Intelligent blast furnace stockyard management system and method

Abstract

The present application relates to the field of blast furnace on the raw fuel supply, especially to a kind of blast furnace intelligent bunker management system and method, including several bunkers, several unloading trolleys and the belt for conveying the several unloading trolleys, the upper end of the several bunkers is equipped with radar material level meter for detecting material level line in bunker at any time, the bottom of the belt is equipped with electronic belt scale, the upper end of the several bunkers is equipped with Gray busbar for accurately determining the position of the bunker needing to be dosed, the present application realizes intelligent dosing, executes the next cycle after the end of dosing, accurately identifies and positions the bunker, and the wrong material cannot appear, the incoming material quantity is accurate, the reduction of feeding frequency greatly reduces the occurrence of mixing accident, and the full automation of feeding operation effectively avoids the accidents of unloading trolley and wrong position, reduces the opportunity of post worker to contact dust, improves the production capacity and protects the health of workers, and is suitable for wide promotion.

Description

Technical Field

[0001] This invention relates to the field of raw material and fuel supply in blast furnace troughs, and more particularly to an intelligent blast furnace silo management system and method. Background Technology

[0002] The blast furnace top-feeding system is a crucial link in the blast furnace raw material supply process. It plays a vital role in providing raw materials to the bottom-feeding system and storing raw materials for blast furnace smelting. Its operation is closely related to the smooth flow of bottom-feeding and ensuring high blast furnace utilization. When the silos need replenishment, operators move the unloading trolley to the required location, confirm the location, and then notify the supply department to begin feeding. To prevent overflow due to blockages or overfilling during unloading, operators must be present to promptly address any such incidents. Throughout this process, the environment is noisy and heavily polluted, making it essential to free the operators from this environment.

[0003] Chinese Patent CN 110286614 A discloses an unmanned remote monitoring method and unloading system for a material unloading trolley, including an unloading trolley, a WCS positioning system, a control system, and a monitoring system. The unloading trolley, WCS positioning system, and monitoring system are networked to the control system. The method utilizes an intelligent pipe-type unloading trolley, WCS positioning system, and monitoring system combined with the control system to achieve remote, synchronous, real-time monitoring and operation of multiple unloading trolleys and silos, determining the unloading time and location of each silo.

[0004] However, the existing technology is not accurate enough in identifying and locating the silos, which is prone to incorrect material delivery, affecting the smooth operation of the blast furnace and the quality of pig iron. After incorrect delivery, the material will accumulate, resulting in low silo volume utilization. Furthermore, the material delivery is not accurate enough, either some silos are not full or too much material is delivered, causing overflow or overflowing material to be delivered to other silos, resulting in mixed materials. Summary of the Invention

[0005] The present invention proposes an intelligent blast furnace silo management system and method, which accurately identifies and locates the silo, prevents incorrect material delivery, and ensures accurate material intake, thus solving the aforementioned problems.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a blast furnace intelligent silo management system, comprising several silos, several unloading trolleys, and belts for conveying the several unloading trolleys. Each of the several silos is equipped with a radar level gauge at its upper end for constantly detecting the material level line in the silo. An electronic belt scale is installed at the bottom of the belt. A Gray line is installed at the upper end of the several silos for accurately determining the position of the silo that needs to be batched.

[0007] Preferably, each of the plurality of silos is provided with a weighing hopper at its bottom.

[0008] Preferably, the unloading trolley is equipped with a PLC controller and a frequency converter for controlling its automatic movement.

[0009] Preferably, the Gray bus is provided with two pairs of induction loops for data induction communication.

[0010] Preferably, it includes the following steps:

[0011] Step 1: After starting, data collection is performed first, specifically by collecting the material level lines in all silos, determining the position of the unloading trolley, the amount of material discharged under the blast furnace trough, and the value of the electronic belt scale through the radar level gauge;

[0012] Step 2: Determine whether to discharge material based on the material level data collected by the radar level gauge in the silo. If the material levels in the silos are the same, determine the silo to be discharged first based on the total material volume of the same silo and the amount of material discharged from the blast furnace trough.

[0013] Step 3: Establish a mathematical model based on the structural dimensions, material specific gravity, and material stability angle parameters of each ore bin on site. Use the mathematical model to calculate the amount of material required for the silo based on the material level data collected by the radar level gauge. At the same time, calculate the total amount of material V1 required for the same silo.

