CN105803153B - The real time on-line monitoring system and method for converter lining refractory material security - Google Patents

Abstract

The invention relates to a real-time on-line monitoring system and method for the safety of converter lining refractory materials. The system includes a temperature measurement unit, a data transmission unit, a data processing unit and an output unit. The temperature measurement unit has a thermal instrument; The data processing unit has a model module and a calculation module; the output unit outputs the processing results of the data processing unit; the monitoring method includes the following steps: (1) setting a converter furnace type module and a furnace lining parameter module; The temperature unit collects the converter shell temperature in real time, and transmits it to the data processing unit through the data transmission unit; (3) The calculation module of the data processing unit calculates the thickness of the converter lining refractory material according to the converter shell temperature. The detection result of the monitoring system and method is a cloud image of the furnace lining thickness, which can comprehensively and directly reflect the detection result, not only can monitor in real time, but also has a theoretical basis for the result, which is more accurate than the traditional empirical detection method.

Description

Real-time on-line monitoring system and method for safety of converter lining refractories

technical field

The invention relates to the technical field of safe production and equipment maintenance of a steelmaking converter, in particular to a real-time on-line monitoring system and method for the safety of a converter lining refractory material.

Background technique

The safe operation of the converter is a necessary guarantee for the smooth production of iron and steel enterprises. During the steelmaking process, the lining refractories of the converter will continue to erode along with the smelting, which will bring great safety hazards to the steelmaking production. Therefore, in the production process, it is necessary to The safety of converter lining refractories is inspected and maintained. The areas where potential safety hazards occur in converter lining refractories mainly include converter bottom, converter ironing side, converter tapping side, especially the position of the bottom blowing gas supply element and the joint position of the furnace bottom, and the impact area of scrap steel and molten iron.

At present, the current detection methods for the safety of converter bottom lining refractories mainly include: the empirical "push rod method or liquid level measurement method" for small converters with a nominal capacity of less than 100t, and the large and medium-sized converters with a nominal capacity of more than 100t The intermittent thickness gauge measurement method; and the detection methods for the safety of converter body lining refractories mainly include: empirical manual observation and thickness gauge measurement. The above methods have the following disadvantages: 1) Experience factors are dominant, and the detection time is greatly disturbed by artificial arrangements; 2) Online real-time detection cannot be realized, and real-time tracking is lacking. At the same time, the detection time is long, which affects the rhythm of production and smelting, and requires on-site Production scheduling to cooperate with the inspection, resulting in hasty measurement and affecting the measurement results; 3) The measurement is all local point measurement, lacking an intuitive and comprehensive measurement of the whole, and the measurement of the furnace body and other areas is even less good, especially for the furnace after slag splashing The formed false furnace lining is helpless, and the effect of maintenance measures is lack of tracking. Although there are reports on the thermocouple detection method, there is no practical application.

Contents of the invention

In view of the above analysis, the present invention aims to provide a real-time online monitoring system and method for the safety of converter lining refractory materials, to solve the problem that the existing detection methods cannot be monitored in real time, are greatly affected by empirical factors, are limited by the rhythm of smelting production and Lack of traceability of maintenance results.

The purpose of the present invention is mainly achieved through the following technical solutions:

One aspect of the present invention provides a real-time online monitoring system for the safety of converter lining refractory materials, including a temperature measurement unit, a data transmission unit, a data processing unit and an output unit, wherein the temperature measurement unit has a thermometer to collect real-time The shell temperature is transmitted to the data processing unit through the data transmission unit; the data processing unit has a model module and a calculation module; wherein the model module has a converter furnace type module and a furnace lining parameter module, according to the furnace type and furnace lining of the measured converter The parameters are set; the calculation module has a heat transfer principle formula and an empirical correction formula, and according to the set converter furnace type module and lining parameter module, through the heat transfer principle formula and the empirical correction formula, the temperature collected by the temperature measurement unit The furnace shell temperature is converted into the thickness of the converter lining refractory material; the output unit outputs the processing result of the data processing unit.

Further, the data processing module also includes a safety identification module and an expert module, and the data processing unit also includes a safety identification module and an expert module, wherein the safety identification module has the original state thickness of the measured converter lining refractory material, so The safety appraisal module combines the calculation results of the calculation module to calculate the change range of the thickness of the converter lining refractory material, and gives a furnace condition judgment; the expert module has a database of smelting classic cases, and combines the furnace condition judgment to give safe production guidance .

Further, the acquisition area where the temperature measuring unit collects the temperature of the converter shell in real time includes: the bottom of the converter, the shaft of the converter on the ironing side, and the shaft of the converter on the tapping side.

