Method for predicting thickness of refractory brick based on converter wall temperature

Abstract

The invention relates to the technical field of converter safety monitoring, in particular to a method for predicting the thickness of refractory bricks based on converter wall temperature. The temperature distribution and the residual thickness of the refractory bricks are estimated according to the external furnace body temperature and the melt smelting temperature, and then the overhaul of the converter is judged according to the temperature distribution and the residual thickness of the refractory bricks, so that the real-time safety monitoring in the operation process of the converter is realized. The problem of how to monitor the operation risk of the converter is solved.

Description

Technical Field

[0001] The present application relates to the technical field of converter safety monitoring, and in particular to a method for predicting the thickness of refractory bricks based on the converter wall temperature. Background Art

[0002] During the converter steelmaking process, refractory bricks are subjected to long-term exposure to high temperatures, high pressures, chemical corrosion, and mechanical erosion. Temperatures within the converter can reach as high as 1700°C. Over extended periods of operation, these bricks are susceptible to erosion and fall off. This can cause the ladle, directly exposed to the high temperature, to soften and even melt and fall off, potentially burning through the furnace wall and causing safety accidents.

[0003] Since refractory bricks are located inside the converter and are in a harsh environment, it is difficult to directly monitor their degree of wear. The solutions for monitoring refractory brick loss in related technical solutions mostly rely on manual experience and judgment and regular shutdown inspections, which are prone to problems such as missed detection, false detection, and untimely detection. Summary of the Invention

[0004] The main purpose of this application is to provide a method for predicting the thickness of refractory bricks based on the converter wall temperature, aiming to solve the problem of how to monitor the operation risks of the converter.

[0005] To achieve the above objectives, the present application provides a method for predicting the thickness of refractory bricks based on the converter wall temperature, the method comprising:

[0006] Collect the external wall temperature and internal melt temperature of the converter;

[0007] Calculating the temperature of refractory bricks in each layer of the converter according to the external furnace wall temperature and the internal melt temperature;

[0008] The mathematical model is constructed to predict the current refractory brick wear rate corresponding to the refractory brick temperature, wherein the mathematical model establishes a mapping relationship between the refractory brick wear rate and the refractory brick temperature and the smelting cycle by collecting the refractory brick temperature change trend within a historical period and the historical average external furnace wall temperature and the internal melt temperature within the historical period;

[0009] The predicted value of the remaining thickness of the refractory brick is calculated according to the current refractory brick wear rate, the smelting cycle and the known initial refractory brick thickness.

[0010] Optionally, the step of calculating the temperature of refractory bricks in each layer of the converter according to the external furnace wall temperature and the internal melt temperature includes:

[0011] According to the external furnace wall temperature T out and the internal melt temperature T in , determine the heat flux density q corresponding to each layer of refractory bricksi :

[0012]

[0013] Among them, L i is the thickness of the i-th layer of refractory bricks, n is the number of refractory brick layers, k i is the thermal conductivity of the thickness of the i-th layer of refractory bricks;

[0014] According to the heat flux q i , calculate the refractory brick temperature T of each layer layer by layer in the order from inside to outside i ;

[0015]

[0016] Where T1 = T in , T i＝n =T out .

[0017] Optionally, the step of calculating the current wear rate of the refractory brick based on the refractory brick temperature and the known initial refractory brick thickness comprises:

[0018] S1, assuming the initial refractory brick thickness d0, the initial furnace wall temperature T wall,0 , under steady-state conditions, the total thermal resistance R is expressed as follows total and furnace wall temperature T wall The relationship between:

[0019] T wall =T melt -q·R total

[0020] Where, T melt is the melt temperature (K), q is the heat flux (W / m 2 ), R total It is the series connection of thermal resistance of each layer and the total thermal resistance of steady-state heat conduction of multiple layers of refractory bricks;

[0021] in,

[0022]

[0023] Where, d i is the thickness of the i-th layer (m), k i is the thermal conductivity of the i-th layer (W / m·K);

[0024] in,

[0025]

[0026] Where k is the thermal conductivity of the material (W / m·K); is the temperature gradient (K / m);

[0027] S2, calculate the remaining thickness d of the refractory brick:

[0028] d=d0-Δd

[0029] Among them, according to the change of thermal resistance, the change of thermal resistance of the refractory brick layer is expressed as:

[0030]

[0031] Where k ref is the thermal conductivity of the refractory brick (W / m·K);

[0032] S3, update the furnace wall temperature T by measuring wall , reverse the remaining thickness d:

[0033] T wall =T melt -q·(R total +ΔR)

[0034] The thermal resistance change ΔR of the refractory brick layer can be obtained, the thickness change of the refractory brick layer is Δd, and the remaining thickness d of the refractory brick can be obtained.

