pre-repair profile calculation step to calculate, a refractory wear amount calculation step to calculate the wear amount of the refractory 5 from the difference between both profiles of the repair state profile and the pre-repair profile, It has.
Hereinafter, each process will be described with reference to the drawings.

<Repair status data acquisition process>
The repair state data acquisition step is a step of acquiring image data by photographing the refractory 5 on the furnace wall in the repair state.
As shown in FIG. 1, a digital 3D camera 7 is installed on the outside of the carbonization chamber 3 to be imaged on the kiln side. The 3D camera 7 may be a digital camera that can perform stereoscopic image processing on an object to be imaged. For example, two cameras such as DigiCats StereoProfiler SP-50 manufactured by Komatsu Engineering are separated by a predetermined distance and stored in one box. Use something like that.
The 3D camera 7 can capture a plurality of images with different imaging angles with respect to the same object.

  Since the 3D camera 7 used for photographing is a precision device, a heat shield plate, a cooling device, etc. are provided to protect the 3D camera 7 from heat, particularly when photographing in a pre-repair state described later. Is desirable.

  In the state after the repair, the carbonization chamber 3 to be imaged has a flat flat furnace wall 9 as shown in FIG. 3 which is a cross-sectional view taken along the line BB in FIG. The line representing the furnace wall 9 is linear.

At the time of shooting, a point that serves as a reference for associating each position of each profile of the profile based on the data obtained by imaging the restoration state and the profile based on the data obtained by imaging the pre-repair state described later is included. Take an image. The reference point needs to have no change at two points in time when the image is taken in the restoration state and when the image is taken in the state before the restoration.
In this Embodiment, as shown in FIG. 4 which expands and shows a part of FIG. 2, the upper and lower two points 13a and 13b of the iron skin 11 installed in the kiln and the refractory which is the refractory 5 Three points with the specific point 13c of the brick joint are used as reference points, and the refractory 5 on the furnace wall is photographed by the 3D camera 7 so as to include these points. Note that the reference point is not installed for the purpose of imaging, and a specific part of an existing structure may be used as a reference point.
Image data obtained by photographing is input and stored in a memory of a personal computer (hereinafter referred to as “PC”).

Since the carbonization chamber 3 has a long furnace length (depth), when the reference points 13a and 13b in the furnace port and the refractory 5 in the furnace cannot be imaged simultaneously, the reference points 13a and 13b and the refractory 5 May be imaged in two steps and combined.
In addition, as shown in FIG. 2, the carbonization chamber 3 has about 6 m in the height direction, and thus imaging is performed, for example, by dividing it into six in the height direction. In this case, as shown in FIG. 2, it can be easily synthesized by overlapping a part vertically.
Moreover, since the carbonization chamber 3 has a long length (depth), photographing is performed from both sides of the coke discharge side and the extruder side.

Shooting is performed from outside the furnace in a narrow gap, but if the optical axis of the camera lens and the wall surface are not parallel and a certain angle can be formed, imaging is possible. It is possible to calculate a profile based on the principle of plane trigonometry.
Regarding the wear of the furnace wall 9 of the carbonization chamber 3, coke is caused by the fact that coal is inserted from the coal loading holes 15 (see FIG. 1) provided at a plurality of locations in the furnace length direction above the carbonization chamber 3. The inventor's investigation shows that the wear of the furnace wall 9 below the coal hole 15 closest to the discharge side on the discharge side (furnace wall 9 at a position about 3 m from the coke side entrance) Therefore, by taking an image centering on this position, it is possible to know the wear state of the most worn portion in the furnace. Therefore, it is possible to know the repair timing by imaging the above-mentioned part in the furnace wall 9, and imaging only this part is also an effective method for managing the furnace wall wear state.

<Repair state profile calculation process>
The repair state profile calculation step is a step of creating a profile of the refractory 5 based on the captured image data of the repair state. This step is performed by the CPU executing a predetermined program in the PC (the same applies to a “pre-restoration profile calculation step” and a “refractory wear amount calculation step” described below). Specifically, the following processing is performed.

First, spatial coordinates for analyzing imaging data are created (see FIG. 5). As a method of creating coordinates, first, for example, an installation point C of one camera is determined as a point to be the origin, the x axis is set in the right direction in the drawing of the origin, and the installation point B of the other camera is on the x axis. To be in. A direction passing through the origin and perpendicular to the x-axis is taken as the y-axis. A direction passing through the origin and orthogonal to the paper surface is taken as the z-axis.
When the spatial coordinates are made, the profile of the refractory 5 is created by analyzing the captured digital data of the refractory 5 of the coke oven 1 and displaying the surface of the refractory 5 in the spatial coordinates. The principle of creating a profile by analyzing the digital data will be described in a pre-restoration profile calculation step described later.

