Blast furnace iron channel erosion detection system and method

Abstract

The present invention relates to a blast furnace iron ditch, and in particular to a blast furnace iron ditch erosion detection system and method, comprising an image acquisition device and a server, wherein the image acquisition device comprises a bracket, a 3D scanner is arranged on the upper end of the bracket, the 3D scanner is connected to the server signal, and the image acquisition device can acquire images of the iron ditch from multiple angles; the server is a PC, a camera performs contactless image information acquisition, and then the erosion state of the iron ditch is obtained through picture comparison and analysis, which is convenient and practical, has high detection accuracy, and low manual labor intensity, and can scan from multiple angles to fully cover the iron ditch, thereby improving the detection accuracy.

Description

Technical Field

[0001] The invention relates to a blast furnace iron ditch, and in particular to a blast furnace iron ditch erosion detection system and method. Background Art

[0002] The blast furnace iron ditch is the main equipment for the blast furnace. The molten iron of the blast furnace flows out through the iron ditch, which seriously erodes the iron ditch, especially the main ditch, where the molten iron flow is large. Due to the high temperature of the molten iron and the different corrosion resistance of the iron ditch castables of different materials, the erosion monitoring of the blast furnace iron ditch is troublesome. The existing monitoring method is to monitor in a coordinated manner with temperature monitoring and appearance monitoring. Temperature monitoring is to install a temperature sensor on the side wall of the iron ditch to monitor the temperature in real time. When the temperature is detected to exceed the preset value, an alarm is issued; appearance monitoring is to observe the state of the inner wall of the iron ditch when the furnace is shut down, and then judge the erosion state of the iron ditch.

[0003] Due to the high temperature of the iron groove, the temperature sensor is easily damaged and easily interfered with, the appearance monitoring accuracy is low, and the manual labor intensity is high. Summary of the invention

[0004] The purpose of the present invention is to overcome the deficiencies in the prior art and to provide a blast furnace iron groove erosion detection system and method which can detect the blast furnace iron groove erosion state in a contactless manner.

[0005] The present invention is realized by the following technical scheme: a blast furnace iron groove erosion detection system, comprising an image acquisition device, a server,

[0006] The image acquisition device includes a bracket, a 3D scanner is arranged on the upper end of the bracket, the 3D scanner is connected to the server signal, and the image acquisition device can acquire images of the iron ditch from multiple angles;

[0007] The server is a PC.

[0008] Furthermore, the image acquisition device performs 3D scanning on the iron groove at least from the front end, the middle part and the tail end.

[0009] A method for detecting erosion of blast furnace iron grooves comprises the following steps:

[0010] Step 1: 3D scan the new ditch to obtain an initial 3D model;

[0011] Step 2: After the iron is tapped, the iron trough is 3D scanned to obtain the current 3D model, and the current 3D model is compared with the initial 3D model to obtain the coordinate change value of each point, and then the iron trough erosion value is obtained.

[0012] Furthermore, the 3D scanning of the new trench includes 3D scanning of prefabricated parts and 3D scanning of the working layer castable.

[0013] Furthermore, the 3D scanning of the iron groove is performed at least at six points, namely, both sides of the front end, both sides of the middle, and both sides of the tail end of the iron groove.

[0014] Furthermore, the 3D scanner is leveled before 3D scanning.

[0015] The beneficial effects of the present invention are: the camera collects image information without contact, and then the erosion status of the iron groove is obtained through picture comparison and analysis. It is convenient and practical, has high detection accuracy, low manual labor intensity, and can scan from multiple angles to fully cover the iron groove, thereby improving detection accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a schematic diagram of the installation position relationship between the 3D scanner and the iron ditch;

[0017] Figure 2 It is a schematic diagram of the connection relationship between the 3D scanner and the bracket;

[0018] Figure 3 It is a schematic diagram of the control principle diagram of the temperature monitoring system;

[0019] Figure 4 This is a schematic diagram of the temperature sensor installation location;

[0020] Figure 5 is a schematic diagram of a cross-section of a temperature sensor;

[0021] Figure 6 It is a schematic diagram of the left view of the thermal head;

