A steel material consumption management and control system applied to production practice

Abstract

This invention discloses a steel material consumption control model applicable to actual production, relating to steelmaking processes. It includes an information acquisition unit that collects iron element data in raw materials before they enter the converter and the iron loss during converter smelting; a billet modeling unit that constructs a theoretical molten steel analysis model based on the iron element data and iron loss to obtain theoretical molten steel values; obtains the actual molten steel volume after smelting and the billet volume obtained after casting; and an analysis and judgment unit that analyzes whether the smelting process is abnormal based on the theoretical molten steel value, actual molten steel volume, and billet volume. This invention realizes the transformation of daily management of steel material consumption data from offline to online, achieving control over each heat of steel; it can promptly identify problems in steel consumption control during production, enabling staff to take timely measures to optimize and adjust, continuously promoting operational improvements.

Description

Technical Field

[0001] This invention relates to steelmaking processes, and more specifically, to a steel consumption control system applied in actual production. Background Technology

[0002] The consumption of steel feedstock in converters is closely related to the content of scrap steel, the iron content in molten iron, the control of the smelting process, and the input of alloys. Manufacturers use different types of scrap steel in actual production. Some manufacturers do not periodically test the iron content of the scrap steel before it enters the furnace, while others do. The testing method generally involves taking iron samples from each furnace to analyze the iron content in the molten iron and monitoring the blowing process. However, most manufacturers currently only test the iron content in the molten iron without establishing a theoretical model based on the iron flow from furnace entry to steel production. Without systematic and real-time control and evaluation, workers often operate based on their experience, and the results cannot be evaluated promptly. This hinders real-time control and evaluation of smelting results and makes it difficult to quickly identify problems and make improvements. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a steel material consumption control system that can be applied to actual production, addressing the shortcomings of the existing technology.

[0004] The present invention discloses a steel material consumption control system applied in actual production, comprising:

[0005] The information acquisition unit collects data on the iron element content in the raw materials before they enter the converter, as well as the iron loss of the raw materials during the converter smelting process.

[0006] The billet modeling unit constructs a theoretical molten steel analysis model based on the iron element data and iron loss to obtain the theoretical molten steel value; it also obtains the actual molten steel quantity after the raw material is smelted and the billet quantity obtained after casting.

[0007] The analysis and judgment unit analyzes whether the smelting process is abnormal based on the theoretical molten steel value, the actual molten steel quantity, and the billet quantity.

[0008] The theoretical steel analysis model is specifically as follows:

[0009] ;

[0010] in, This is the theoretical value of molten steel; This refers to the total amount of molten iron originally present in the converter; The iron content ratio of the original molten iron in the converter is taken as 0.94-0.95; This refers to the total amount of scrap steel fed into the converter; This refers to the iron content ratio in scrap steel. This refers to the total amount of return ore fed into the converter; The iron content ratio in the return ore is 0.56-0.58. This is the ratio of the iron content in the steel slag to the total amount of molten iron in the converter, and is set to 0.01. The percentage of iron elements damaged by the dust removal system of the converter is 0.005. This refers to the total amount of alloy fed into the converter; For alloy yield; Steel material added after the molten iron is discharged from the converter; This refers to the steel yield.

[0011] The scrap steel includes reinforcing bars and heavy scrap steel, industrial briquettes, slag steel, and shavings.

[0012] When the scrap steel is reinforcing steel. The value is 0.94-0.96; when the scrap steel is heavy scrap steel, The value is between 0.90 and 0.94; when the scrap steel is industrial briquettes, The value is between 0.87 and 0.92; when the scrap steel is slag steel, The value is 0.65-0.71; when the scrap steel is shavings, The value ranges from 0.80 to 0.84.

[0013] The actual amount of molten steel is calculated using the following formula.

[0014] ;

[0015] In the formula, This represents the actual amount of molten steel. The total weight of the actual object lifted by the crane; This is the net weight of the vessel used to hold molten steel.