<Pre-repair data acquisition process>
The pre-repair data acquisition step is a step of acquiring image data by imaging the refractory 5 including the reference point after extruding coke from the carbonization chamber 3. When imaging, it is desirable to open the door of the carbonization chamber 3 and the charring hole 15 to burn carbon adhering to the surface of the refractory 5 to expose the refractory 5.
Also in this case, the refractory 5 is imaged including the three reference points 13a, 13b, and 13c in the same manner as the imaging in the repaired state described above. However, in this case, since the refractory 5 is in a red-hot state, the brightness of the refractory 5 and the reference points 13a and 13b outside the furnace are too different from each other, so the refractory 5 and the reference points 13a and 13b are different. Even if images are taken at the same time, both cannot be taken. That is, if the exposure of the 3D camera 7 is adjusted to the refractory 5, the reference points 13 a and 13 b outside the furnace are dark and cannot be imaged. Conversely, if the exposure of the 3D camera 7 is adjusted to the reference points 13 a and 13 b outside the furnace, The part of the object 5 causes halation and cannot be imaged.
Therefore, the following is performed.

  First, the 3D camera 7 is adjusted to a state suitable for imaging the reference points 13a and 13b outside the furnace, and the refractory 5 is imaged including the reference points 13a and 13b. FIG. 6 shows this imaging state. In this state, the reference points 13a and 13b can be imaged, but the refractory 5 is too bright to image. In FIG. 6, what can be imaged is indicated by a solid line, and what cannot be imaged is indicated by a broken line.

Next, without moving the 3D camera 7 described above, the refractory including the reference points 13a and 13b is set in a state suitable for imaging the red refractory refractory 5, for example, with a filter installed. 5 is imaged. FIG. 7 shows this imaging state. In this state, the refractory 5 can be imaged, but the reference points 13a and 13b are too dark to be imaged.
Next, the image data of the refractory 5 including the reference points 13a and 13b and the reference point 13c outside the furnace is synthesized by synthesizing the two image data. FIG. 8 shows this synthesized data.
This image composition processing is performed by the CPU of the PC executing a predetermined program.

<Pre-restoration profile calculation process>
In the pre-repair profile calculation step, the synthesized digital data is analyzed and the surface of the refractory 5 is displayed in spatial coordinates, so that the profile of the refractory 5 after coke extrusion is converted into spatial coordinates in the same manner as the repair state profile. It is a process to create.
Hereinafter, the principle of creating a profile by analyzing digital data will be described with reference to FIG.

  FIG. 9 shows a part of the refractory 5 in a worn state on the coordinates shown in FIG. In FIG. 9, point C is the origin and the position of one camera. Point B is a point on the x-axis that is a distance a away from point C, and is the position of the other camera. Point A is an arbitrary point on the refractory 5. In order to create the profile of the refractory 5, the coordinates of the point A need only be known.

If one side a and corners B and C are obtained by plane trigonometry, the corner A and the side lengths b and c are given by the following equations.
A = π− (B + C)
b = asinB / sinA
c = asinC / sinA

To obtain the coordinates of point A using the above relationship, the following is performed.
The refractory 5 is imaged from two points B and C, and ∠B and ∠C are obtained by image analysis for the point A on the refractory. If point C is the origin of coordinates, the coordinates of point A are as follows.
A (x, y) = A (bcosC, bsinC)
Similarly, the coordinates of the point A ′ are as follows.
A ′ (x ′, z ′) = A ′ (b′cosC ′, b′sinC ′)
∠C ′ is obtained by considering C ′ = C + ΔC and obtaining a displacement ΔC from the reference point by image analysis of digital data. In addition, since the information in the Z direction is included in the image analysis, the three-dimensional coordinates A (x, y, z) can be obtained by analyzing the information in the same manner. By repeating this at many points, the three-dimensional unevenness of the refractory surface can be measured.
Since the profile creation method in the present embodiment is based on such a principle, as long as the refractory 5 of the furnace wall 9 can be imaged, the profile can be obtained and can be applied to imaging in a narrow space.

<Refractory wear amount calculation process>
The refractory wear amount calculation step is a step of calculating the wear amount of the refractory 5 from the difference between both the restoration state profile and the pre-repair profile.
The profile in the repair state and the profile in the pre-repair state include the same reference point and can be displayed in the same spatial coordinates, and thus can be superimposed. And the wear amount of the refractory 5 can be calculated | required by calculating | requiring the difference of both in each position of a profile. FIG. 10 shows a state in which two profiles are superimposed in a cross-sectional view, where a broken line indicates a repaired state and a solid line indicates a state before repairing.
In FIG. 10, the difference between the two profiles, for example, the portion indicated by the arrow is the amount of wear.

In the case of a furnace wall refractory, if the maximum value of the amount of wear (wear depth) is 20 mm or more, it is repaired and the wear is filled. If the furnace wall refractory becomes larger than this amount of wear, coke enters the portion and becomes a resistance at the time of extrusion, so that pressing or clogging occurs.
In addition, as long as repair is the method of repairing the refractory 5, what kind of method may be employ | adopted. For example, for furnace wall refractories, thermal spraying, dry (dry) spraying, semi-dry spraying, wet spraying methods, and the like can be given.