[0022] Figure 7 The temperature variation curves of multiple iron-tapping cycles in Example 1;

[0023] Figure 8 This is a temperature variation curve of one of the tapping cycles in Example 1;

[0024] Among them: 1- steel shell, 2- working lining, 3- groove, 4- temperature sensor, 401- heat conduction plate, 402- heat conduction head, 403- connecting pipe, 404- working head, 405- thermocouple, 406- thrust spring, 407- guide sleeve, 408- positioning sleeve, 409- gland, 410- boss, 5- cable, 6- bridge, 7- iron groove, 8- 3D scanner, 9- bracket. DETAILED DESCRIPTION

[0025] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0026] The following will be combined with the drawings in the embodiments of the invention to clearly and completely describe the technical solutions in the embodiments of the invention. Obviously, the described embodiments are only part of the embodiments of the invention, not all of the embodiments. Based on the embodiments of the invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the invention.

[0027] Example 1

[0028] like Figure 1-8 As shown, a blast furnace iron groove erosion detection system includes an image acquisition device and a server. The image acquisition device includes a bracket 9. A 3D scanner 8 is installed on the upper end of the bracket. The 3D scanner is connected to the server signal. The image acquisition device can acquire images of the iron groove from multiple angles. The server is a PC. Specifically, the 3D scanner has at least 6 scanning points. The 6 scanning points perform 3D scanning on the iron groove from the front end, middle part and tail end of the iron groove 7, and then can perform full coverage 3D scanning to obtain a complete 3D model.

[0029] After the new iron trough is made, and after each iron tapping is completed and the residual iron is released, a 3D scan is performed. The image obtained by the 3D scan is converted into a 3D model of the iron trough working surface. The iron trough erosion value is obtained by comparing the coordinate change value of each point in the 3D model.

[0030] During the 3D scanning process, not only the working layer castable is 3D scanned, but also the refractory prefabricated parts are 3D scanned, which can accurately determine the erosion status of each component with high detection accuracy.

[0031] In actual production, there are often temperature fluctuations. There are two types of fluctuations. One is a sudden sharp rise in temperature, which is extremely rare. The main reason for this is the quality problem of the iron ditch material, which causes large pieces to peel off or molten iron to penetrate into the ditch material. At this time, the iron tapping should be stopped immediately. The other is a sudden drop in temperature, which is generally caused by gunning or wind stoppage, and the temperature drop situations of these two types are not quite the same.

[0032] In order to improve the monitoring stability, the iron channel is also equipped with a temperature monitoring system, such as Figure 3As shown, it includes multiple temperature sensors distributed on the side walls of the blast furnace iron groove, the spacing between two adjacent temperature sensors is 800mm, the temperature sensors are located on both sides of the blast furnace iron groove and correspond to the middle position of the groove, and can detect with high accuracy. Each temperature sensor is connected to a controller, the controller is connected to an alarm, and the controller is connected to a host computer.