[0016] The billet quantity includes the theoretical billet quantity and the actual billet quantity.

[0017] The theoretical billet quantity is calculated using the following formula.

[0018] ;

[0019] In the formula, This is the theoretical weight of the steel billet; This refers to the total length of the casting. This refers to the weight of each meter of steel billet.

[0020] The theoretical billet quantity is calculated using the following formula.

[0021] ;

[0022] In the formula, This refers to the actual weight of the steel billet; This refers to the amount of molten steel remaining in the tank. This represents the amount of molten steel lost during the casting process.

[0023] Beneficial effects

[0024] The advantages of this invention are: it establishes a theoretical management model for steel consumption based on smelting raw materials and iron loss during the smelting process, realizing the transformation of daily management of steel consumption data from offline to online, and achieving control over each furnace of steel; it can promptly identify problems in steel consumption control during the production process, enabling staff to take timely measures to optimize and adjust based on these problems, and continuously promote job improvement. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the implementation process of the steel material consumption control system of the present invention. Detailed Implementation

[0026] The present invention will be further described below with reference to embodiments, but this does not constitute any limitation on the present invention. Any limited modifications made by any person within the scope of the claims of the present invention are still within the scope of the claims of the present invention.

[0027] See Figure 1 The present invention provides a steel material consumption control system for practical production, comprising an information acquisition unit, a billet modeling unit, and an analysis and judgment unit.

[0028] The information acquisition unit is used to collect data on the iron content of the raw materials before they enter the converter and the iron loss of the raw materials during the converter smelting process. Specifically, the collected iron content data includes the total amount of molten iron in the converter, the total amount of scrap steel fed into the converter, and the total amount of return ore fed into the converter. Based on the iron content ratios in these data, the net iron content is obtained. In addition, the collected iron loss data includes the ratio of iron content in the steel slag to the total amount of molten iron in the converter, the ratio of iron content damaged by the dust removal system, the net amount of alloys (such as vanadium-nitrogen alloys) fed into the converter, and the net amount of steel added after the molten iron is discharged from the converter.

[0029] The collected data will be modeled and analyzed using the billet modeling unit to obtain the theoretical molten steel value, the actual molten steel quantity, the theoretical billet quantity, and the actual billet quantity.

[0030] The theoretical molten steel analysis model is specifically as follows:

[0031] .

[0032] in, This is the theoretical value of molten steel; This refers to the total amount of molten iron originally present in the converter; The ratio of iron content in the original molten iron in the converter is taken as 0.94-0.95. This refers to the total amount of scrap steel fed into the converter; This refers to the iron content ratio in scrap steel. This refers to the total amount of return ore fed into the converter; The iron content ratio in the return ore is 0.56-0.58. This is the ratio of the iron content in the steel slag to the total amount of molten iron in the converter, and is set to 0.01. The percentage of iron elements damaged by the dust removal system of the converter is 0.005. This refers to the total amount of alloy fed into the converter; For alloy yield; Steel material added after the molten iron is discharged from the converter; This refers to the steel yield.

[0033] Among them, the iron content of molten iron is the test value of each ladle of molten iron, the content of various scrap steel is the test value of scrap steel content periodically, and the iron loss is corrected according to the actual operation of slag quantity, slag iron content and dust removal system slag quantity and iron content.

[0034] Because there are many types of scrap steel, such as reinforcing bars and heavy scrap steel, industrial briquettes (e.g., stamping scrap and offcuts), slag steel (e.g., small scrap iron and steel generated from daily life), and shavings (e.g., waste generated during lathe and milling machine operations), and because the iron content varies among different types of scrap steel, the steel content will also differ. For example, when the scrap steel is reinforcing bars... The value is 0.94-0.96; when the scrap steel is heavy scrap steel, The value ranges from 0.90 to 0.94; when the scrap steel is industrial briquettes, The value ranges from 0.87 to 0.92; when the scrap steel is slag steel, The value is 0.65-0.71; when the scrap steel is shavings, The value should be between 0.80 and 0.84. The specific value can be determined based on the quality of the scrap steel, or an intermediate value can be used.