[0035] Optionally, the step of calculating the predicted value of the remaining thickness of the refractory brick according to the wear rate of the refractory brick and the known initial thickness of the refractory brick includes:

[0036] Calculating the wear amount of the refractory bricks according to the product of the wear rate of the refractory bricks and the smelting cycle;

[0037] The difference between the initial refractory brick thickness and the wear amount is determined as the remaining thickness prediction value.

[0038] Optionally, the heat conduction resistance between the refractory brick temperature and the heat transfer medium The calculation expression is:

[0039]

[0040] in, is the thermal resistance between the melt and the refractory brick layer, is the thermal resistance between the air and the external furnace wall, R s1 , R s2 , R s3 and R ε They are refractory brick thermal resistance, anti-seepage layer thermal resistance, angle steel thermal resistance and contact thermal resistance, among which refractory brick thermal resistance δ represents the thickness of the thermal conductive material, and λ represents the thermal conductivity.

[0041] Optionally, the method further includes:

[0042] Collect the temperature change trend of refractory bricks in the historical period;

[0043] The refractory brick wear rate corresponding to each node under the refractory brick temperature change trend is predicted by the constructed mathematical model;

[0044] Taking the average of the wear rates of each refractory brick as the average wear rate of the refractory brick in the historical period;

[0045] Calculating the time required for the predicted value of the remaining thickness of the refractory brick to reach a critical thickness threshold based on the average refractory brick wear rate;

[0046] The required duration is outputted so that monitoring personnel can formulate a maintenance plan and an overhaul cycle for the converter according to the required duration.

[0047] Optionally, after the step of calculating the predicted value of the remaining thickness of the refractory brick according to the wear rate of the refractory brick, the smelting cycle and the known initial thickness of the refractory brick, the method further comprises:

[0048] When the temperature of the refractory brick is greater than a preset temperature threshold and / or the remaining thickness prediction value is less than a critical thickness threshold, a refractory brick operation risk warning signal is triggered.

[0049] In addition, to achieve the above-mentioned purpose, the present application also provides a computer system, which includes: a memory, a processor, and a computer program stored on the memory and runnable on the processor. When the computer program is executed by the processor, the steps of the method for predicting the thickness of refractory bricks based on the converter wall temperature as described in any one of the above items are implemented.

[0050] In addition, to achieve the above-mentioned purpose, the present application also provides a computer-readable storage medium, on which a computer program is stored. When the computer program is executed by a processor, the steps of the method for predicting the thickness of refractory bricks based on the converter furnace wall temperature as described in any of the above items are implemented.

[0051] This application has at least the following beneficial effects:

[0052] The temperature distribution and remaining thickness of the refractory bricks are estimated by the external furnace temperature and the melt melting temperature, and then the maintenance of the converter is judged based on the temperature distribution and remaining thickness of the refractory bricks to achieve real-time safety monitoring during the operation of the converter. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 This is a flow chart of a first embodiment of the method for predicting the thickness of refractory bricks based on the converter wall temperature of the present application;

[0054] Figure 2This is a flow chart of a second embodiment of the method for predicting the thickness of refractory bricks based on the converter wall temperature of the present application;

[0055] Figure 3 This is a schematic diagram of the structure of the device for predicting the thickness of refractory bricks based on the converter wall temperature of the method for predicting the thickness of refractory bricks based on the converter wall temperature of the present application;

[0056] Figure 4 A schematic diagram of the architecture of the hardware operating environment of the computer system involved in the embodiments of the present application;

[0057] Figure 5 This is a schematic diagram of the converter side structure of the method for predicting the thickness of refractory bricks based on the converter wall temperature in this application.

[0058] The realization of the objectives, functional features and advantages of this application will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0059] To better understand the above technical solutions, exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments described herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art.

