TWI733385B - Method for predicting reusable times of ladle - Google Patents

Abstract

A method for predicting reusable times of a ladle is described, which is used to calculate reusable times of the ladle according to a residual wall thickness of the ladle and use times of the ladle so as to provide a reference for operates to manage the ladle, thereby extending usage life of the ladle and improving use efficiency and operation safety of the ladle.

Description

Method for predicting the number of reusable steel drums

This disclosure relates to a forecasting method, and in particular, to a forecasting method for the number of reuses of steel drums.

In recent years, orders for steelmaking products and steel grades have continued to increase, resulting in an increase in the output of the compound process for producing high-grade steel grades, which has led to the gradual complexity of the scheduling of ladle drums in operations. The ladle must not only be able to withstand the high temperature operating environment of the compound process and the large variability of the slag after the diversification of steel types, but also be able to withstand the corrosion of its refractory lining. Therefore, it is necessary to increase the service life of the ladle's refractory lining and reduce the maintenance frequency of the ladle to cope with the dilemma of insufficient preparation of the ladle after the increase in production capacity.

Ladles play a key role in the production process. A well-supplied ladle can make production smoother. Therefore, how to improve the management and scheduling of ladle has long been an issue that steel mills have attached great importance to. However, with the increasingly stringent conditions of the work industry, when steel drums are leaking, they often force production interruptions and equipment damage. In addition to financial losses, they also cause great psychological burden on operators in scheduling work. Therefore, how to establish a safety monitoring and forecasting system for ladle steel drums is a top priority.

Therefore, one of the objectives of this disclosure is to provide a method for predicting the number of reuses of ladle, which is based on the thickness of the remaining wall of the ladle and the number of times of use to predict the number of reuses of ladle, as Operators can refer to operations such as ladle management, maintenance schedule planning, maintenance scheduling, etc. to extend the life of ladle, improve its use efficiency and operational safety.

According to the above-mentioned purpose of this disclosure, a method for predicting the number of reuses of steel drums is proposed. This prediction method includes the following steps. The judgment step is performed to judge whether the ladle is the first inspection and repair, if the judgment result is yes, the first prediction step is performed, and if the judgment result is no, the second prediction step is performed. Among them, the first prediction step includes: obtaining the initial wall thickness of the ladle before the first wet spraying step; calculating the initial prediction number, where the initial prediction number = (the value of the initial wall thickness -45)/1.2; Perform the first wet spraying step in the ladle to make the ladle have the first wall thickness; calculate the predicted value of the number of first reuses, where the predicted value of the number of first reuses = (the value of the first wall thickness- The value of the initial wall thickness)/2+the number of initial predictions. The second prediction step includes: obtaining the thickness of the front wall of the ladle before the second wet spraying step, the thickness of the wall after the previous wet spraying, the number of times the previous wall was used, and the number of times the wall was used this time; Calculate the melt loss rate, where the melt loss rate = (the thickness of the wall before the wet spray-the thickness of the wall after the previous wet spray) / (the number of times the wall is used-the number of times the previous wall is used); calculate the predicted return before wet spray Number, where the predicted number of times before wet spraying = (the value of the wall thickness before this wet spraying-45)/melt loss rate; the second wet spraying step is carried out in the ladle to make the ladle have this wet spraying Back wall thickness; calculate the predicted value of the number of second reuses, where the predicted value of the number of second reuses = (the value of the wall thickness after the wet spray-the value of the wall thickness before the wet spray) / 2 + wet spray Number of previous predictions.

According to an embodiment of the present disclosure, the initial wall thickness is obtained by taking the thickness of the side with the smallest thickness among the multiple sides of the inner wall of the ladle as the initial wall thickness.

According to an embodiment of the present disclosure, the melting loss rate is calculated based on the largest difference between the thickness of the wall before the current wet spray and the thickness of the wall after the previous wet spray among the multiple sides of the inner wall of the ladle. Calculated by the side difference value.

According to an embodiment of the present disclosure, after calculating the predicted value of the first reuse count, the aforementioned method further includes revising the predicted value of the first reuse count based on historical data.

According to an embodiment of the present disclosure, after calculating the second reuse count prediction value, the aforementioned method further includes revising the second reuse count prediction value based on historical data.

According to an embodiment of the present disclosure, the aforementioned historical data is associated with the steel type in the ladle, the time when the ladle is exposed to steel, the time of electric shock in the ladle, and/or the repair record of the ladle .