Further, the acquisition area where the temperature measurement unit collects the temperature of the converter shell in real time includes: during the oxygen-blowing smelting process of the converter, the acquisition area is the front shaft area between the bottom of the converter ironing side and the liquid level of the molten pool; During the process, the collection area is the bottom of the converter; before the slag splashing is completed, the collection area is the furnace body of the converter on the ironing side and the furnace on the tapping side of the converter; after the slag splashing, the collection area is the bottom of the converter, the side Body, converter tapping side furnace body.

Further, the position of the thermostat is fixed, and the temperature of the furnace shell in the area within the viewing angle is obtained according to the shaking of the converter body.

Another aspect of the present invention also provides a real-time online monitoring method for the safety of converter lining refractories, comprising the following steps:

(1) Set converter furnace type module and furnace lining parameter module;

(2) Use the temperature measurement unit to collect the temperature of the converter shell in real time, and send it to the data processing unit through the data transmission unit;

(3) The calculation module of the data processing unit calculates the temperature of the converter shell as the thickness of the converter lining refractory material according to the heat transfer principle formula and the empirical correction formula.

Further, the method further includes: inputting the thickness of the original lining refractory material of the converter, comparing the thickness of the converter lining refractory material with the original lining refractory material thickness of the converter through the safety identification module to calculate the variation range of the converter lining refractory material thickness, and giving the furnace condition Judgment: The furnace condition judgment result is given safety production guidance through the expert module.

Further, the empirical correction formula is obtained by correcting the heat transfer principle formula according to the different periods of the converter operation and the condition of the previous converter.

Further, the empirical correction formula includes correction 1, correction 2 and correction 3, wherein correction 1 is: H ₁ =K×2.04×(T ₁ -T ₂ )-1765, and correction 2 is: H ₂ =K×2586ln (T ₁ -T ₂ )-17654, Amendment 3 is: Where: T ₁ is the temperature in the furnace, T ₂ is the temperature of the furnace shell, H ₁ , H ₂ and H ₃ are the thicknesses of the furnace lining refractories, K is a correction coefficient related to temperature, and K is 0.92 to 1.10; the furnace operation of the converter is In the early stage, when the condition of the previous furnace converter is good, the empirical correction formula is selected as correction 1; the converter operation is the early stage, and when the previous furnace condition is good, the empirical correction formula is selected as correction 2; the converter operation is the early stage, When the condition of the previous converter is poor, the empirical correction formula is selected as Amendment 3; when the converter is in intermediate service and the previous converter is in excellent or good condition, the empirical correction formula is selected as Amendment 2; If the converter is in middle service and the condition of the previous converter is poor, the empirical correction formula should be selected as Amendment 3; if the converter is in post service and the condition of the previous converter is excellent or good, the empirical correction formula should be selected as Amendment 2; When the above-mentioned converter operation is the latter operation, and the previous converter operation is in poor condition, the empirical correction formula is selected as revision 3.

Further, if the range of change in the thickness of the converter lining refractory material is increased, and the increase range is greater than 200mm, the furnace condition of the converter is judged to be that the furnace lining has risen; the range of change in the thickness of the converter lining refractory material is less than 100mm, and the converter condition is judged to be The furnace condition is excellent; the range of change in the thickness of the converter lining refractory material is reduced and the decrease range is greater than 100 mm and less than 200 mm, or the range of change is increased and the range of growth is between 100-200 mm, and the furnace condition of the converter is judged to be in good condition; If the range of change in the thickness of the converter lining refractory material is reduced, and the range of reduction is greater than 200mm, the furnace condition of the converter is judged to be poor.

The structure of the converter lining from outside to inside along the lining section is: metal furnace shell, permanent layer and working layer, and the permanent layer and working layer are both made of refractory materials. According to the principle of heat conduction, when the heat transfer coefficient and the temperature on one side of the heat transfer medium are constant, the temperature on the other side of the heat transfer medium can be calculated from the thickness of the heat transfer medium according to the heat conduction formula. According to this principle, the temperature in the converter furnace (the inner end of the refractory material furnace) is determined by the temperature of molten steel for smelting, and has a definite temperature, and the thermal conductivity of each structural layer of the converter lining is known, so the thickness change of the refractory material will cause Changes in the outer section of the refractory furnace (converter shell temperature), the temperature of the furnace shell is measured by a thermal imager, and the thickness of the refractory material is calculated through the heat conduction formula to obtain the safety of the road-produced refractory material.

