Industrial furnace energy consumption allocation calculation method and system

Abstract

The application discloses an energy consumption apportioning calculation method of an industrial furnace, and comprises the following steps: S1, collecting data of a single industrial furnace in real time; S2, calculating the heat load coefficient of each section of each single industrial furnace and the fuel supply amount in unit time; S3, calculating the fuel consumption distribution coefficient of each section of each single industrial furnace in unit time; S4, calculating the fuel consumption of all the pipe blanks in each single industrial furnace in unit time according to the distribution coefficient; and S5, calculating the total fuel consumption in the whole heating process. The energy consumption apportioning calculation method provided by the application calculates the energy consumption that should be apportioned by each kind of pipe blank for each section, thereby reasonably and accurately determining the energy consumption apportioning proportion of fuel in each single industrial furnace, and finally obtaining the total fuel consumption in each single industrial furnace, thereby providing data support for energy saving.

Description

Technical Field

[0001] This invention relates to the field of energy consumption calculation technology, and in particular to a method and system for calculating the energy consumption allocation of an industrial furnace. Background Technology

[0002] Industrial furnaces primarily utilize 17 energy media, including electricity, mixed coal gas, coke oven gas, natural gas, and oxygen. Electricity and mixed coal gas are the top two energy consumers, accounting for over 85% of total energy consumption. With electricity and other energy media prices expected to continue rising, energy conservation and emission reduction are becoming increasingly important for businesses.

[0003] Therefore, it is necessary to provide a method and system for calculating the energy consumption of industrial furnaces, so as to calculate the energy consumption of industrial furnaces and provide data support for energy conservation. Summary of the Invention

[0004] The purpose of this invention is to provide a method and system for calculating the energy consumption of industrial furnaces, so as to calculate the energy consumption of industrial furnaces and thus provide data support for energy saving.

[0005] To address the problems existing in the prior art, the present invention provides a method for calculating the energy consumption allocation of an industrial furnace. Each industrial furnace is equipped with multiple fuel transfer devices and multiple burners installed on each fuel transfer device. The fuel transfer devices are interconnected. A tube blank is placed in the industrial furnace and continuously moved and processed. The industrial furnace is divided into multiple sections according to the number of fuel transfer devices.

[0006] Includes the following steps:

[0007] S1. Real-time acquisition of data from a single industrial furnace, including: furnace temperature, preset unit time in seconds, instantaneous fuel consumption of fuel transfer equipment, tube blank length, tube blank diameter, tube blank outer diameter, difference between tube blank outer diameter and tube blank diameter, heat transfer coefficient of inner tube blank, heat transfer coefficient of outer tube blank, thermal conductivity of tube blank wall, number of tube blanks, and temperature of each tube blank.

[0008] S2. Calculate the heat load coefficient and fuel supply amount for each section of each individual industrial furnace per unit time. The calculation method is as follows:

[0009]

[0010] Where R_si is the convective heat transfer resistance inside the tube blank, R_pipe is the heat transfer resistance of the tube blank wall, R_so is the convective heat transfer resistance outside the tube blank, U is the heat load coefficient of the tube blank, MC is the heat load coefficient of each section of each individual industrial furnace per unit time, a_si is the heat transfer coefficient inside the tube blank, d_pipe is the outer diameter of the tube blank, d_core is the diameter of the tube blank, r is the thermal conductivity of the tube blank wall, a_so is the heat transfer coefficient outside the tube blank, d_out is the difference between the outer diameter and the diameter of the tube blank, M is the instantaneous fuel consumption of the fuel transfer equipment, and S is the preset unit time in seconds.

[0011] S3. Calculate the fuel consumption distribution coefficient of the tube blank in each section of each individual industrial furnace per unit time.

[0012] S4. Calculate the fuel consumption per unit time for all tube blanks in each individual industrial furnace based on the allocation coefficient.

[0013] S5. Calculate the total fuel consumption for the entire heating process.

[0014] Optionally, in the industrial furnace energy consumption allocation calculation method, in step S3, the fuel consumption allocation coefficient is calculated as follows:

[0015]

[0016] Qa = Td * Sa;

[0017] Qacj=j∑(Qai), j=1, 2,...,h;

[0018]

[0019] Where Td is the fourth-order temperature difference, Sa is the surface area of ​​the tube blank, Qa is the product of the fourth-order temperature difference and the surface area of ​​the tube blank, j is the section number of any section in the industrial furnace, h is the total number of sections in the industrial furnace, Qacj is the sum of the products of the fourth-order temperature difference and the surface area of ​​the tube blank in section j, kj is the fuel consumption distribution coefficient of the tube blank in section j, T is the furnace temperature of the industrial furnace, i is the i-th tube blank, ti ​​is the temperature of the i-th tube blank, n is the number of tube blanks, and L is the length of the tube blank.