[0060] First embodiment

[0061] Reference Figure 1 In a first embodiment, the method for predicting the thickness of refractory bricks based on the converter wall temperature comprises the following steps:

[0062] Step S10, collecting the external wall temperature and internal melt temperature of the converter;

[0063] In this embodiment, the external wall temperature and the internal melt temperature of the converter are collected.

[0064] Optionally, multiple high-precision infrared thermal imagers can be evenly arranged on the outer wall of the converter to collect the surface temperature of different areas outside the furnace body. The obtained temperature data can be processed and sent to the monitoring end backend as the external furnace wall temperature.

[0065] Optionally, a high-temperature resistant thermocouple array made of platinum-rhodium alloy may be embedded in the inner wall of the converter to record the internal melt temperature data of the molten pool area at regular intervals.

[0066] In addition, for abnormal data that inevitably appears during the data collection process, in this embodiment, when the temperature difference between the external temperature of a certain area and the adjacent area is greater than 200 degrees Celsius, the external temperature data of this part of the area is regarded as abnormal, and the Kriging spatial interpolation method is used to interpolate the data.

[0067] Step S20, calculating the temperature of refractory bricks in each layer of the converter according to the external furnace wall temperature and the internal melt temperature;

[0068] In this embodiment, for the refractory brick temperature that cannot be directly obtained, its predicted value is indirectly calculated through the external furnace wall temperature and the internal melt temperature.

[0069] It should be noted that the refractory brick temperature is not an actual measured value. There will be a certain error between the obtained value and the actual measured value. This error needs to be taken into account when calculating or judging other values ​​in the future.

[0070] Optionally, the steps of calculating the refractory brick temperature include:

[0071] S21, according to the external furnace wall temperature T out and the internal melt temperature T in , determine the heat flux density q corresponding to each layer of refractory bricks i :

[0072]

[0073] Among them, L i is the thickness of the i-th layer of refractory bricks, n is the number of refractory brick layers, k i is the thermal conductivity of the thickness of the i-th layer of refractory bricks;

[0074] S22, according to the heat flux density q i , calculate the refractory brick temperature T of each layer layer by layer in the order from inside to outside i ;

[0075]

[0076] Where T1 = T in , T i＝n =T out .

[0077] Specifically and optionally, in this embodiment, a multi-layer temperature prediction model of converter refractory bricks is established, and the influence of the internal and external temperatures of the furnace wall on the temperature distribution of the refractory material layer is quantified by heat conduction theory.

[0078] First, based on the unsteady three-dimensional heat conduction theory, the control equation describing the dynamic changes of the refractory brick temperature field is constructed:

[0079]

[0080] Where, It represents the cumulative amount of heat energy per unit volume of refractory material over time, ρ is the material density, c is the specific heat capacity, The temperature change when the external furnace wall temperature is transferred to the refractory bricks; Characterizes the thermal energy diffusion caused by heat conduction, λ is the thermal conductivity, Q slag (t) is the dynamic slag corrosion reaction heat source term, which serves as a dynamic correction term to quantify the heat released by the chemical reaction between slag and refractory bricks.

[0081] in,

[0082]

[0083] Where k0 is the reaction rate constant, C is the real-time mass concentration of the material to be melted in the slag, E is the reaction activation energy, R is the gas constant, and T is the internal melt temperature.

[0084] Arranged:

[0085]

[0086] Where ΔT represents the change in temperature of the refractory bricks.

[0087] Assuming the initial temperature of the refractory brick is T0, the refractory brick temperature T1 is:

[0088] T1=T0+ΔT

[0089] In addition, all refractory brick temperature data calculated each time are recorded and stored in the database to facilitate subsequent data analysis and converter status evaluation.

[0090] In addition, optionally, since the thickness of the heat-conducting material of the refractory bricks will change during long-term operation, the heat conduction thermal resistance between the heat transfer medium of the refractory bricks will change accordingly. Therefore, in order to ensure the accuracy of the refractory brick temperature, the heat conduction thermal resistance between the heat transfer medium of the refractory brick temperature is proposed in this embodiment. The calculation expression is:

[0091]

[0092] in, is the thermal resistance between the melt and the refractory brick layer, is the thermal resistance between the air and the external furnace wall, R s1 , R s2 , R s3 and R ε They are refractory brick thermal resistance, anti-seepage layer thermal resistance, angle steel thermal resistance and contact thermal resistance, among which refractory brick thermal resistance δ represents the thickness of the thermal conductive material, and λ represents the thermal conductivity.