According to an embodiment of the present disclosure, the aforementioned historical data is extracted from a refining process computer.

According to an embodiment of the present disclosure, the aforementioned current wall usage times, previous wall usage times, and wall thickness after the previous wet spray are extracted from the refining process computer.

It can be seen from the above that this disclosure establishes a relational formula for predicting the number of reuses of the ladle based on the historical data of the ladle and the operating experience of the operator. Therefore, this relationship can be used according to the residual thickness and the remaining thickness of the ladle. Use the number of times to predict the number of times that the ladle will be reused. On the other hand, through the establishment of a ladle management system to track the ladle's scheduling process and historical status, and then establish the ladle's repair schedule and preparation schedule plan, so as to improve the efficiency and safety of the ladle. sex.

The ladle must be taken off the assembly line for lining repair after being preheated and used for about 32 times. The dispatching process of ladle includes maintenance, servicing, converter receiving molten steel, refining station processing, continuous casting machine, etc. The time for the ladle to contain molten steel in each furnace is about 2 hours, and the number of ladle used at the same time is about 10 to 14 depending on the process. In addition, the steel drum has a span of 430 meters in the dispatching space, 16 meters high from the ground, and the total weight after receiving steel is about 225 tons, so the dispatch and maintenance of the steel drum is complicated and cumbersome. Therefore, it is very important to prevent steel drums from leaking due to wall refractory problems.

Traditional ladle safety monitoring is to predict the reusable number of ladle steel drums by relying on the accumulated experience and explanations of operation and maintenance personnel. However, there is no reference point for the remaining wall thickness when the lining life of the ladle is at the end. If the ladle is too conservative and repaired early, the supply of the ladle will not be sufficient for dispatch. However, if the ladle continues to be used beyond its service life The barrel will have the risk of leaking steel, which will cause the psychological burden of the operator in order to repair.

Accordingly, this disclosure discloses the integration of the BOF, dynamic scheduling (DPSS1), flat steel billet continuous casting (SCC), and large billet continuous casting (BCC) in the upstream and downstream processes of the steelmaking plant. Zengsheng steel drum management screen and steel drum scheduling screen are used to track the actual location, use history, maintenance records and other historical data of the steel drum, and measure the residual thickness of each side wall of the steel drum when the steel drum is repaired in the cold room. And mark the measurement points, and then convert the relationship between the residual thickness of the steel drum wall and the number of times to be used by the computer to calculate the erosion rate, and calculate the reproducible steel drum according to the erosion, residual thickness, and dry and wet spray volume of the steel drum. Use times. For example, the number of times the ladle is used mainly depends on the degree of erosion of brick linings such as slag-line magnesia-carbon bricks, mixing bricks, and wall bricks. Therefore, the safe residual thickness value of the brick lining can be used to calculate the erosion rate and refer to it. The historical operating experience data is used to calculate the number of reusable ladle drums.

Please refer to FIG. 1, which is a flowchart of a method for predicting the number of reuses of steel drums according to the present disclosure. The method 100 for predicting the number of reused steel drums in this embodiment includes the following steps. First, proceed to step 110 to determine whether the ladle is the first inspection and repair. If the determination result is yes, proceed to step 120 (ie, the first prediction step), if the determination result is no, then proceed to step 130 (ie, the second prediction step). step).

As shown in Fig. 1, when the steel drum is inspected for the first time, step 120 is performed. In step 120, step 121 is first performed to obtain the initial wall thickness of the ladle before the first wet spray step. In one embodiment, the initial wall thickness is obtained by taking the thickness of the side with the smallest thickness among the plurality of sides of the inner wall of the ladle as the initial wall thickness. For example, you can first divide the side wall of a steel bucket into four parts: east, west, south, and north, and then measure the thickness of these four sides, and then use the thickness of the side with the smallest thickness among the four side walls as the initial Wall thickness.

After the initial wall thickness is obtained, step 122 is then performed to calculate the initial prediction number by using the initial wall thickness. In this embodiment, the number of initial predictions=(the value of initial wall thickness-45)/1.2, where the unit of thickness in this example is mm. After step 122 is performed, step 123 is then performed to perform a first wet spray step inside the ladle, so that the ladle has a first wall thickness. In one example, after the lining or inner wall of the ladle is eroded or damaged, the lining or inner wall of the ladle can be sprayed, for example, by wet spraying, so as to increase its service life. The gunning material is usually made of the same material as the original lining or inner wall of the ladle, and the thickness of the inner lining or inner wall of the ladle is increased.