[0020] Optionally, in the industrial furnace energy consumption allocation calculation method, in S4, the calculation method for the fuel consumption per unit time of all tube blanks in each individual industrial furnace is as follows:

[0021] Gcj = kj * MC; where Gcj is the fuel consumption per unit time for all tube blanks in section j.

[0022] Optionally, in the industrial furnace energy consumption allocation calculation method, the industrial furnace is provided with multiple fixed slots, and the tube blank moves according to the fixed slots.

[0023] Optionally, in the industrial furnace energy consumption allocation calculation method, in S5, the total fuel consumption of the entire heating process is calculated as follows:

[0024] sum=∑(Gcjp), p=1, 2,...,q;

[0025] Where sum is the total fuel consumption of the entire heating process, p is the fixed slot number in the current industrial furnace, and q is the total number of fixed slots in the current industrial furnace.

[0026] Optionally, in the industrial furnace energy consumption allocation calculation method, in S1, the process computer issues basic information data of the billet and records the static data of the billet to obtain the data.

[0027] Optionally, in the industrial furnace energy consumption allocation calculation method, one industrial furnace is equipped with 6 fuel transfer devices, and each fuel transfer device is equipped with 60 burners.

[0028] The present invention also provides an industrial furnace energy consumption allocation calculation system for performing the above-described industrial furnace energy consumption allocation calculation method.

[0029] Optionally, in the industrial furnace energy consumption allocation calculation system, the collected data and the calculated data are displayed in a graphical and / or digital manner.

[0030] Compared with the prior art, the present invention has the following advantages:

[0031] (1) Collect data from a single industrial furnace in real time and use it to calculate the fuel consumption of the industrial furnace, determine the fuel consumption influencing factors and take measures to improve it, thereby saving energy consumption;

[0032] (2) By establishing a calculation model, the present invention can calculate the energy consumption of various types of industrial furnaces, thus improving its applicability. Attached Figure Description

[0033] Figure 1 A flowchart illustrating the industrial furnace energy consumption allocation calculation method provided in this embodiment of the invention;

[0034] Figure 2 This is a schematic diagram of the actual width adjustment results provided in an embodiment of the present invention;

[0035] Figure 3 The calculation results are shown in the figure below, which is a calculation model for the instantaneous fuel consumption of each section of an industrial furnace provided in the embodiments of the present invention. Detailed Implementation

[0036] The specific embodiments of the present invention will now be described in more detail with reference to the accompanying drawings. The advantages and features of the present invention will become clearer from the following description. It should be noted that the drawings are all in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the present invention.

[0037] In the following, if the methods described herein include a series of steps, the order of these steps presented herein is not necessarily the only order in which these steps can be performed, and some of the steps described may be omitted and / or some other steps not described herein may be added to the method.

[0038] To address the problems existing in the prior art, this invention provides a method for calculating the energy consumption allocation of an industrial furnace. Each industrial furnace is equipped with multiple fuel transfer devices and multiple burners installed on each fuel transfer device. The fuel transfer devices are interconnected. A tube blank is placed in the industrial furnace and continuously moved and processed until it reaches the furnace's discharge end. Furthermore, within the industrial furnace, the tube blank is powered by corresponding fuel transfer devices and burners at different locations. In one embodiment, an industrial furnace is equipped with six fuel transfer devices, and each fuel transfer device has 60 burners.

[0039] This invention divides the industrial furnace into multiple sections based on the number of fuel transfer devices; for example... Figure 1 As shown, the method includes the following steps:

[0040] S1. Real-time acquisition of data from a single industrial furnace, including: furnace temperature, preset unit time in seconds (e.g., 30 seconds), instantaneous fuel consumption of fuel transfer equipment, billet length, billet diameter, billet outer diameter, difference between billet outer diameter and billet diameter, inner heat transfer coefficient of billet, outer heat transfer coefficient of billet, thermal conductivity of billet wall, number of billets, and temperature of each billet; This invention uses a process computer to distribute basic billet information data and record static billet data to obtain the aforementioned data.