[0093] Step S30, predicting the refractory brick wear rate corresponding to the refractory brick temperature by using a constructed mathematical model, wherein the mathematical model establishes a mapping relationship between the refractory brick wear rate, the refractory brick temperature, and the smelting cycle by collecting the refractory brick temperature change trend within a historical period and the historical average external furnace wall temperature and the internal melt temperature within the historical period;

[0094] In this embodiment, the mathematical model extracts features from the data by retrieving data recorded in historical periods in the database. Optionally, the features may include: the temperature change curve of each layer of refractory bricks, the average temperature of the external furnace wall, the fluctuation amplitude of the internal melt temperature, and the duration of the smelting cycle. Based on the above features, a wear rate model is constructed through a multivariate nonlinear regression equation, and the coefficient R is determined after cross-validation of the wear rate model. 2 When it reaches 0.91, it is considered as a mathematical model that meets the accuracy standard.

[0095] Optionally, the step of determining the current wear rate of refractory bricks comprises:

[0096] S31, assuming the initial refractory brick thickness d0, the initial furnace wall temperature T wall,0 , under steady-state conditions, the total thermal resistance R is expressed as follows total and furnace wall temperature T wall The relationship between:

[0097] T wall =T melt -q·R total

[0098] Where, T melt is the melt temperature (K), q is the heat flux (W / m 2 ), R total It is the series connection of thermal resistance of each layer and the total thermal resistance of steady-state heat conduction of multiple layers of refractory bricks;

[0099] in,

[0100]

[0101] Where, d i is the thickness of the i-th layer (m), k i is the thermal conductivity of the i-th layer (W / m·K);

[0102] in,

[0103]

[0104] Where k is the thermal conductivity of the material (W / m·K); is the temperature gradient (K / m);

[0105] S32, calculate the remaining thickness d of the refractory brick:

[0106] d=d0-Δd

[0107] Among them, according to the change of thermal resistance, the change of thermal resistance of the refractory brick layer is expressed as:

[0108]

[0109] Where k ref is the thermal conductivity of the refractory brick (W / m·K);

[0110] S33, update the furnace wall temperature T by measuring wall , reverse the remaining thickness d:

[0111] T wall =T melt -q·(R total +ΔR)

[0112] The thermal resistance change ΔR of the refractory brick layer can be obtained, the thickness change of the refractory brick layer is Δd, and the remaining thickness d of the refractory brick can be obtained.

[0113] Step S40, calculating a predicted value of the remaining thickness of the refractory brick according to the wear rate of the refractory brick, the smelting cycle and the known initial thickness of the refractory brick;

[0114] In this embodiment, after the refractory brick wear rate is calculated, the wear amount of the refractory brick is calculated according to the product of the refractory brick wear rate and the smelting cycle, and the difference between the initial refractory brick thickness and the wear amount is determined as the remaining thickness prediction value.

[0115] Optionally, after step S40, the method further includes:

[0116] When the temperature of the refractory brick is greater than a preset temperature threshold and / or the remaining thickness prediction value is less than a critical thickness threshold, a refractory brick operation risk warning signal is triggered.

[0117] In this embodiment, after obtaining the predicted values ​​of the refractory brick temperature and the remaining thickness, the refractory brick temperature and the remaining thickness of the refractory brick are used as operation risk criteria. If it is found that the refractory brick temperature is too high (that is, the refractory brick temperature is greater than the preset temperature threshold), or the refractory brick layer loss exceeds the critical value (that is, the predicted value of the remaining thickness is less than the critical thickness threshold), the refractory brick operation risk warning signal is immediately triggered.

[0118] Optionally, the preset temperature threshold can be determined comprehensively based on the temperature resistance limit of the refractory brick material, converter design parameters and historical operating data, and the critical thickness threshold is the factory parameter of the refractory brick layer.

[0119] Optionally, the refractory brick operation risk warning signal may include a refractory brick overtemperature warning signal and / or a refractory brick layer damage warning signal. When the back-end monitoring personnel receive a refractory brick overtemperature warning signal, they will take appropriate converter cooling measures, such as stopping converter operation, to reduce the refractory brick temperature. If a refractory brick layer damage warning signal is received, the back-end monitoring personnel will be prompted to perform regular converter maintenance.