After the first wet spraying step is performed, step 124 can be followed to calculate the predicted value of the first reuse number. Among them, the predicted value of the number of first reuses = (the value of the first wall thickness-the value of the initial wall thickness)/2 + the number of initial predictions, where the unit of the thickness in this example is mm. Specifically, after the ladle is subjected to the first wet spraying step, the number of reusable times of the ladle can be increased. Therefore, in step 122, the estimated use time of the ladle that has not been subjected to the first wet spraying step is first calculated. The difference between the first wall thickness of the ladle after the first wet spraying step and the initial wall thickness of the ladle before the first wet spraying step is used can be used to calculate the reuse of the ladle. Number of references.

In one embodiment, after obtaining the predicted value of the first reuse count, the predicted value of the first reuse count may be revised according to historical data. In this embodiment, the historical data is associated with the steel type in the ladle, the time when the ladle is exposed to steel, the time of electric shock of the molten steel in the ladle, and/or the maintenance record of the ladle. Among them, the historical data is extracted from the refining process computer. The refining process computer can not only integrate and retrieve data with the upstream and downstream process computers of the steelmaking plant, but also contain the production scheduling management data related to the ladle. In one example, the production scheduling management data of the ladle is divided into management data such as maintenance management, production scheduling, operation information, and safety monitoring. Maintenance management includes information such as the record and frequency of the refractory maintenance of the ladle. Production scheduling includes information such as preheating of steel drums, hot room maintenance, hot room sliding door refractory maintenance, processing stations, waiting time and other information. The operation information includes the steel type, process, steel receiving time, tapping time, blowing start time, electric shock time, mixing time, use times and replacement records of the working layer and wall tiles in the ladle, etc. Relevant information in the operation and historical records of steel receiving, etc. Safety monitoring includes information such as the end of the ladle and the management of abnormal residual thickness. In addition, the operator can also input the furnace number, barrel number, sand filling time, turntable position, sand filling person, repair type, repair replacement personnel, sand filling quantity and other historical records and status records of the ladle through the refining process computer . In this way, after obtaining the predicted value of the first reuse count in step 124, the predicted value of the first reuse count can be adjusted according to historical data to improve the prediction accuracy of the predicted value of the first reuse count.

Please refer to FIG. 1 again. If the judgment result of step 110 is no, it means that the ladle is not inspected for the first time, so step 130 (that is, the second prediction step) is directly performed. In step 130, step 131 is first performed to obtain the thickness of the front wall of the ladle before the second wet spray step, the thickness of the wall after the previous wet spray, the number of times the previous wall was used, and the current The number of times the wall is used. In this embodiment, the thickness of the wall after the previous wet spraying, the number of times the wall was used in the previous time, and the number of times the wall was used this time can be retrieved from the aforementioned historical data in the refining process computer.

After step 131 is performed, step 132 is then performed to calculate a melt loss rate. Among them, the melting loss rate = (the thickness of the wall before the current wet spray-the thickness of the wall after the previous wet spray) / (the number of times the wall was used this time-the number of times the previous wall was used). In one embodiment, among the multiple sides of the inner wall of the ladle, the difference between the thickness of the wall before the current wet spray and the thickness of the wall after the previous wet spray is calculated. For example, you can first divide the side wall of the ladle into four parts: east, west, south, and north, and compare the thickness of the front wall of this wet spray with the back wall of the previous wet spray of the side walls of these four directions. The difference between the thicknesses is calculated on the side with the largest difference. In some examples, the thickness of the wall after the previous wet spray can be retrieved from historical data in the aforementioned refining process computer.

After obtaining the erosion rate, step 133 is then performed to calculate the predicted number of times before wet spraying. Among them, the predicted number of times before wet spraying = (the value of the wall thickness before wet spraying-45)/melt loss rate, where the unit of thickness in this example is mm. After step 133 is performed, step 134 is then performed to perform a second wet spraying step inside the ladle, so that the ladle has the wall thickness after this wet spraying.

After the second wet spraying step is performed, step 135 can be followed to calculate the second predicted value of the number of reuses. Among them, the predicted value of the number of second reuse cycles=(the value of the wall thickness after this wet spray-the value of the wall thickness before this wet spray)/2+the predicted number of times before wet spray. Specifically, after the ladle is subjected to the second wet spraying step, the number of reuses of the ladle can be increased. Therefore, in step 133, the estimated number of uses of the ladle that has not been subjected to the second wet spraying step is first calculated. , The thickness of the wet spraying back wall thickness of the ladle after the second wet spraying step and the wet spraying front wall thickness of the ladle that have not yet been subjected to the second wet spraying step can be used to calculate the number of reuses of the ladle The reference.

