A device for measuring the thickness of copper wall in the later stage of blast furnace service and its usage method

Abstract

This invention proposes a device and method for measuring the thickness of copper wall in the later stage of blast furnace service. The device includes a synchronous wear mechanism, a coupling agent self-adjusting mechanism, and a measuring probe mechanism. The synchronous wear mechanism is horizontally installed on the blast furnace cooling wall, with its tail end flush with the inner surface of the copper wall and its head end connected to one end of the coupling agent self-adjusting mechanism. The coupling agent self-adjusting mechanism contains a measuring probe mechanism, which is connected to an external computer via a data cable to record measurement data. This invention can measure and track the wear rate of the copper wall under different smelting conditions online and predict its remaining lifespan. This allows for guidance in blast furnace adjustment operations, improvement of smelting conditions at worn areas, and extension of its service life.

Description

Technical Field

[0001] This application relates to the technical field of blast furnace smelting, and more specifically, to a device for measuring the thickness of copper wall in the later stage of blast furnace service and its usage method. Background Technology

[0002] After 7 to 10 years of use, the dovetail groove structure on the hot surface, which is responsible for slag adhesion, wears down to a smooth plate. The slag adhesion capacity of the wall surface decreases significantly, and the slag skin is prone to repeated peeling off, leading to accelerated wear of the copper wall. Eventually, the cooling pipes wear through and leak, forcing a shutdown to repair the damaged wall. This significantly deteriorates the blast furnace's smelting conditions and economic indicators. In severe cases, large areas of the blast furnace copper wall melt and the furnace shell glows red, posing safety hazards.

[0003] Therefore, it is necessary to install a thickness detection device that can detect wear synchronously on the copper wall in the middle and late stages of furnace operation. This device is used to track the wear of the wall and analyze its wear rate, monitor the copper wall that is about to break, and propose methods and countermeasures to control its wear and extend its service life.

[0004] The invention, entitled "A Method for Measuring the Temperature of Cooling Walls in a Blast Furnace and a Blast Furnace" (CN110578026A), includes the following steps: pre-cutting slots along the length of all cooling walls located in the same layer of the blast furnace, so that all slots together form a ring groove; embedding an optical fiber in the ring groove; opening an outlet in the outer shell of the blast furnace; and electrically connecting the two ends of the optical fiber to a signal processor after passing through the outlet. The blast furnace includes an outer shell, cooling walls, and a refractory layer. Slots are cut along the length of all cooling walls located in the same layer of the blast furnace, and all slots together form a ring groove. An optical fiber is embedded in the ring groove, and an outlet is opened in the outer shell. The two ends of the optical fiber pass through the outlet and are electrically connected to a signal processor. This invention, based on the principle of optical fiber temperature measurement, can comprehensively and accurately detect the temperature of the cooling walls of a blast furnace, reducing the risk of the cooling walls being burned. However, it cannot measure the thickness of the cooling walls, nor can it dynamically predict their operating conditions and remaining lifespan.

[0005] The patent "Blast Furnace Cooler Damage Detection Device" (CN2608513Y) discloses a damage detection device comprising a pressure reducing device, a pressure display device, a high-efficiency gas trap, an online gas detection signal generator, a central alarm display, a signal power cable, and a handheld gas detection signal generator. When the cooler is damaged, the signal generator sends an alarm signal to the operator. The pressure reducing device and pressure display device, in conjunction with the handheld gas detection signal generator, can detect the water head of each cooler with minimal investment, determining the exact location and extent of damage (hot surface, cold surface, and perforated types), providing a basis for the operator to take appropriate measures. This device is primarily used to monitor cooler damage and does not involve a method for analyzing blast furnace cooling wall structures using non-destructive thickness measurement.