The beneficial effects of the present invention are as follows:

The present invention provides a real-time on-line monitoring system and method for the safety of refractory material in converter lining. Under the condition that the temperature in the converter furnace (inner end of refractory material furnace) is constant, the difference in temperature of refractory material (refractory material furnace shell end) can be Responding to the heat transfer principle of the thickness of the refractory material with a certain heat transfer coefficient, the temperature data of the converter shell section is obtained through the online real-time detection of the thermal imager, and is transmitted to the computer for data processing, and the thickness of the furnace lining is calculated back, combined with the experts in the computer The module gives guidance on safe production. The detection result of the present invention is a cloud map of the furnace lining thickness, which can comprehensively and directly reflect the detection results. Not only can real-time monitoring, but also the results have a theoretical basis. Compared with the traditional empirical detection method, it is more accurate. sex;

The present invention can monitor the temperature value of the furnace lining refractory material in real time during the smelting process and give the feedback of the furnace lining refractory material parameters according to a settable time interval; for the feedback of the monitoring effect, both the current monitoring result status and the original furnace status can be selected The comparison can be used to observe the change trend of the furnace lining, and the comparison between the current monitoring results and the previous N (N=1~10) furnace monitoring results can be selected to provide a reference for the maintenance effect tracking.

Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

Description of drawings

The drawings are for the purpose of illustrating specific embodiments only and are not to be considered as limitations of the invention, and like reference numerals refer to like parts throughout the drawings.

Fig. 1 is the real-time on-line monitoring method schematic diagram of converter lining refractory material safety of the present invention;

Fig. 2 is a schematic diagram of selection of the empirical correction formula of the calculation module of the present invention;

Fig. 3 is a schematic diagram for judging the furnace condition of the safety identification module of the present invention;

Fig. 4 is the working schematic diagram of expert module of the present invention;

Fig. 5 is the furnace bottom temperature nephogram detected by thermal imager in the embodiment of the present invention;

Fig. 6 is the schematic diagram of setting isotherm L1 of the furnace bottom temperature nephogram detected by thermal imager in the embodiment of the present invention;

Fig. 7 is the heat transfer coefficient and specific heat capacity of the furnace shell material of the embodiment of the present invention;

Fig. 8 is the heat transfer coefficient and specific heat capacity of the permanent layer material of the embodiment of the present invention;

Fig. 9 is the heat transfer coefficient and specific heat capacity of the working layer material of the embodiment of the present invention;

Fig. 10 is the furnace shell temperature and comprehensive heat transfer coefficient of the embodiment of the present invention;

Fig. 11 is the temperature and calculated thickness of line L1 of the furnace bottom temperature nephogram detected by the thermal imaging camera according to the embodiment of the present invention.

Detailed ways

Preferred embodiments of the present invention will be specifically described below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of the application and are used together with the embodiments of the present invention to explain the principles of the present invention.

The schematic diagram of the real-time on-line monitoring method for the safety of the converter lining refractory material of the present invention is shown in Figure 1. The temperature measurement unit measures the furnace shell temperature and transmits it to the data processing unit through the data transmission unit. The data transmission unit passes the converter model of the model module and the furnace lining parameters. The heat transfer principle formula and empirical correction formula of the module and calculation model calculate the thickness of the converter lining refractory material; the data processing unit contains a safety appraisal module and an expert module, and the safety appraisal module combines the thickness of the converter lining refractory material calculated by the calculation module with the The furnace condition judgment is obtained by comparing the thickness of the original converter lining refractory material, and the expert module gives guidance on safe production based on the furnace condition judgment combined with classic smelting cases.

The selection of the empirical correction formula of the calculation module is obtained by correcting the heat transfer principle formula according to the different periods of the converter service life and the converter condition, as shown in Figure 2. The required correction formula; the furnace condition judgment of the safety appraisal module is shown in Figure 3. The furnace conditions of the converter include the furnace lining rise, the furnace condition is excellent, the furnace condition is good and the furnace condition is poor; the work of the expert module is shown in Figure 4. When the furnace condition is excellent, the expert module only needs to give a safe Production guidance means that when the furnace condition is rising, good or poor, not only according to the area and area, but also according to the smelting classic database to give safe production guidance.

The embodiment of the present invention takes a 120t converter in a certain factory as an example, the converter adopts annular seam type bottom-blown gas supply elements (six branches, bottom-blown gas supply intensity is 0.08-0.25Nm ³ /min·t, and the thickness of the metal furnace shell of the converter is 500mm , The permanent layer of the furnace bottom is 400mm, the thickness of the furnace lining is 900mm, and the furnace age is 5587 during the test.