In one embodiment, after obtaining the second reuse count forecast value, the second reuse count forecast value can be revised according to historical data to improve the prediction accuracy of the second reuse count forecast value. In this embodiment, the historical data is extracted from the aforementioned refining process computer, so it will not be repeated here.

It can be seen from the above-mentioned implementation of the present disclosure that the present disclosure establishes a relational formula for predicting the number of reuses of the ladle based on the historical data of the ladle and the operating experience of the operator. Therefore, this relational formula can be used according to the ladle The residual thickness of the barrel and the number of times used are used to predict the number of reuse times of the ladle. On the other hand, through the establishment of a ladle management system to track the ladle's scheduling process and historical status, and then establish the ladle's repair schedule and preparation schedule plan, so as to improve the efficiency and safety of the ladle. sex.

100: Prediction method for the number of reuses of steel drums 110: Step 120: Step 121: Step 122: step 123: Steps 124: Step 130: steps 131: Step 132: Step 133: Step 134: Step 135: Step

For a more complete understanding of the embodiments and their advantages, reference is now made to the following description in conjunction with the accompanying drawings, in which: [Figure 1] is a flow chart showing a method for predicting the number of reuses of steel drums according to this disclosure.

Domestic deposit information (please note in the order of deposit institution, date and number) no Foreign hosting information (please note in the order of hosting country, institution, date, and number) no

100: Prediction method for the number of reuses of steel drums

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Claims (8)

A method for predicting the number of reuses of steel drums, including: Carry out a judgment step to judge whether the steel drum is the first inspection and repair; If the judgment result is yes, perform a first prediction step, where the first prediction step includes: Obtain an initial wall thickness of a ladle before performing a first wet spraying step; Calculate an initial prediction number, where the initial prediction number = (the value of the initial wall thickness -45)/1.2; Performing the first wet spraying step on the ladle, so that the ladle has a first wall thickness; Calculate a predicted value of the number of first reuses, where the predicted value of the number of first reuses = (the value of the first wall thickness-the value of the initial wall thickness)/2 + the initial prediction number; If the judgment result is no, then perform a second prediction step, where the second prediction step includes: Obtain the wall thickness of the ladle before the second wet spraying step, the thickness of the wall after the previous wet spray, the number of times the wall was used before, and the number of times the wall was used this time; Calculate a melting loss rate, where the melting loss rate = (the thickness of the wall before the current wet spray-the thickness of the wall after the previous wet spray) / (the number of times the wall is used this time-the number of times the previous wall is used); Calculate the number of predicted times before wet spraying, where the predicted number of times before wet spraying = (the value of the wall thickness before this wet spraying -45)/the melting loss rate; Performing the second wet spraying step on the ladle, so that the ladle has a wall thickness after this wet spray; Calculate a predicted value of the second reuse number, where the predicted value of the second reuse number = (the value of the wall thickness after the current wet spray-the value of the wall thickness before the current wet spray)/2 + the wet Predict the number of times before spraying. The method according to claim 1, wherein the initial wall thickness is obtained by taking the thickness of the side with the smallest thickness among the plurality of sides of the inner wall of the ladle as the initial wall thickness. The method according to claim 1, wherein when calculating the melting loss rate, the thickness of the wall before the current wet spray and the thickness of the wall after the previous wet spray in the plural sides of the inner wall of the ladle is calculated Calculate the difference on the side with the largest difference between them. The method according to claim 1, wherein after calculating the predicted value of the first reuse count, the method further includes revising the predicted value of the first reuse count according to a historical data. The method according to claim 1, wherein after calculating the second reuse count forecast value, the method further includes revising the second reuse count forecast value based on a historical data. The method according to claim 4 or claim 5, wherein the historical data and the steel grade in the ladle, the time of receiving the steel in the ladle, the electric shock time of the molten steel in the ladle, and/or the Corresponding to the maintenance record of the ladle. The method according to claim 4 or claim 5, wherein the historical data is retrieved from a refining process computer. The method according to claim 1, wherein the current number of wall usage cycles, the previous wall usage cycles, and the wall thickness after the previous wet spray are retrieved from a refining process computer.

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