[0035] In addition, the actual amount of molten steel is calculated using the following formula.

[0036] .

[0037] In the above formula, This represents the actual amount of molten steel. The total weight of the actual object lifted by the crane; This is the net weight of the vessel used to hold molten steel.

[0038] The theoretical billet quantity is calculated using the following formula:

[0039]

[0040] In the above formula, This is the theoretical weight of the steel billet; This refers to the total length of the casting. This refers to the weight of each meter of steel billet.

[0041] The theoretical billet quantity is calculated using the following formula:

[0042] .

[0043] In the above formula, This refers to the actual weight of the steel billet; This refers to the amount of molten steel remaining in the tank. This represents the amount of molten steel lost during the casting process.

[0044] After obtaining the theoretical molten steel value, actual molten steel quantity, and billet quantity, the analysis and judgment unit can analyze whether the smelting process is abnormal based on these values ​​and provide corresponding abnormality prompts so that the staff can adjust the subsequent smelting process according to these prompts.

[0045] Specifically, the following relationships exist between the theoretical molten steel value, actual molten steel quantity, theoretical billet quantity, and actual billet quantity during the production process:

[0046] (1) If the theoretical molten steel value is greater than the actual molten steel quantity, it indicates that there are fluctuations in the control of the smelting process or the quality of scrap steel, and targeted adjustments are needed. For example, staff should be advised to control the quality of scrap steel and manage the process flow to reduce iron loss.

[0047] (2) The theoretical molten steel value ≤ the actual molten steel quantity indicates that the smelting process is under stable control and the scrap steel quality is relatively stable. Production can continue to be carried out according to the current process and raw materials.

[0048] (3) The theoretical billet quantity is greater than the actual billet quantity, indicating that there is an abnormality in the continuous casting surplus and the continuous casting process control. It is suggested that the staff should pay close attention to the casting process to avoid phenomena such as under-casting or missing casting.

[0049] (4) The theoretical billet quantity ≤ the actual billet quantity indicates that the continuous casting surplus and the continuous casting process are under stable control and can be maintained.

[0050] The following is the data obtained from the above model and the abnormal prompts obtained from the analysis when a converter smelts the same steel grade HRB400E-2 in three heats.

[0051] In the first heat, the molten iron charge was 109.8t, with an iron content of 0.9469%. Other charges included 0t of slag steel blocks, 1.24t of high-phosphorus pig iron, 3.23t of heavy scrap, 7t of reinforcing steel, 3.28t of industrial briquettes, 3214.8kg of return ore, 0t of post-heat steel addition, and 2837.6kg of alloy additives. The theoretical molten steel output calculated from the model was 122.43t, and the theoretical billet output was 119.88t. The actual molten steel output and billet output were both 120.6t and 1048.14kg / t (theoretical steel consumption), respectively, while the actual steel consumption was 1061.67kg / t. These data indicate anomalies in the converter smelting process and scrap steel quality. The actual issue was slag overflow and splashing during smelting, resulting in a lower actual steel output than the theoretical output. Therefore, timely improvements to the smelting operation are necessary to reduce slag overflow and splashing, while also controlling the quality of the scrap steel.

[0052] In the second heat, the molten iron charge was 108.4t, with an iron content of 0.9485%. Other charges included 1.22t of slag steel blocks, 0.89t of high-phosphorus pig iron, 2.17t of heavy scrap steel, 7.3t of rebar briquettes, 3.55t of industrial briquettes, and 2752.66kg of return ore. There was no additional steel added after the furnace, and the alloy addition was 2752.66kg. Based on the model, the theoretical molten steel volume was 120.47t, while the actual molten steel volume was 120.55t. The theoretical billet volume was 119.83t, while the actual billet volume was 120.15t. The theoretical steel consumption was 1052.57kg / t, while the actual consumption was 1049.11kg / t. The data indicates that the converter smelting process and scrap steel quality were normal, and the continuous casting control was normal; smelting could continue.