[0006] A simulated erosion device for determining the erosion state of a blast furnace cooler (CN201228266Y) comprises a constant-temperature water tank, an inlet pipe, a heating device, an erosion test tube, a steam pipe, and a condenser. Water enters the erosion test tube through the inlet pipe, is heated in the heating device to form water and steam, which then erodes the test tube. The steam then enters the condenser through the steam pipe. A relative erosion comparison plate at the upper end of the condenser simultaneously compares the erosion. The steam condenses back into water through the condenser and flows back into the constant-temperature water tank for reuse, forming a circulating system. This allows for experimental research on the influence of cooling water pipe wall temperature on the erosion performance of cooling water, providing a more accurate description of the erosion patterns of cooling water. This device does not involve improvements to the cooling wall of a new blast furnace. It integrates the thickness measuring element with the wall structure as a single unit, along with a corresponding arrangement method, forming an analytical technique for assessing the slag-coating capacity of the wall during the early and mid-term operation of the furnace. This technique or method can then be used to improve blast furnace operation and extend its service life.

[0007] CN106319118B, entitled "A Method for Extending the Service Life of Blast Furnace Copper Cooling Walls," is used to effectively protect blast furnace copper cooling walls. The method includes: a blast furnace copper cooling wall hot surface temperature calculation system to obtain the hot surface temperature of the blast furnace copper cooling wall; a blast furnace copper cooling wall hot surface slag thickness judgment system to determine whether a certain thickness of slag skin needs to be rapidly established to protect the copper cooling wall; a blast furnace copper cooling wall cooling system to forcibly cool the blast furnace copper cooling wall that needs protection, enabling the rapid establishment of an effective slag skin on the hot surface of the copper cooling wall; and a ventilation and purification device and control system responsible for completing the ventilation and heat dissipation of the entire system and the liquefaction and circulation process of the cooling medium. Compared with existing technologies, this invention alleviates the contradiction of rapid damage and difficulty in replacement of blast furnace copper cooling walls, thereby improving the service life of a generation of blast furnaces. This invention can reduce the temperature fluctuations in the blast furnace hearth caused by abnormal slag skin shedding from the blast furnace copper cooling wall, ensuring the long-term stable operation of the blast furnace. It does not involve a blast furnace cooling wall structure or analysis method suitable for non-destructive thickness measurement.

[0008] In summary, there is currently no online measurement device or method for measuring the copper wall thickness in the later stages of blast furnace operation, which is used to monitor the copper wall thickness of blast furnaces with high precision and predict the remaining working life of the copper wall under different temperature conditions by continuously analyzing the latest thickness measurement and historical temperature data, so as to guide the blast furnace to adjust the wall operating conditions and extend its service life. Summary of the Invention

[0009] The technical problem to be solved by the present invention is to provide a copper wall thickness measuring device and a method for using it in the later stage of blast furnace service, so as to realize online continuous high-precision thickness measurement of the wall, and continuously evaluate the damage trend and remaining life of the copper wall by continuously updating the thickness measurement data and the temperature data of the corresponding parts, so as to guide the adjustment operation of the blast furnace and control the damage of the wall.

[0010] The embodiments of this application are implemented as follows:

[0011] This application provides a device for measuring the thickness of copper wall in the later stage of blast furnace service. The device comprises a synchronous wear mechanism, a coupling agent self-adjustment mechanism, and a measuring probe mechanism. The synchronous wear mechanism is horizontally mounted on the blast furnace cooling wall, with its tail end flush with the inner surface of the copper wall and its head end connected to one end of the coupling agent self-adjustment mechanism. The measuring probe mechanism is housed within the coupling agent self-adjustment mechanism and is connected to an external computer via a data cable to record measurement data.

[0012] In some alternative embodiments, the synchronous wear mechanism includes a synchronous wear column made of the same material as the copper wall, the synchronous wear column being provided with a sealing ring, the tail end of the synchronous wear column being inserted into the blast furnace cooling wall, the sealing ring being in contact with the blast furnace shell, and the head end of the synchronous wear column being exposed outside the blast furnace and connected to the coupling agent self-adjustment mechanism.