[0033] The temperature sensor includes a temperature measuring seat, which includes a heat conducting plate 401. The heat conducting plate is a circular plate. A heat conducting head 402 is integrally formed on the first side of the heat conducting plate. A connecting pipe 403 is fixed on the second side of the heat conducting plate. The heat conducting plate and the heat conducting head are integrally formed by stainless steel material. The heat conducting head is cylindrical. During the installation process, a hole is opened on the steel shell, and the hole extends into the working lining 2. Then the heat conducting head is processed and inserted into the hole. The heat conducting plate is fitted with the steel shell 1 and fixed by welding or bonding. It can detect the temperature of the working lining with high detection accuracy. The connecting pipe is a circular pipe made of stainless steel material and is connected to the heat conducting plate 1. The plates are fixed by coaxial welding, a temperature probe is installed in the connecting pipe, the detection end of the temperature probe is fitted with the heat conducting plate, the temperature probe includes a working head 404, the working head is formed by buckling two stainless steel petals of the same shape, a thermocouple mounting groove is processed on the stainless steel petals, the thermocouple 405 is installed in the insulating ceramic tube, and then placed in the thermocouple mounting groove, the two stainless steel petals are buckled, welded and polished to obtain the working head, in order to improve the thermal conductivity and thermal stability, the inner end of the working head is spherical, the heat conducting plate is processed with a groove matching the working head, and a heat conducting plate is installed at one end of the connecting pipe away from the heat conducting plate. The guide sleeve 407 is made of rubber material and has good heat insulation effect. The outer end of the working head is installed with a heat insulation rod. Specifically, the heat insulation rod is made of nylon material and is cylindrical. The heat insulation rod is processed with a wire hole along the length direction for passing the cable 5. To ensure the connection stability, the outer end of the working head is processed with a cylindrical boss 410, and the inner end of the heat insulation rod is processed with a groove matching the boss. The outer end of the heat insulation rod is matched with the guide sleeve gap and passes through the guide sleeve. For further positioning, a positioning sleeve 408 is installed between the outer end of the guide sleeve and the temperature measuring probe. The positioning sleeve is a silicone sleeve. The inner end of the positioning sleeve is tapered, and the outer end of the guide sleeve is processed with a tapered opening that matches the positioning sleeve. The outer end of the guide sleeve is fitted with a pressure cap 409, which presses the positioning sleeve inward. Through the cooperation between the positioning sleeve and the guide sleeve, not only can the thermal insulation connecting rod be radially positioned, but also the thermal insulation connecting rod can be axially positioned through the friction between the silicone and the thermal insulation connecting rod. The temperature measuring probe passes through the pressure cap outward. In order to ensure the fit between the working head and the heat conduction plate, a thrust spring 406 is installed between the outer end of the working head and the guide sleeve. After installation, the thrust spring is compressed, thereby causing the thrust spring to push the working head inward.

[0034] A bridge 6 is also installed outside the steel shell. The cables of the temperature sensors are connected to the controller after being collected through the bridge. The temperature sensors are used to monitor the real-time temperature of the corresponding position and upload it to the controller.

[0035] The controller uses an industrial controller with many data interfaces and a display. It can stably process the received sensor data, calculate the temperature change curve, and display it on the display. It can also judge the erosion state of the blast furnace iron groove according to the shape of the curve and alarm when it exceeds the preset value. The controller is connected to the host computer via Ethernet. The host computer is a server PC, which stores data and curves.

[0036] The alarm is a buzzer.

[0037] The temperature monitoring method comprises the following steps:

[0038] Step 1: Install multiple temperature sensors on the side wall of the blast furnace iron groove, the temperature sensors are connected to the controller, and the controller is connected to the alarm;

[0039] Step 2: The controller collects the detection values ​​of each temperature sensor in real time and generates curves that change with time. The early detection temperature value is used to generate the curve, and the detection cycle is 10s. The iron ditch works stably in the middle period, and the detection cycle is 10min. The iron ditch erosion intensifies in the later period, and the detection cycle is 1min.

[0040] Step 3: The controller analyzes the curve to determine the erosion status of the iron ditch.

[0041] Among them, in step 2, temperature compensation is performed for the wind-off period and the spraying period, including the following steps:

[0042] A, the controller detects that the temperature drops rapidly, determines that it has entered the wind-off period or the spraying period, and records the temperature inflection point value T1 and the time t1;

[0043] B, the controller detects that the temperature starts to rise, and when the temperature returns to T1, the time t2 is recorded;

[0044] C, compensate the temperature detection during the time period from t1 to t2, so that the temperature detection indication during the time period from t1 to t2 is T1.

[0045] In step 3, the controller analyzes the curve and determines the erosion state of the iron ditch through the following formula:

[0046] Wear = (T-Tw) × Wcc,

[0047] Where Wear is the erosion value, T is the real-time temperature, Tw is the stable temperature, and Wcc is the slope.

[0048] Since thermocouples are in a high-temperature working state for a long time, they are easy to be damaged. The detection standard is that when the temperature value detected exceeds the detection upper limit, the thermocouple is judged to be open circuit; when the temperature value detected is always zero, the thermocouple is judged to be short circuit; when the temperature is detected to be a negative value, the thermocouple is judged to be reversely connected; when the temperature is detected to be low and the fluctuation is small, the thermocouple working part is judged to be faulty. For thermocouples that cannot work normally, they should be repaired and eliminated when calculating the real-time temperature T.