[0053] In the third heat, the molten iron charge was 111.8t, with an iron content of 0.9469%. Other charges included 1.37t of slag steel blocks, 0.97t of high-phosphorus pig iron, 2.33t of heavy scrap steel, 6.89t of rebar briquettes, 2.95t of industrial briquettes, 3016kg of return ore, 0.55t of steel added after the furnace, and 2719.46kg of alloying agents. The theoretical molten steel volume calculated from the model was 123.55t, while the actual molten steel volume was 123.62t. The theoretical billet volume was 122.88t, while the actual billet volume was 122.38t. The theoretical steel consumption was 1049.47kg / t, while the actual consumption was 1053.19kg / t. The data indicates that the converter smelting process and scrap steel quality were normal, and the slag volume and iron loss were lower than the theoretical values. However, the actual billet volume was less than the theoretical billet volume, indicating a problem in the continuous casting operation, which staff can immediately address.

[0054] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention, and these will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.

Claims

1. A steel material consumption management system applied to actual production, characterized by, include, The information acquisition unit collects data on the iron element content in the raw materials before they enter the converter, as well as the iron loss of the raw materials during the converter smelting process. The billet modeling unit constructs a theoretical molten steel analysis model based on the iron element data and iron loss to obtain the theoretical molten steel value; it also obtains the actual molten steel quantity after the raw material is smelted and the billet quantity obtained after casting. The analysis and judgment unit analyzes whether the smelting process is abnormal based on the theoretical molten steel value, the actual molten steel quantity, and the billet quantity. The theoretical steel analysis model is specifically as follows: ； in, This is the theoretical value of molten steel; This refers to the total amount of molten iron originally present in the converter; The iron content ratio of the original molten iron in the converter is taken as 0.94-0.95; This refers to the total amount of scrap steel fed into the converter; This refers to the iron content ratio in scrap steel. This refers to the total amount of return ore fed into the converter; The iron content ratio in the return ore is 0.56-0.

58. This is the ratio of the iron content in the steel slag to the total amount of molten iron in the converter, and is set to 0.

01. The percentage of iron elements damaged by the dust removal system of the converter is 0.

005. This refers to the total amount of alloy fed into the converter; For alloy yield; Steel material added after the molten iron is discharged from the converter; This refers to the steel yield.

2. The steel material consumption management system according to claim 1, wherein The scrap steel includes reinforcing bars and heavy scrap steel, industrial briquettes, slag steel, and shavings.

3. The steel material consumption management system according to claim 2, wherein When the scrap steel is reinforcing steel. The value is between 0.94 and 0.96; when the scrap steel is heavy scrap steel, The value is 0.90-0.94; when the scrap steel is industrial briquettes, The value is between 0.87 and 0.92; when the scrap steel is slag steel, The value is 0.65-0.71; when the scrap steel is shavings, The value ranges from 0.80 to 0.

84.

4. The steel material consumption management system according to claim 1, wherein The actual amount of molten steel is calculated using the following formula. ； In the formula, This represents the actual amount of molten steel. The total weight of the actual object lifted by the crane; This is the net weight of the vessel used to hold molten steel.

5. The steel material consumption management system according to claim 4, wherein The billet quantity includes the theoretical billet quantity and the actual billet quantity.

6. The steel material consumption management system according to claim 5, wherein The theoretical billet quantity is calculated using the following formula. ； wherein is the theoretical billet weight; is the total casting length; is the weight of the billet per meter.

7. The steel material consumption management system according to claim 5, wherein The theoretical billet quantity is calculated using the following formula. ； In the formula, This refers to the actual weight of the steel billet; This refers to the amount of molten steel remaining in the tank. This represents the amount of molten steel lost during the casting process.

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