[0120] In the technical solution provided in this embodiment, the temperature distribution and remaining thickness of the refractory bricks are estimated by the external furnace temperature and the melt melting temperature, and then the maintenance of the converter is judged by the temperature distribution and remaining thickness of the refractory bricks to achieve real-time safety monitoring during the operation of the converter.

[0121] Second embodiment

[0122] Based on the first embodiment, refer to Figure 2 In this embodiment, the method for predicting the thickness of refractory bricks based on the converter wall temperature further includes:

[0123] S100, collects the temperature change trend of refractory bricks in the historical period;

[0124] S200, predicting the refractory brick wear rate corresponding to each node under the refractory brick temperature change trend using the constructed mathematical model;

[0125] S300, taking the average of the wear rates of the refractory bricks as the average wear rate of the refractory bricks in the historical period;

[0126] S400, calculating the time required for the predicted value of the remaining thickness of the refractory brick to reach the critical thickness threshold based on the average refractory brick wear rate;

[0127] S500: Output the required time so that monitoring personnel can formulate a maintenance plan and overhaul cycle for the converter according to the required time.

[0128] In this embodiment, in order to facilitate monitoring personnel in formulating maintenance plans and overhaul cycles for the converter, this embodiment also provides a method for calculating the time required for the refractory bricks to reach a critical thickness threshold from the current thickness.

[0129] Specifically, the average refractory brick wear rate The calculation expression can be:

[0130]

[0131] Where V wear is the refractory brick temperature corresponding to each node in the refractory brick temperature change trend, N is the number of nodes, and σ is the conservative estimation coefficient used to reduce the error between the predicted value and the actual value.

[0132] Furthermore, regarding how to calculate the time required for the predicted value of the remaining thickness of the refractory brick to reach the critical thickness threshold based on the average refractory brick wear rate, refer to the following formula:

[0133]

[0134] Where, t cycle_avg is the average furnace rotation time corresponding to one furnace rotation process, L cerrent Indicates the predicted value of the remaining thickness of refractory bricks, L crit Represents the critical thickness threshold.

[0135] In addition, considering the error between the predicted value and the actual value, a safety factor with a value less than 1 and greater than 0 is set to reduce the calculated value of the required time, that is:

[0136]

[0137] In addition, as an implementation solution, Figure 3 This is a schematic diagram of the architecture of the hardware operating environment of the computer system involved in the embodiment of the present application.

[0138] like Figure 3 As shown, the computer system may include: a processor 1001, such as a CPU, a memory 1005, a user interface 1003, a network interface 1004, and a communication bus 1002. Among them, the communication bus 1002 is used to realize the connection and communication between these components. The user interface 1003 may include a display screen (Display), an input unit such as a keyboard (Keyboard), and the user interface 1003 may optionally include a standard wired interface and a wireless interface. The network interface 1004 may optionally include a standard wired interface and a wireless interface (such as a WI-FI interface). The memory 1005 may be a high-speed RAM memory or a stable memory (non-volatile memory), such as a disk memory. The memory 1005 may optionally be a storage device independent of the aforementioned processor 1001.

[0139] Those skilled in the art will understand that Figure 3 The computer system architecture shown in the figure does not constitute a limitation of the computer system, and may include more or fewer components than shown in the figure, or combine certain components, or arrange the components differently.

[0140] like Figure 3 As shown, the memory 1005 as a storage medium may include an operating system, a network communication module, a user interface module and a computer program. Among them, the operating system is a program that manages and controls the hardware and software resources of the computer system, the operation of the computer program and other software or programs.

[0141] exist Figure 3 In the computer system shown, the user interface 1003 is mainly used to connect to the terminal and communicate data with the terminal; the network interface 1004 is mainly used to communicate data with the background server; the processor 1001 can be used to call the computer program stored in the memory 1005.