[0014] Step 4: After calculating the initial material requirement, a material supply instruction and preliminary demand are issued to the raw materials. The material supply system dispenses materials according to the type and quantity of the provided materials, and at the same time, the unloading trolley moves to the material bin where the material needs to be dispensed.

[0015] Step 5: The electronic belt scale detects the material arrival time and provides accurate real-time material quantity information entering the ore bin, which is then recalculated against the pre-set feeding amount for the ore bin.

[0016] Step 6: Verify the total material quantity to achieve the maximum material supply, improve the utilization rate of the silo, and reduce the number of feeding operations. The time from the issuance of the material demand signal to the detection of the material by the belt scale is t1. Then, calculate the time t2 required to complete feeding based on the existing silo capacity. The total time T = t1 + t2. The material feeding amount under the blast furnace trough at time T is V2. The total required amount Vtotal = V1 + V2.

[0017] Step 7: Compare the information provided by the electronic belt scale with the amount of material added to each hopper calculated by the mathematical model in the previous step, and automatically control the timing and position of the unloading trolley during the unloading process to achieve intelligent material distribution. After the material is discharged, the next cycle is executed.

[0018] The beneficial effects of this invention are:

[0019] The present invention includes several silos, several unloading trolleys, and belts for transporting the unloading trolleys. Each of the silos is equipped with a radar level gauge at the top for constantly detecting the material level line in the silo. An electronic belt scale is installed at the bottom of the belt. A Gray busbar is installed at the top of the silos for accurately determining the position of the silo that needs to be batched. The process begins with data acquisition, specifically using radar level gauges to collect material level lines in all silos, determine the position of the unloading trolley, the amount of material discharged from the blast furnace trough, and the values ​​from the electronic belt scale. Based on the material level data collected by the radar level gauges, it is determined whether material needs to be added. If the material levels in the silos are the same, the silo to be added is prioritized based on the total material volume of the same silos and the amount of material discharged from the trough. A mathematical model is established based on the structural dimensions of each trough, the specific gravity of the material, and the stable angle of repose parameters of the material. The mathematical model is used to calculate the amount of material required for each silo based on the material level data collected by the radar level gauges, and simultaneously calculates the total amount of material required for the same silo, V1. After calculating the initial material requirement, a supply command and preliminary demand are issued to the raw material suppliers. The supply system dispenses the materials according to the provided material type and quantity, while the unloading trolley moves to the location of the silo to be added. The electronic belt scale detects the material arrival time and provides accurate real-time material quantity information entering the ore bin. This information is then recalculated against the pre-set feeding amount for that bin to verify the total material quantity and maximize the material arrival rate. This improves bin utilization and reduces the number of feeding cycles. The time from the issuance of the material demand signal to the belt scale detecting the material arrival is t1. The time t2 required to complete feeding is then calculated based on the existing bin capacity. The total time T = t1 + t2. The material discharge amount under the blast furnace bin at time T is V2. The total demand Vtotal = V1 + V2. The information provided by the electronic belt scale is compared with the feeding amount of each bin calculated by the mathematical model in the steps. The timing and position of the unloading trolley during the unloading process are automatically controlled to achieve intelligent material distribution. After feeding is completed, the next cycle is executed. The bin identification and positioning are accurate, preventing incorrect feeding. The material arrival quantity is accurate, solving the technical problem.

[0020] Furthermore, this invention improves unloading efficiency and reduces energy consumption. By maximizing the utilization of remaining effective storage capacity, it increases the utilization rate of the ore bins, maximizing capacity utilization and thus improving operational efficiency. This ensures full utilization of storage capacity each time, reducing the total number of feeding operations and the total number of operations of the conveyor belt system. The reduced feeding frequency significantly reduces the occurrence of material mixing accidents. The fully automated feeding operation effectively avoids unloading trolley slippage and misalignment accidents, further preventing material mixing accidents and greatly improving the operational quality of the trolley, reducing the occurrence of quality accidents. This achieves a double harvest of economic and social benefits. The fully automated trolley operation reduces workers' exposure to dust, lowering operational and health risks. It increases productivity while protecting worker health, achieving a win-win situation and making it suitable for widespread application. Attached Figure Description

[0021] Figure 1 This is a flowchart of the workflow of the present invention.

[0022] Figure 2 This is a schematic diagram of the layout of the unloading system of the present invention.