[0013] In some optional embodiments, the couplant self-adjusting mechanism includes a couplant adjusting cylinder and a bellows expander. The couplant adjusting cylinder is filled with couplant, has a connecting flange at the center of its front end face, and a conduit extending rearward at the center of its rear end face. The tail end of the synchronous wear column is connected to the connecting flange, and the tail end face of the synchronous wear column is flush with the inner wall of the front end face of the couplant adjusting cylinder. The measuring probe mechanism extends into the couplant adjusting cylinder, and the data cable passes through the conduit. The bellows expander is installed at the top of the couplant adjusting cylinder and is connected to it through a through hole.

[0014] In some alternative implementations, the measuring probe mechanism includes an ultrasonic probe and a probe displacement drive. The ultrasonic probe is placed inside the coupling agent adjustment cylinder and connected to an external computer via a data cable. The probe displacement drive is located outside the coupling agent adjustment cylinder, closely fitted to the conduit, and drives the ultrasonic probe to move back and forth.

[0015] In some alternative implementations, the tail end of the synchronous wear column is provided with a snap-fit ​​protrusion, and the snap-fit ​​protrusion is provided with connecting lugs on both sides. The snap-fit ​​protrusion is snapped into the connecting flange, and the connecting lugs are connected and fastened to the connecting flange by bolts.

[0016] In some alternative implementations, the probe displacement drive includes a drive motor, a rotating screw, and an adjusting nut. One end of the rotating screw is connected to the ultrasonic probe, and the other end passes through the conduit and is connected to the drive motor. The adjusting nut is fixed to the end of the conduit and is configured to work with the rotating screw.

[0017] A method for using a copper wall thickness measuring device in the later stage of blast furnace service, characterized by comprising the following steps:

[0018] Step a: Drill mounting holes in the cooling wall between the two water channels, close to the thermocouple of the cooling wall. Measure the length of the wall material at the drilling location. Cut the synchronous wear column so that the length of the insertion part is the same as the depth of the mounting hole. Install the synchronous wear structure into the mounting hole and seal it by pouring in refractory liquid slurry. Connect the front end of the coupling agent adjustment cylinder to the tail end of the synchronous wear column with bolts. Then connect the probe displacement drive to the ultrasonic probe.

[0019] Step b: During use, the probe displacement drive is activated to propel the ultrasonic probe forward. Simultaneously, the couplant inside the cylinder is squeezed into the bellows expander through the through-hole, causing it to expand. When the ultrasonic probe moves and fits against the tail of the synchronous wear column, it stops moving forward, and the couplant achieves automatic lubrication. High-definition ultrasonic thickness signal measurement is performed on the synchronous wear column. After the measurement is completed, the ultrasonic probe retracts to its original position, and the couplant inside the bellows expander flows back into the couplant adjustment cylinder.

[0020] Step c: Based on the measured copper wall thickness data and cooling wall temperature data, calculate the wear rate law of the blast furnace copper wall under different temperature conditions.

[0021] Step d involves dynamically estimating the remaining lifespan range and overall remaining lifespan of the copper wall based on the copper wall thickness data. This information is then used to guide adjustments to the furnace charge structure near the copper wall, thereby reducing wear.

[0022] In some optional implementations, the calculation of the wear rate of the copper wall in step c includes the following:

[0023] Based on the actual temperature range of the blast furnace copper wall, the temperature range is divided into n intervals, and the temperature of each interval is denoted as T. n The m-th time entering the temperature range T will be measured. n The thickness measured at that time is denoted as L. n -E m The thickness L measured when the wall temperature jumps out of this temperature range n -O m The duration is denoted as t. n-m ;

[0024] Statistical analysis of the total operating time of the copper wall body within a certain temperature range T1 and total wear thickness Calculate the wear rate υ of the copper wall in various temperature ranges. n ,but,

[0025]