[0041] S2. Calculate the heat load coefficient and fuel supply amount for each section of each individual industrial furnace per unit time. The calculation method is as follows:

[0042]

[0043]

[0044] Where R_si is the convective heat transfer resistance inside the tube blank, R_pipe is the heat transfer resistance of the tube blank wall, R_so is the convective heat transfer resistance outside the tube blank, U is the heat load coefficient of the tube blank, MC is the heat load coefficient of each section of each individual industrial furnace per unit time, a_si is the heat transfer coefficient inside the tube blank, d_pipe is the outer diameter of the tube blank, d_core is the diameter of the tube blank, r is the thermal conductivity of the tube blank wall, a_so is the heat transfer coefficient outside the tube blank, d_out is the difference between the outer diameter and the diameter of the tube blank, M is the instantaneous fuel consumption of the fuel transfer equipment, and S is the preset unit time in seconds.

[0045] S3. Calculate the fuel consumption distribution coefficient of the tube blank in each section of each individual industrial furnace per unit time.

[0046] S4. Calculate the fuel consumption per unit time for all tube blanks in each individual industrial furnace based on the allocation coefficient.

[0047] S5. Calculate the total fuel consumption for the entire heating process.

[0048] Furthermore, in S3, the fuel consumption allocation coefficient is calculated as follows:

[0049]

[0050] Qa = Td * Sa;

[0051] Qacj=jΣ(Qai), j=1, 2,...,h;

[0052]

[0053] Where Td is the fourth-order temperature difference, Sa is the surface area of ​​the tube blank, Qa is the product of the fourth-order temperature difference and the surface area of ​​the tube blank, j is the section number of any section in the industrial furnace, h is the total number of sections in the industrial furnace, Qacj is the sum of the products of the fourth-order temperature difference and the surface area of ​​the tube blank in section j, kj is the fuel consumption distribution coefficient of the tube blank in section j, T is the furnace temperature of the industrial furnace, i is the i-th tube blank, ti ​​is the temperature of the i-th tube blank, n is the number of tube blanks, and L is the length of the tube blank.

[0054] In S4, the fuel consumption per unit time for all tube blanks in each individual industrial furnace is calculated as follows:

[0055] Gcj = kj * MC; where Gcj is the fuel consumption per unit time for all tube blanks in section j.

[0056] Typically, the industrial furnace is equipped with multiple fixed slots, and the tube blank moves according to the fixed slots.

[0057] In S5, the total fuel consumption for the entire heating process is calculated as follows:

[0058] sum=Σ(Gcjp), p=1, 2,...,q;

[0059] Where sum represents the total fuel consumption for the entire heating process, p represents the fixed slot number in the current industrial furnace, and q represents the total number of fixed slots in the current industrial furnace. All tube blanks need to be moved to each fixed slot sequentially; therefore, by calculating the fuel consumption of each slot, the total fuel consumption for the entire heating process can be obtained.

[0060] Typically, within a given period, the same batch of tube blanks exists within a single industrial furnace, resulting in identical parameters for all tube blanks. The calculation process involves separately calculating the heat load coefficient and fuel supply amount for each section of the individual industrial furnace, as well as the fuel consumption distribution coefficient for the tube blanks within each section. This allows for the calculation of the fuel consumption per unit time for all tube blanks within each individual industrial furnace in different sections. Finally, the total fuel consumption for the entire heating process is calculated by integrating all tube blanks across all sections.

[0061] like Figure 2 As shown, Figure 2 This is a schematic diagram of the actual width adjustment results provided in an embodiment of the present invention. Figure 2 It includes multiple parameters of the tube blank and the fuel consumption per unit. It can be seen that the present invention incorporates parameters such as tube blank size into the calculation formula, so that the calculation model of the present invention can be used in various types of industrial furnaces, thus improving its applicability.

[0062] like Figure 3 As shown, Figure 3 The diagram shows the calculation results of the instantaneous fuel consumption calculation model for each section of the industrial furnace provided in this embodiment of the invention. In order to verify the accuracy of the calculation results and alarm conclusions of the calculation model of this invention, actual production data was sampled on the bar steel production line of a steel plant in China. After the data was imported into the model, the output results were basically consistent with the actual production situation.

[0063] This invention also provides an industrial furnace energy consumption allocation calculation system for performing the above-described industrial furnace energy consumption allocation calculation method. Preferably, the collected data and the calculated data are displayed graphically and / or digitally.

[0064] In summary, compared with the prior art, the present invention has the following advantages:

[0065] (1) Collect data from a single industrial furnace in real time and use it to calculate the fuel consumption of the industrial furnace, determine the fuel consumption influencing factors and take measures to improve it, thereby saving energy consumption;

[0066] (2) By establishing a calculation model, the present invention can calculate the energy consumption of various types of industrial furnaces, thus improving its applicability.