[0142] In this embodiment, the computer system includes: a memory 1005, a processor 1001, and a computer program stored in the memory and executable on the processor, wherein:

[0143] When the processor 1001 calls the computer program stored in the memory 1005, it performs the following operations:

[0144] Collect the external wall temperature and internal melt temperature of the converter;

[0145] Calculating the temperature of refractory bricks in each layer of the converter according to the external furnace wall temperature and the internal melt temperature;

[0146] The mathematical model is constructed to predict the current refractory brick wear rate corresponding to the refractory brick temperature, wherein the mathematical model establishes a mapping relationship between the refractory brick wear rate and the refractory brick temperature and the smelting cycle by collecting the refractory brick temperature change trend within a historical period and the historical average external furnace wall temperature and the internal melt temperature within the historical period;

[0147] The predicted value of the remaining thickness of the refractory brick is calculated according to the current refractory brick wear rate, the smelting cycle and the known initial refractory brick thickness.

[0148] When the processor 1001 calls the computer program stored in the memory 1005, it performs the following operations:

[0149] According to the external furnace wall temperature T out and the internal melt temperature T in , determine the heat flux density q corresponding to each layer of refractory bricks i :

[0150]

[0151] Among them, L i is the thickness of the i-th layer of refractory bricks, n is the number of refractory brick layers, k i is the thermal conductivity of the thickness of the i-th layer of refractory bricks;

[0152] According to the heat flux q i , calculate the refractory brick temperature T of each layer layer by layer in the order from inside to outside i ;

[0153]

[0154] Where T1 = T in , T i＝n =T out .

[0155] When the processor 1001 calls the computer program stored in the memory 1005, it performs the following operations:

[0156] S31, assuming the initial refractory brick thickness d0, the initial furnace wall temperature T wall,0 , under steady-state conditions, the total thermal resistance R is expressed as follows total and furnace wall temperature T wall The relationship between:

[0157] T wall =T melt -q·R total

[0158] Where, T melt is the melt temperature (K), q is the heat flux (W / m 2 ), R total It is the series connection of thermal resistance of each layer and the total thermal resistance of steady-state heat conduction of multiple layers of refractory bricks;

[0159] in,

[0160]

[0161] Where, d i is the thickness of the i-th layer (m), k i is the thermal conductivity of the i-th layer (W / m·K);

[0162] in,

[0163]

[0164] Where k is the thermal conductivity of the material (W / m·K); is the temperature gradient (K / m);

[0165] S32, calculate the remaining thickness d of the refractory brick:

[0166] d=d0-Δd

[0167] Among them, according to the change of thermal resistance, the change of thermal resistance of the refractory brick layer is expressed as:

[0168]

[0169] Where k ref is the thermal conductivity of the refractory brick (W / m·K);

[0170] S33, update the furnace wall temperature T by measuring wall , reverse the remaining thickness d:

[0171] T wall =T melt -q·(R total +ΔR)

[0172] The thermal resistance change ΔR of the refractory brick layer can be obtained, the thickness change of the refractory brick layer is Δd, and the remaining thickness d of the refractory brick can be obtained.

[0173] When the processor 1001 calls the computer program stored in the memory 1005, it performs the following operations:

[0174] Calculating the wear amount of the refractory bricks according to the product of the wear rate of the refractory bricks and the smelting cycle;

[0175] The difference between the initial refractory brick thickness and the wear amount is determined as the remaining thickness prediction value.

[0176] When the processor 1001 calls the computer program stored in the memory 1005, it performs the following operations:

[0177] Collect the temperature change trend of refractory bricks in the historical period;

[0178] The refractory brick wear rate corresponding to each node under the refractory brick temperature change trend is predicted by the constructed mathematical model;

[0179] Taking the average of the wear rates of each refractory brick as the average wear rate of the refractory brick in the historical period;

[0180] Calculating the time required for the predicted value of the remaining thickness of the refractory brick to reach the critical thickness threshold according to the average refractory brick wear rate;

[0181] The required duration is outputted so that monitoring personnel can formulate a maintenance plan and an overhaul cycle for the converter according to the required duration.

[0182] In addition, refer to Figure 4 This embodiment further provides a device for predicting the thickness of refractory bricks based on the converter wall temperature. The device for predicting the thickness of refractory bricks based on the converter wall temperature includes:

[0183] The data storage module 100 is used to store converter operation data, maintenance records, and pre-obtained mathematical models and converter physical parameters;

[0184] The module 200 for predicting the thickness of refractory bricks based on the converter wall temperature is used to determine whether to output a refractory brick operation risk warning signal according to any of the above methods for predicting the thickness of refractory bricks based on the converter wall temperature;

[0185] Decision support module 300, for generating operation and maintenance strategies for the converter;

[0186] The user interaction interface 400 is used to display prediction results, maintenance suggestions and system operation interface, wherein the prediction results include refractory brick operation risk warning signals and the time required for the refractory brick remaining thickness prediction value to reach the critical thickness threshold.