[0026] The overall wear rate of the copper wall over the total statistical period for:

[0027]

[0028] In some optional implementations, the calculation of the remaining lifetime range in step d includes the following:

[0029] Statistics show that within a certain temperature range T of the copper wall of a blast furnace over a period of time (h). n Wear rate υ n And estimate the temperature T that the copper cooling wall remains at. n The remaining working capacity when working within a range is as follows:

[0030] Among them, △L n Let be the remaining thickness from the worn surface of the copper wall to the cooling wall channel. From this, the maximum remaining lifespan of the copper wall can be calculated as follows:

[0031] MaxD = {D1, D2, ..., D} n},

[0032] The remaining minimum lifetime of the copper wall is: MinD = {D1, D2, ..., D} n},

[0033] The remaining working life of the cooling wall is: MinD~MaxD.

[0034] In some alternative implementations, the calculation of the overall remaining lifetime of the copper wall includes the following:

[0035] Calculate the overall wear rate of a certain part of the copper wall of a blast furnace over a period of time (h). The overall wear rate of the copper wall over the preceding h-hour period was then calculated weekly and recorded as follows: Then, using the obtained wear rate data, a method is used to regress and predict the relationship between the overall wear rate and time of the wall:

[0036]

[0037] The overall remaining life x of the copper wall satisfies the equation:

[0038]

[0039] The obtained x is the total remaining life of the wall.

[0040] The beneficial effects of this application are as follows: This application provides a copper wall thickness measuring device and method for measuring the thickness of a blast furnace wall in the later stages of its service life. By adding a synchronous wear structure to the worn copper wall of the blast furnace in the later stages of its service life, and with a matching automatic control device, it realizes online continuous thickness measurement of the wall using ultrasound. Combined with the thickness measurement data and blast furnace wall temperature data, it dynamically analyzes the damage rate and remaining life of the blast furnace wall in different temperature ranges. The wear structure is made of high-purity copper of the same material as the wall, enabling precise measurement of synchronously worn parts of the wall using ultrasound. Simultaneously, the invented self-filling coupling agent cylinder and probe displacement device enable the device to have an automatic continuous thickness measurement function. The method of synchronously acquiring thickness measurement device and wall thermocouple data, and comparing and analyzing thickness and temperature data, establishes a method for evaluating the wear rate and remaining life of the wall in different temperature ranges. It establishes a range of remaining life of the copper wall in the later stages of its service life and a comprehensive dynamic analysis method for remaining life, dynamically predicting the wall wear rate and ultimate life, guiding the blast furnace to adjust the burden structure and operating parameters near the wall, thereby extending the service life of the copper wall in the later stages of its service life. Attached Figure Description

[0041] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0042] Figure 1 This is a cross-sectional view of an embodiment of this application;

[0043] Figure 2 This is an installation diagram of an embodiment of this application. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0045] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0046] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0047] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this application is in use. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0048] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0049] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0050] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0051] The features and performance of this application will be further described in detail below with reference to the embodiments.

[0052] like Figure 1 , Figure 2As shown, this invention proposes a copper wall thickness measuring device in the later stage of blast furnace service, including a synchronous wear mechanism, a coupling agent self-adjustment mechanism, and a measuring probe mechanism. The synchronous wear mechanism is horizontally installed on the blast furnace cooling wall 1, with its tail end flush with the inner surface of the copper wall 2, and its head end connected to one end of the coupling agent self-adjustment mechanism. The coupling agent self-adjustment mechanism is equipped with a measuring probe mechanism, which is connected to an external computer 4 via a data cable 3 to record measurement data.