The expression of the heat transfer coefficient of the furnace shell is: As shown in Figure 7;

The expression of the heat transfer coefficient of the working layer is: As shown in Figure 8;

The expression of the permanent layer heat transfer coefficient is: As shown in Figure 9;

The expression of furnace shell surface temperature and comprehensive heat transfer coefficient is: _{λcomprehensive} =9.953e ^0.002T , as shown in Figure 10; the comprehensive heat transfer coefficient is a comprehensive heat transfer coefficient of the three parts of converter working layer, permanent layer and furnace shell.

The calculation expression for the thickness of the lining refractory material in the implementation case is: H=K×2586ln(T ₁ -T ₂ )-17654,

In the formula, _T1 is the temperature in the furnace, _T2 is the temperature of the furnace shell, H is the thickness of the lining refractory material, and K is the correction coefficient related to the temperature.

The infrared thermal imaging camera model selected in this example is VarioCAM HD head 880, equipped with a 60mm infrared lens, thermal sensitivity (NETD): 30mK@30°C, temperature measurement accuracy: +/-1.5K or +/-1.5%.

Then carry out real-time online monitoring of the safety of the converter lining refractory material, and its method includes the following steps:

(1) Set up the converter furnace type module and the furnace lining parameter module. The converter model is a 120t top-bottom combined blown converter. The thickness of the metal furnace shell of the furnace lining is 500mm, the permanent layer of the furnace bottom is 400mm, and the thickness of the furnace lining layer is 950mm. The heat transfer coefficient expression of the furnace shell is: The expression of the heat transfer coefficient of the working layer is: The expression of the permanent layer heat transfer coefficient is: The expression of comprehensive heat transfer coefficient is: _{λcomprehensive} =9.953e ^0.002T

(2) Use the thermal instrument of the temperature measuring unit to collect the temperature of the converter shell in real time, the collection area is the bottom of the converter during the tapping process, and transmit it to the data processing unit through the data transmission unit;

(3) The calculation module of the data processing unit calculates the thickness of the converter lining refractory material according to the temperature of the converter shell; the furnace is in intermediate service, and the previous converter is in good condition, so the correction 2 is selected: H ₂ =K×2586ln(T ₁ -T ₂ )-17654, where _T1 is the furnace temperature, _T2 furnace shell temperature, _H2 is the thickness of the furnace lining refractory material, K is a correction coefficient related to temperature, and the K value is selected as 0.96. The embodiment measures the furnace temperature T ₁ = 1651°C. The furnace bottom temperature cloud diagram detected by the thermal imager in the embodiment of the present invention is shown in Figure 5; with the furnace shell temperature of 380°C as the isothermal boundary, the furnace bottom temperature cloud diagram detected by the line thermal imager is shown in Figure 6 along the L1 line; along the isothermal The temperature data in the direction of the line arrow and the calculated thickness results are shown in Fig. 11.

(4) Input the original converter lining thickness, compare the calculated thickness of the converter lining refractory material with the original state thickness of the converter through the safety identification module, calculate the variation range of the converter lining refractory material thickness, and give the furnace condition judgment; the lining thickness of the L1 line is reduced The amplitude is in the range of 104.1-169.6mm, and the judgment result is: the furnace is in good condition;

(5) The safety parameters of the converter lining are given safety production guidance through the expert module. Among them, the area ratio of the high-temperature area defined by the 380°C isotherm is 11.13%, and the iron side is thinner. The safety production guidance given by the expert module is: reduce the addition of large and heavy scrap steel.

In summary, the embodiment of the present invention provides a detection system and method for the safety of converter lining refractory materials. The temperature data of the converter shell section is obtained through online real-time detection by a thermal imager, and is transmitted to a computer for data processing. Calculate the thickness of the furnace lining, and combine with the expert system in the computer to give guidance on safe production. The detection result of the present invention is a cloud map of the furnace lining thickness, which can comprehensively and directly reflect the detection results. Not only can real-time monitoring, but also the results have a theoretical basis. Compared with Compared with the traditional empirical detection method, it is more accurate.

The above is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed in the present invention can easily think of changes or Replacement should be covered within the protection scope of the present invention.