[0067] The above are merely preferred embodiments of the present invention and do not constitute any limitation on the present invention. Any equivalent substitutions or modifications made by those skilled in the art to the technical solutions and content disclosed in the present invention without departing from the scope of the present invention shall be deemed to have remained within the protection scope of the present invention.

Claims

1. A method for calculating the energy consumption allocation of an industrial furnace, wherein each industrial furnace is equipped with multiple fuel transfer devices and multiple burners installed on each fuel transfer device, the fuel transfer devices are interconnected, and a tube blank is placed in the industrial furnace and continuously moved and processed; characterized in that, The industrial furnace is divided into multiple sections based on the number of fuel transfer devices; Includes the following steps: S1. Real-time acquisition of data from a single industrial furnace, including: furnace temperature, preset unit time in seconds, instantaneous fuel consumption of fuel transfer equipment, tube blank length, tube blank diameter, tube blank outer diameter, difference between tube blank outer diameter and tube blank diameter, heat transfer coefficient of inner tube blank, heat transfer coefficient of outer tube blank, thermal conductivity of tube blank wall, number of tube blanks, and temperature of each tube blank. S2. Calculate the heat load coefficient and fuel supply amount for each section of each individual industrial furnace per unit time. The calculation method is as follows: Where R_si is the convective heat transfer resistance inside the tube blank, R_pipe is the heat transfer resistance of the tube blank wall, R_so is the convective heat transfer resistance outside the tube blank, U is the heat load coefficient of the tube blank, MC is the heat load coefficient of each section of each individual industrial furnace per unit time, a_si is the heat transfer coefficient inside the tube blank, d_pipe is the outer diameter of the tube blank, d_core is the diameter of the tube blank, r is the thermal conductivity of the tube blank wall, a_so is the heat transfer coefficient outside the tube blank, d_out is the difference between the outer diameter and the diameter of the tube blank, M is the instantaneous fuel consumption of the fuel transfer equipment, and S is the preset unit time in seconds. S3. Calculate the fuel consumption distribution coefficient of the tube blank in each section of each individual industrial furnace per unit time. S4. Calculate the fuel consumption per unit time for all tube blanks in each individual industrial furnace based on the allocation coefficient. S5. Calculate the total fuel consumption for the entire heating process.

2. The method for calculating energy consumption allocation in industrial furnaces as described in claim 1, characterized in that, In S3, the fuel consumption allocation coefficient is calculated as follows: Qa = Td * Sa; Qacj=j∑(Qai), j=1, 2,...,h; Where Td is the fourth-order temperature difference, Sa is the surface area of ​​the tube blank, Qa is the product of the fourth-order temperature difference and the surface area of ​​the tube blank, j is the section number of any section in the industrial furnace, h is the total number of sections in the industrial furnace, Qacj is the sum of the products of the fourth-order temperature difference and the surface area of ​​the tube blank in section j, kj is the fuel consumption distribution coefficient of the tube blank in section j, T is the furnace temperature of the industrial furnace, i is the i-th tube blank, ti ​​is the temperature of the i-th tube blank, n is the number of tube blanks, and L is the length of the tube blank.

3. The method for calculating energy consumption allocation in industrial furnaces as described in claim 2, characterized in that, In S4, the fuel consumption per unit time for all tube blanks in each individual industrial furnace is calculated as follows: Gcj = kj * MC; where Gcj is the fuel consumption per unit time for all tube blanks in section j.

4. The method for calculating energy consumption allocation in industrial furnaces as described in claim 3, characterized in that, The industrial furnace is equipped with multiple fixed slots, and the tube blank moves according to the fixed slots.

5. The method for calculating the energy consumption allocation of an industrial furnace as described in claim 4, characterized in that, In S5, the total fuel consumption for the entire heating process is calculated as follows: sum=∑(Gcjp), p=1, 2,...,q; Where sum is the total fuel consumption of the entire heating process, p is the fixed slot number in the current industrial furnace, and q is the total number of fixed slots in the current industrial furnace.

6. The method for calculating energy consumption allocation in industrial furnaces as described in claim 1, characterized in that, In S1, the process computer issues basic information data of the tube blank and records the static data of the tube blank to obtain the data.

7. The method for calculating energy consumption allocation in industrial furnaces as described in claim 1, characterized in that, An industrial furnace is equipped with 6 fuel transfer devices, and each fuel transfer device has 60 burners.

8. An industrial furnace energy consumption allocation calculation system, characterized in that, Used to perform the industrial furnace energy consumption allocation calculation method according to any one of claims 1 to 7.

9. The industrial furnace energy consumption allocation calculation system as described in claim 8, characterized in that, The collected data and the calculated data are displayed in a graphical and / or digital manner.

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