[0049] Take the No. 1 trench of the No. 1 blast furnace of Rizhao Company of Shandong Steel Plant as an example. The design capacity of the No. 1 blast furnace is 5,100 cubic meters. The blast furnace is equipped with 4 iron mouths and adopts a double rectangular iron-making yard. The two iron-making yards are symmetrically arranged. Each iron-making yard has 2 iron mouths with a length of about 21m and an angle of 81° between the iron mouths. There are 44 thermocouples in each main trench, 25 on one side and 19 on the other side. The distance between each two temperature sensors is 80cm. The material of the working layer is Al-SiC-C with a thickness of 807mm.

[0050] Take the 4 temperature sensors (thermocouples) of groove 1 as an example to draw a curve. This temperature curve contains 8 complete tapping cycles. When a tapping cycle begins, the molten iron is constantly flushed and accumulated in the iron groove, and the temperature of the refractory in the main groove continues to rise. At the same time, as the amount of tapping increases, the refractory in the working layer is corroded and gradually becomes thinner, so the temperature will rise further. The test results are shown in Figure 5 .

[0051] Depend on Figure 7 It can be seen that in the first four iron-out cycles, the temperature extreme value measured by the thermocouple can exceed 550°C. Starting from the fifth cycle, the extreme temperature measured by the thermocouple gradually decreases and the extreme value is below 500°C. For this reason, it is necessary to continuously fine-tune and optimize Tw in the formula so that the calculated value of the formula is closer to the actual corrosion value. The stable temperature of the fifth cycle is selected as Tw. Figure 5 There may be some abnormal thermocouple temperature curves, such as the measured temperature far exceeding 700°C. This is caused by a short circuit in the line during use and has no effect on the overall temperature trend.

[0052] Wcc is obtained based on the ratio of the erosion value to the temperature rise value. The temperature rise value is the difference between the real-time temperatures T and Tw during the iron-making cycle. The erosion value is obtained by judging the thickness of the working layer through 3D scanning. Through the detection of multiple iron-making cycles, the erosion value data and the temperature rise value data are obtained, and then Wcc is calculated. In the later use process, only the real-time detection of the temperature value is required to judge the erosion status. It is easy to use, has a fast response speed and high accuracy.

[0053] To facilitate measurement, the sensors on each side of the iron groove are divided into a group, and the Wcc of each temperature sensor is calculated to obtain the average value, which is recorded as the Wcc of this side. Both sides of the iron groove have corresponding Wcc and the same stable temperature Tw. The real-time temperature value of this side can reflect the corrosion state of this side. The measurement speed is fast, but the measurement accuracy is low.

[0054] Take the temperature curve of four temperature sensors in one iron-making cycle as an example, see Figure 6 .

[0055] from Figure 8 It can be seen more clearly that when iron tapping begins, the refractory temperature rises rapidly, and then begins to rise steadily. This is because before iron tapping, the refractory in the main groove will be pre-baked, and the temperature during the pre-baking period is around 100°C. After iron tapping, since the temperature of the molten iron is around 1500°C, the refractory temperature in the main groove will rise rapidly, and then it will reach a stable rising process.

[0056] Since the temperatures measured by thermocouples in different parts are different, for example, the temperature near the iron mouth and the tail of the main groove will be lower, while the temperature in the turning area (near the iron falling point) is usually the highest in the main groove.

[0057] exist Figure 6 In the middle and late stages of iron tapping, the temperature shows an obvious drop and then rise again process. This is because there will be on-site operations such as wind stop or gunning during the iron tapping cycle. This operation will have a temporary change in temperature, but will not have a major impact on the overall temperature trend.

[0058] Depend on Figure 6 It can also be seen that during the tapping cycle, the temperature curve will show a temperature drop phenomenon. This is because there will be gunning and wind-down operations in the normal tapping cycle. Generally speaking, in a complete tapping cycle, the temperature of the working layer refractory will gradually increase with the increase in the amount of tapping, and the temperature reaches the highest at the end of the tapping cycle.