[0187] Optionally, as an implementation solution, refer to Figure 5 The schematic diagram of the converter side structure is shown, in which the outer wall is made of steel plate, the refractory bricks are refractory bricks, and a layer of magnesia-chromium fire mud is placed between the outer wall and the refractory bricks.

[0188] Furthermore, those skilled in the art will appreciate that all or part of the steps in the method of the above-described embodiment can be implemented by instructing the relevant hardware through a computer program. The computer program includes program instructions, which can be stored in a storage medium that is a computer-readable storage medium. The program instructions are executed by at least one processor in a computer system to implement the steps in the process of the above-described method embodiment.

[0189] Therefore, the present application also provides a computer-readable storage medium, which stores a computer program. When the computer program is executed by a processor, it implements the various steps of the method for predicting the thickness of refractory bricks based on the converter furnace wall temperature as described in the above embodiment.

[0190] The computer-readable storage medium may be any computer-readable storage medium that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM), a magnetic disk, or an optical disk.

[0191] It should be noted that since the storage medium provided in the embodiments of this application is the storage medium used to implement the method of the embodiments of this application, based on the method described in the embodiments of this application, those skilled in the art will be able to understand the specific structure and deformation of the storage medium, and therefore will not be described in detail here. All storage media used in the method of the embodiments of this application fall within the scope of protection to be provided by this application.

[0192] Those skilled in the art will appreciate that the embodiments of the present application can be provided as methods, systems or computer program products. Therefore, the present application can adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment in combination with software and hardware. Moreover, the present application can adopt the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) that contain computer-usable program code.

[0193] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the steps in the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0194] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0195] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0196] It should be noted that in the claims, any reference signs placed between brackets shall not be construed as limiting the claims. The word "comprising" does not exclude the presence of components or steps not listed in the claim. The word "a" or "an" preceding a component does not exclude the presence of a plurality of such components. The present application may be implemented by means of hardware comprising several different components and by means of a suitably programmed computer. In a unit claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The use of the words first, second, and third etc. does not indicate any order. These words may be interpreted as names.

[0197] Although the preferred embodiments of the present application have been described, those skilled in the art may make additional changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present application.

[0198] Obviously, those skilled in the art may make various changes and modifications to this application without departing from the spirit and scope of this application. Thus, if these modifications and variations of this application fall within the scope of the claims of this application and their equivalents, this application is intended to include these modifications and variations.

Claims

1. A method for predicting the thickness of refractory bricks based on converter wall temperature, characterized in that: The method comprises the following steps: Collect the external wall temperature and internal melt temperature of the converter; Calculating the temperature of refractory bricks in each layer of the converter according to the external furnace wall temperature and the internal melt temperature; The mathematical model is constructed to predict the current refractory brick wear rate corresponding to the refractory brick temperature, wherein the mathematical model establishes a mapping relationship between the refractory brick wear rate and the refractory brick temperature and the smelting cycle by collecting the refractory brick temperature change trend within a historical period and the historical average external furnace wall temperature and the internal melt temperature within the historical period; The predicted value of the remaining thickness of the refractory brick is calculated according to the current refractory brick wear rate, the smelting cycle and the known initial refractory brick thickness.

2. The method according to claim 1, wherein The step of calculating the temperature of refractory bricks in each layer of the converter according to the external furnace wall temperature and the internal melt temperature comprises: According to the external furnace wall temperature T out and the internal melt temperature T in , determine the heat flux density q corresponding to each layer of refractory bricks i : Among them, L i is the thickness of the i-th layer of refractory bricks, n is the number of refractory brick layers, k i is the thermal conductivity of the thickness of the i-th layer of refractory bricks; According to the heat flux q i , calculate the refractory brick temperature T of each layer layer by layer in the order from inside to outside i ; Where T1 = T in , T i＝n =T out .