As described above, according to the present embodiment, since the amount of wear of the refractory 5 before repair can be quantitatively known, the management of the refractory 5 can be performed reliably and appropriately. As a result, troubles such as clogging and stoppage due to wear of the refractory 5 can be surely prevented, which can contribute to improvement of coke production efficiency.
In addition, in the pre-repair state, imaging can be performed in a state where the refractory 5 is red hot, and the imaging itself can be performed in a very short time, so that the operation can be performed without affecting the operation.

Further, in the above embodiment, since the image is picked up so as to include three points as the reference points, the image data obtained by picking up the repaired state and the state before the repair are picked up. Even when there is a three-dimensional difference between two pieces of image data, both pieces of image data can be compared.
Of course, when the image data in these two states has only one-dimensional or two-dimensional differences, the reference point may be one point or two points.

  In the above embodiment, the photographing action is performed in order to obtain the profile of the refractory 5 in the repaired state. However, the refractory 5 in the same state as the repaired state, that is, the refractory 5 in the state where the refractory 5 is not worn is used. Since the profile can be obtained by, for example, a blueprint of the coke oven 1, in such a case, the profile of the refractory 5 obtained from the blueprint and the carbonization chamber 3 before repairing are obtained by imaging. The amount of wear of the refractory 5 can be known by comparing the profile calculated from the obtained image data. However, in this case as well, a reference point is required to compare the two profiles, and therefore it is necessary to include a reference point that enables this comparison when photographing in the pre-repair state.

In addition, the above description has been made on the furnace wall 9 of the carbonization chamber 3, but the amount of wear of the refractory 5 can be measured on the furnace bottom in the same manner as the furnace wall 9.
When photographing the bottom of the furnace, a camera 7 is installed on the lift carriage at the coke side kiln, and the bottom of the furnace is imaged obliquely from above. In this case, the reference points are, for example, specific points of both corners of the iron door and the joint of the refractory 5 in the furnace.
When shooting the bottom of the furnace, take pictures from both the extruder side and the coke discharge side.
In the case of the furnace bottom, when the maximum wear depth becomes 30 mm or more, the worn part is repaired by repairing spraying, dry (dry) spraying, semi-dry spraying, wet spraying, throwing material, etc. Repair.

It is a figure for demonstrating the thickness measurement method of the refractory in the coke oven which concerns on one embodiment of this invention. It is arrow AA sectional view taken on the line in FIG. It is arrow BB sectional drawing in FIG. It is a figure which expands and shows a part of FIG. It is explanatory drawing of the coordinate for analyzing image data. It is explanatory drawing of the imaging method of the coke oven of the state before repair. It is explanatory drawing of the imaging method of the coke oven of the state before repair. It is explanatory drawing of the imaging method of the coke oven of the state before repair. It is explanatory drawing of the creation principle of the profile by the analysis of digital data. It is explanatory drawing of the amount of wear of a furnace wall.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coke oven 3 Coking chamber 5 Refractory 7 3D camera 9 Furnace wall 11 Iron skin 13a, 13b, 13c Reference point 15 Charging hole

Claims (6)

A method for measuring a profile of the refractory in a coke oven in which the refractory is installed on the furnace wall and the bottom of the furnace,
After extruding the coke, the refractory is in a red-hot state and is imaged including the refractory and a reference point disposed in the vicinity thereof, and the imaging is a plurality of images with different photographic angles for the same object. A method for measuring a profile of a refractory in a coke oven, which captures an image and calculates the profile of the refractory by acquiring the image data. The imaging is to obtain image data including both the refractory and the reference point by combining the first data taken in accordance with the brightness of the red refractory and the second data taken in accordance with the brightness of the reference point. A method for measuring a profile of a refractory in a coke oven according to claim 1, further comprising a synthesis step. The method of measuring a profile of a refractory in a coke oven according to claim 1 or 2, wherein the reference point is a specific point on the iron skin of the kiln and a specific point on the joint of the refractory. A method for measuring the amount of wear of the refractory in a coke oven in which the refractory is installed on the furnace wall and the bottom of the furnace,
Calculating the profile of the refractory with the refractory repaired;
After the coke is extruded from the coke oven, the refractory is in a red-hot state and is imaged including the refractory and a reference point located near the refractory. A plurality of images obtained by acquiring the image data and calculating a profile of the refractory, and calculating a wear amount of the refractory from a difference between the profiles. A method for measuring the amount of wear of a refractory in a coke oven. The step of acquiring a profile of the refractory in a state where the refractory is repaired includes imaging the refractory and a reference point disposed in the vicinity thereof, and the imaging is performed at an imaging angle with respect to the same object. 5. The method for measuring a wear amount of a refractory in a coke oven according to claim 4, wherein the method is a step of taking a plurality of different images and calculating the profile of the refractory by acquiring the image data. . Imaging in a state where the refractory is red-hot is performed by combining the first data captured in accordance with the brightness of the red refractory and the second data captured in accordance with the brightness of the reference point, and the refractory and the reference. The method for measuring the amount of wear of a refractory in a coke oven according to claim 4 or 5, further comprising a synthesizing step of acquiring image data including both points.

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