[0023] In the diagram: 1-unloading trolley, 2-radar level gauge, 3-electronic belt scale, 4-Gray busbar, 5-silo, 6-weighing hopper, 7-belt. Detailed Implementation

[0024] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0025] Reference Figures 1-2 A blast furnace intelligent silo management system includes 10 silos 5, several unloading trolleys 1, and belt conveyors 7 for transporting the unloading trolleys 1. Each of the 10 silos 5 is equipped with a radar level gauge 2 at the top for constantly detecting the material level line in the silo. An electronic belt scale 3 is installed at the bottom of the belt conveyor 7. A Gray wire 4 is installed at the top of the 10 silos 5 for accurately determining the position of the silo that needs to be batched. A weighing hopper 6 is installed at the bottom of each of the 10 silos 5.

[0026] The Gray busbar 4 is located beside the track of the unloading trolley 1. The movement position of the unloading trolley 1 is detected by the Gray busbar 4, thereby obtaining the coordinates of the unloading trolley 1. The detection accuracy is 5 mm. It monitors the current position of the unloading trolley 1 in real time, that is, the identification of its location in the bin (slot), to prevent collisions. The Gray busbar 4 ensures that the position signal of the unloading trolley 1 is reliable and accurate, and can work reliably in environments with strong dust.

[0027] The location of the required material bin 5 can be accurately determined using the Gray busbar 4, ensuring that the unloading trolley 1 distributes materials within the designated area and prevents mixing with adjacent bins 5. This achieves multi-point uniform material distribution (discharge), improving bin capacity utilization. Precise operation optimizes the process, reduces the probability of human error, and prevents accidents such as mixing materials in the wrong bin or deviating from the unloading port during unloading.

[0028] Because of the high dust levels and low visibility inside hopper 5 during the material loading and unloading process, this invention preferably employs a radar level gauge 2 to detect the material level height and real-time changes in hopper 5. The detection signals from the radar level gauge 2 are synchronously uploaded to the management host and the automation management software of the conveyor belt 7 for interactive communication within the automation control system. This allows for real-time monitoring of the actual material level in each hopper 5, enabling precise material placement and automatic hopper-switching operations.

[0029] The unloading trolley 1 is equipped with a PLC controller and a frequency converter for controlling its automatic movement. According to the process, it can be used in conjunction with the radar level gauge 2 to realize remote control, semi-automatic and fully automatic operation.

[0030] This system enables bidirectional data exchange between the vehicle and the ground. Address information can be transmitted via induction, radio, or signal cables. Two pairs of induction loops are added to the Gray busbar 4 cable for data induction communication. The ground station's induction communication unit is directly connected to the material yard monitoring system computer, and the vehicle's induction communication unit is connected to the PLC controller on the unloading trolley 1. This induction communication method enables bidirectional communication between the unloading trolley 1 and the material yard monitoring system computer. It also enables computer management, remote monitoring, and production status storage and retrieval throughout the production process.

[0031] This system enables interlocking control between the unloading trolley 1 and the underground equipment, preventing material blockage accidents. It also protects worker health and safety, improves work efficiency and production management, and extends the service life of the unloading trolley 1.

[0032] Commands are issued to the unloading trolley 1 from the dispatch room to achieve automatic control of the unloading trolley 1. Combined with the radar level gauge 2, it can automatically display and count the material level of each hopper 5, and can display and record the working status and position of the unloading trolley 1 in real time. The system computer controls the locomotive operation with the help of real-time position detection signals. Through the coordinated work of the Gray busbar 4 and the control system, the locomotive can move smoothly and stop accurately and reliably. At the same time, the movement of the unloading trolley 1 can be operated on the computer through the effective position provided by the positioning system.

[0033] The method of using this invention is as follows:

[0034] Step 1: After starting, data collection is carried out first. Specifically, the radar level gauge 2 collects the material level lines in all silos 5, determines the position of the unloading trolley 1, the amount of material discharged under the blast furnace trough, and the value of the electronic belt scale 3.

[0035] Step 2: Determine whether to discharge material based on the material level data collected by radar level gauge 2 in silo 5. If the material level in silo 5 is the same, determine the silo 5 to be discharged first based on the total material volume of the same silo 5 and the amount of material discharged from the blast furnace trough.