3. The method according to claim 1, wherein The calculation steps of the current wear rate include: S31, assuming the initial refractory brick thickness d0, the initial furnace wall temperature T wall,0 , under steady-state conditions, the total thermal resistance R is expressed as follows total and furnace wall temperature T wall The relationship between: T wall =T melt -q·R total Where, T melt is the melt temperature (K), q is the heat flux (W / m 2 ), R total It is the series connection of thermal resistance of each layer and the total thermal resistance of steady-state heat conduction of multiple layers of refractory bricks; in, Where, d i is the thickness of the i-th layer (m), k i is the thermal conductivity of the i-th layer (W / m·K); in, Where k is the thermal conductivity of the material (W / m·K); is the temperature gradient (K / m); S32, calculate the remaining thickness d of the refractory brick: d=d0-Δd Among them, according to the change of thermal resistance, the change of thermal resistance of the refractory brick layer is expressed as: Where k ref is the thermal conductivity of the refractory brick (W / m·K); S33, update the furnace wall temperature T by measuring wall , reverse the remaining thickness d: T wall =T melt -q·(R total +ΔR) The thermal resistance change ΔR of the refractory brick layer can be obtained, the thickness change of the refractory brick layer is Δd, and the remaining thickness d of the refractory brick can be obtained.

4. The method according to claim 1 or 3, wherein: The step of calculating the predicted value of the remaining thickness of the refractory brick according to the wear rate of the refractory brick and the known initial thickness of the refractory brick comprises: Calculating the wear amount of the refractory bricks according to the product of the wear rate of the refractory bricks and the smelting cycle; The difference between the initial refractory brick thickness and the wear amount is determined as the remaining thickness prediction value.

5. The method according to claim 4, wherein Thermal resistance of heat conduction between refractory bricks and heat transfer medium The calculation expression is: in, is the thermal resistance between the melt and the refractory brick layer, is the thermal resistance between the air and the external furnace wall, R s1 , R s2 , R s3 and R ε They are refractory brick thermal resistance, anti-seepage layer thermal resistance, angle steel thermal resistance and contact thermal resistance, among which refractory brick thermal resistance δ represents the thickness of the thermal conductive material, and λ represents the thermal conductivity.

6. The method according to any one of claims 1 to 5, characterized in that The method further comprises: Collect the temperature change trend of refractory bricks in the historical period; The refractory brick wear rate corresponding to each node under the refractory brick temperature change trend is predicted by the constructed mathematical model; Taking the average of the wear rates of each refractory brick as the average wear rate of the refractory brick in the historical period; Calculating the time required for the predicted value of the remaining thickness of the refractory brick to reach a critical thickness threshold based on the average refractory brick wear rate; The required duration is outputted so that monitoring personnel can formulate a maintenance plan and an overhaul cycle for the converter according to the required duration.

7. The method according to claim 1, wherein After the step of calculating the predicted value of the remaining thickness of the refractory brick according to the wear rate of the refractory brick, the smelting cycle and the known initial thickness of the refractory brick, the method further includes: When the temperature of the refractory brick is greater than a preset temperature threshold and / or the remaining thickness prediction value is less than a critical thickness threshold, a refractory brick operation risk warning signal is triggered.

8. A refractory brick thickness prediction device, characterized in that: The device comprises: Temperature acquisition module, used to collect the external furnace wall temperature and internal melt temperature of the converter; a temperature prediction module, configured to calculate the temperature of refractory bricks in each layer of the converter according to the external furnace wall temperature and the internal melt temperature; A refractory brick wear rate prediction module is used to predict the current refractory brick wear rate corresponding to the refractory brick temperature through a constructed mathematical model, wherein the mathematical model establishes a mapping relationship between the refractory brick wear rate, the refractory brick temperature, and the smelting cycle by collecting the refractory brick temperature change trend within a historical period and the historical average external furnace wall temperature and internal melt temperature within the historical period; The remaining thickness prediction module is used to calculate the predicted value of the remaining thickness of the refractory brick according to the current refractory brick wear rate, the smelting cycle and the known initial refractory brick thickness.

9. A computer system, characterized in that: The computer system includes: a memory, a processor, and a computer program stored in the memory and executable on the processor. When the computer program is executed by the processor, the steps of the method for predicting the thickness of refractory bricks based on the converter wall temperature as described in any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium, characterized in that The computer-readable storage medium stores a computer program, which, when executed by a processor, implements the steps of the method for predicting the thickness of refractory bricks based on the converter wall temperature according to any one of claims 1 to 7.

Images