Claims (7)

1. a kind of real time on-line monitoring system of converter lining refractory material security, it is characterised in that including temperature measuring unit, number According to delivery unit, data processing unit and output unit,

Wherein described temperature measuring unit has hot Wen Yi, gathers converter shell temperature in real time, and send to by data transfer unit Data processing unit；

The data processing unit has model module and computing module；Wherein described model module have converter profile module and Furnace lining parameter module, is configured according to the type of furnace of surveyed converter and furnace lining parameter；The computing module has heat transfer theory public affairs Formula and empirical remedy equation, according to the converter profile module and furnace lining parameter module of setting, by heat transfer theory formula and The casing temperature that the temperature measuring unit gathers, is changed into the thickness of converter lining refractory material by empirical remedy equation；

The output unit exports the handling result of the data processing unit；

The data processing unit further includes secure authentication module and expert module, wherein the secure authentication module has converter The reset condition thickness of fire proof material of furnace lining, the secure authentication module is calculated with reference to the result of calculation of the computing module to be turned Stove fire proof material of furnace lining thickness change amplitude, and provide working of a furnace judgement；The expert module, which has, smelts classical case database, Judge to provide safety in production instruction with reference to the working of a furnace；

The empirical remedy equation includes correcting 1, correct 2 and correcting 3, wherein amendment 1 is：H₁=K × 2.04 × (T₁-T₂)- 1765, correcting 2 is：H₂=K × 2586ln (T₁-T₂) -17654, correcting 3 is：Wherein：T₁For In-furnace temperature, T₂Casing temperature, H₁、H₂And H₃For fire proof material of furnace lining thickness, K is the correction factor related with temperature, and K is 0.92~1.10；The Converter labour is early period, and when previous stove Converter condition is excellent, empirical remedy equation selection corrects 1；It is described Converter labour is early period, and when previous stove Converter condition is good, empirical remedy equation selection corrects 2；The Converter labour is early period, When previous stove Converter condition is difference, empirical remedy equation selection corrects 3；Converter labour is middle labour, previous stove Converter condition For it is excellent or good when, empirical remedy equation selection correct 2；The Converter labour is middle labour, when previous stove Converter condition is difference, experience Correction formula selection corrects 3；The Converter labour is used as a servant after being, when previous stove Converter condition is excellent or good, empirical remedy equation choosing Select amendment 2；The Converter labour is used as a servant after being, when previous stove Converter condition is difference, empirical remedy equation selection corrects 3.

2. the real time on-line monitoring system of converter lining refractory material security according to claim 1, it is characterised in that institute Stating temperature measuring unit and gathering the pickup area of converter shell temperature in real time includes：Converter bottom, converter iron making wing furnace body and converter go out Steel wing furnace body.

3. the real time on-line monitoring system of converter lining refractory material security according to claim 2, it is characterised in that institute Stating temperature measuring unit and gathering the pickup area of converter shell temperature in real time includes：In Converter Oxigen Blowing smelting process, pickup area is to turn The front shaft region in stove iron making wing furnace bottom to bath surface height section；Tapping process, pickup area are converter bottom；Tapping Before slag is splashed in end, pickup area is converter iron making wing furnace body and converter tapping wing furnace body；After splashing slag, pickup area is converter Furnace bottom, converter iron making wing furnace body, converter tapping wing furnace body.

4. the real time on-line monitoring system of converter lining refractory material security according to claim 1, it is characterised in that institute State hot warm instrument position to fix, the casing temperature of visual angle inner region is obtained according to the shake situation of converter body.

It is 5. a kind of using the real time on-line monitoring system of converter lining refractory material security as described in claim 1-4 is any Monitoring method, it is characterised in that comprise the following steps：

(1) converter profile module and furnace lining parameter module are set；

(2) gather converter shell temperature in real time with temperature measuring unit, and data processing unit is sent to by data transfer unit；

(3) computing module of data processing unit according to heat transfer theory formula and empirical remedy equation by converter shell temperature computation For converter lining refractory thickness；

The method further includes：The original fire proof material of furnace lining thickness of converter is inputted, converter lining refractory thickness is passed through into peace Full identification module and the original fire proof material of furnace lining thickness of converter relatively calculate converter lining refractory thickness amplitude of variation, And provide working of a furnace judgement；The working of a furnace is judged to provide safety in production instruction by expert module.

6. monitoring method according to claim 5, it is characterised in that the empirical remedy equation is to be used as a servant not according to Converter Same time and previous stove Converter condition correct gained to heat transfer theory formula.

7. monitoring method according to claim 5, it is characterised in that the converter lining refractory thickness amplitude of variation To increase, and increasing degree is more than 200mm, and the Converter condition is judged as that furnace lining goes up；The converter lining refractory material is thick Degree amplitude of variation is less than 100mm, and the Converter condition is judged as that the working of a furnace is excellent；The converter lining refractory thickness amplitude of variation To reduce and reducing amplitude more than 100mm while be growth and increasing degree in 100-200mm less than 200mm or amplitude of variation Between, the Converter condition is judged as that the working of a furnace is good；The converter lining refractory thickness amplitude of variation reduces width to reduce Degree is more than 200mm, and the Converter condition is judged as that the working of a furnace is poor.