[0036] Step 3: Establish a mathematical model based on the structural dimensions, material specific gravity and material stable stacking angle parameters of each ore bin on site. Use the mathematical model to calculate the amount of material required for silo 5 based on the material level line data collected by radar level gauge 2 in silo 5, and at the same time calculate the total amount of material V1 required for silo 5.

[0037] Step 4: After calculating the initial material requirement, a material supply instruction and preliminary demand are issued to the raw materials. The material supply system will dispense the materials according to the type and quantity of the provided materials. At the same time, the unloading trolley 1 moves to the material bin 5 where the material needs to be dispensed.

[0038] Step 5: The electronic belt scale 3 detects the material arrival time and provides accurate real-time material quantity information entering the ore bin, which is then recalculated against the pre-set feeding amount of the ore bin 5.

[0039] Step 6: Verify the total material quantity to achieve the maximum material quantity, improve the utilization rate of silo 5, and reduce the number of feeding times. The time from the issuance of the material demand signal to the detection of material by belt scale 3 is t1. Then, calculate the time t2 required to complete feeding based on the existing silo capacity. The total time T = t1 + t2. The material quantity V2 fed into the blast furnace trough at time T. The total required quantity Vtotal = V1 + V2.

[0040] Step 7: The information provided by the electronic belt scale 3 is compared with the amount of material added to each hopper 5 calculated by the mathematical model in Step 3. The timing and position of the unloading trolley 1 during the unloading process are automatically controlled to achieve intelligent material distribution. After the material is discharged, the next cycle is executed.

[0041] This invention automatically controls the timing and position of the unloading trolley during the unloading process, achieving intelligent material distribution. After the material distribution is completed, the next cycle is executed. The hopper identification and positioning are accurate, preventing incorrect material distribution and ensuring accurate material intake, thus solving the technical problem.

[0042] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method of using a blast furnace intelligent silo management system, comprising several silos (5), several unloading trolleys (1), and a belt (7) for conveying the several unloading trolleys (1), wherein each of the several silos (5) is equipped with a radar level gauge (2) for constantly detecting the material level line in the silo, an electronic belt scale (3) is installed at the bottom of the belt (7), a Gray line (4) for accurately determining the position of the silo to be batched is installed at the top of each of the several silos (5), a weighing hopper (6) is correspondingly installed at the bottom of each of the several silos (5), a PLC controller and a frequency converter are installed on the unloading trolley (1) for controlling its automatic movement, and two pairs of induction loops are installed in the Gray line (4) for data induction communication, characterized in that Includes the following steps: Step 1: After starting, data collection is carried out first, specifically by collecting the material level lines in all silos (5) through the radar level gauge (2), determining the position of the unloading trolley (1), the amount of material discharged under the blast furnace trough, and the value of the electronic belt scale (3); Step 2: Determine whether to discharge material based on the material level data in the silo (5) collected by the radar level gauge (2). If the material level in the silo (5) is the same, determine the silo (5) to be discharged first based on the total material quantity of the same silo (5) and the material discharge quantity under the blast furnace trough. Step 3: Establish a mathematical model based on the structural dimensions, material specific gravity and material stable stacking angle parameters of each ore bin on site. Use the mathematical model to calculate the amount of material required for the silo (5) based on the material level line data collected by the radar level gauge (2). At the same time, calculate the total amount of material V1 required for the same silo (5). Step 4: After calculating the initial material requirement, a material supply instruction and preliminary demand are issued to the raw materials. The material supply system will distribute the materials according to the type and quantity of the provided materials. At the same time, the unloading trolley (1) moves to the position of the silo (5) that needs to be filled. Step 5: The arrival time is detected by the electronic belt scale (3), and the accurate material quantity information entering the ore bin in real time is provided and recalculated with the pre-set feeding amount of the ore bin (5); Step 6: Verify the total material quantity to reach the maximum material quantity, improve the utilization rate of the silo (5), reduce the number of feeding times, the time from the issuance of the material demand signal to the detection of the material by the belt scale (3) is t1, and then calculate the time t2 required to complete feeding based on the existing silo capacity, the total time T = t1 + t2, the material quantity V2 of the blast furnace trough at time T, and the total demand Vtotal = V1 + V2; Step 7: Compare the information provided by the electronic belt scale (3) with the amount of material added to each hopper (5) calculated by the mathematical model in step (3), automatically control the timing and position of the unloading trolley (1) during the unloading process, realize intelligent material distribution, and execute the next cycle after the material is discharged.

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