[0059] Research has found that when gunning occurs during the iron-making process, the temperature of the main groove will drop rapidly within a few days after the iron-making stops, with a drop range of 50℃-100℃. When the gunning is completed and the iron-making is resumed, the temperature will slowly rise. For ordinary gunning, most of them conform to the "L" type, that is, the temperature drops rapidly and then rises slowly. Temperature compensation is performed at this stage, so that the temperature measured by the controller is still in a state of slowly rising.

[0060] When the wind is stopped, the temperature will also drop rapidly. All the gunning temperatures during the wind stop period show a "V" shape, that is, the temperature drops rapidly and then rises rapidly. Due to the introduction of blast furnace air volume judgment, the controller will automatically eliminate the temperature drop caused by the wind stop, thereby showing that the temperature is still rising slowly.

[0061] The present application performs temperature compensation for the wind-off period and the gunning period, which can make the temperature curve relatively stable and truly reflect the erosion data according to the formula.

[0062] It can be concluded from Example 1 that, under normal conditions, within the same iron-out cycle, the temperature value of the iron groove varies with the process. Due to the heat-insulating effect of the working layer, the temperature rises to a real-time temperature value T and stabilizes at the real-time temperature value T. The erosion value of the iron groove can be obtained through the real-time temperature value T, which is convenient to operate and has high detection accuracy. The real-time temperature values ​​T of different iron-out cycles are different, which represents different erosion values. Maintenance is performed when the erosion value reaches the preset value.

[0063] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A blast furnace iron groove erosion detection system, characterized in that: It includes an image acquisition device and a server; The image acquisition device includes a bracket, a 3D scanner is arranged on the upper end of the bracket, the 3D scanner is connected to the server signal, and the image acquisition device can acquire images of the iron ditch from multiple angles; The server is a PC; It also includes a temperature monitoring system, which includes a plurality of temperature sensors arranged on the two side walls of the iron groove, the distance between the two temperature sensors is 800 mm, the temperature sensors are located on both sides of the blast furnace iron groove and correspond to the middle position of the groove, the temperature sensor includes a temperature measuring seat, the temperature measuring seat includes a heat conducting plate, the heat conducting plate is a circular plate, a heat conducting head is integrally formed on the first side of the heat conducting plate, a connecting pipe is fixed on the second side of the heat conducting plate, the heat conducting head is cylindrical, the temperature sensors are all connected to a controller, the controller is all connected to an alarm, and the controller is connected to a host computer; A temperature measuring probe is installed in the connecting pipe, the detection end of the temperature measuring probe is attached to the heat conducting plate, the temperature measuring probe comprises a working head, the working head is formed by buckling two stainless steel petals of the same shape, a thermocouple mounting groove is processed on the stainless steel petals, and the thermocouple is installed in the insulating ceramic tube; The inner end of the working head is spherical, the heat conducting plate is processed with a groove matching the working head, the end of the connecting pipe away from the heat conducting plate is installed with a guide sleeve, and the outer end of the working head is installed with a heat insulating connecting rod; The thermal insulation connecting rod is cylindrical, and a wire hole is processed along the length direction of the thermal insulation connecting rod. A cylindrical boss is processed at the outer end of the working head, and a groove matching the boss is processed at the inner end of the thermal insulation connecting rod. The outer end of the thermal insulation connecting rod is matched with the guide sleeve and passes through the guide sleeve. A positioning sleeve is installed between the outer end of the guide sleeve and the temperature measuring probe. The inner end of the positioning sleeve is conical, and the outer end of the guide sleeve is processed with a conical opening matching the positioning sleeve. A pressure cover is installed on the outer end of the guide sleeve, and the pressure cover presses the positioning sleeve inward; a thrust spring is installed between the outer end of the working head and the guide sleeve.

2. The blast furnace iron groove erosion detection system according to claim 1, characterized in that: The image acquisition device performs 3D scanning on the iron ditch at least from the front end, the middle part and the tail end.

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