[0053] In some optional embodiments, the synchronous wear mechanism includes a synchronous wear column 5 made of the same material as the copper wall, a sealing ring 6 on the synchronous wear column, the tail end of the synchronous wear column inserted into the blast furnace cooling wall, the sealing ring abutting against the blast furnace shell, and the head end of the synchronous wear column exposed outside the blast furnace and connected to the coupling agent self-adjusting mechanism. The tail end of the synchronous wear column is provided with a snap-fit ​​protrusion, and connecting lugs are provided on both sides of the snap-fit ​​protrusion. The snap-fit ​​protrusion snaps into a connecting flange, and the connecting lugs are fastened to the connecting flange by bolts.

[0054] In some optional implementations, the couplant self-adjusting mechanism includes a couplant adjusting cylinder 7 and a bellows expander 8. The couplant adjusting cylinder is filled with couplant, and a connecting flange 9 is located at the center of the front end face. A conduit 10 extending rearward is located at the center of the rear end face. The tail end of the synchronous wear column is connected to the connecting flange, and the tail end face of the synchronous wear column is flush with the inner wall of the front end face of the couplant adjusting cylinder. The measuring probe mechanism extends into the couplant adjusting cylinder, and the data cable passes through the conduit. The bellows expander is installed at the top of the couplant adjusting cylinder and is connected through a through hole 11 to provide space for outflow and backfilling when the measuring probe mechanism moves to compress the couplant in the cylinder.

[0055] In some alternative implementations, the measuring probe mechanism includes an ultrasonic probe 12 and a probe displacement drive 13. The ultrasonic probe is placed inside a coupling agent adjustment cylinder and connected to an external computer via a data cable. The probe displacement drive is located outside the coupling agent adjustment cylinder and is tightly fitted to the cable tube to drive the ultrasonic probe to move back and forth.

[0056] In some alternative implementations, the probe displacement drive includes a drive motor, a rotating screw, and an adjusting nut. One end of the rotating screw is connected to the ultrasonic probe, and the other end passes through the conduit and is connected to the drive motor. The adjusting nut is fixed to the end of the conduit and configured to work with the rotating screw.

[0057] The method of using the above-mentioned copper wall thickness measuring device in the later stage of blast furnace service includes the following steps:

[0058] Step a: Drill mounting holes in the cooling wall between two water channels, with a channel spacing of approximately 120mm. The diameter of the mounting holes should be 50-70mm. Too large a diameter may break the water channels, while too small a diameter will hinder stable control of the thickness measurement probe. The mounting holes should be placed close to the thermocouple on the cooling wall to facilitate comprehensive analysis of thickness and temperature data, clarifying the relationship between wall wear and temperature changes, and predicting the blast furnace lifespan. Measure the length of the wall material at the drilled location, cut the synchronous wear column so that the insertion length is the same as the mounting hole depth, install the synchronous wear structure into the mounting hole, and seal it by injecting refractory liquid slurry to prevent gas leakage at the joint during blast furnace production. Connect the front end of the coupling agent regulating cylinder to the tail end of the synchronous wear column with bolts, and then connect the probe displacement drive to the ultrasonic probe.

[0059] Step b: During use, the probe displacement drive is activated to propel the ultrasonic probe forward. Simultaneously, the couplant in the cylinder is squeezed into the bellows expander through the through-hole, causing it to expand. When the ultrasonic probe moves and fits against the tail of the synchronous wear column, it stops moving forward, and the couplant achieves automatic lubrication. High-definition ultrasonic thickness signal measurement is performed on the synchronous wear column. After the measurement is completed, the ultrasonic probe retracts to its original position, and the couplant in the bellows expander flows back into the couplant adjustment cylinder.

[0060] Step c: The normal operating temperature of the copper wall is ≤80℃, and the maximum temperature does not exceed 120℃. Since the strength of the copper wall decreases rapidly with increasing temperature, and the actual production process involves frequent fluctuations in the copper wall temperature, sometimes exceeding the operating temperature range, it is necessary to statistically analyze the wear amount and duration of the wall in different temperature ranges over a period of 3-4 months to calculate the wear rate of the wall in different temperature ranges. Based on the empirical operating range of the actual temperature of the blast furnace copper wall, the temperature range is divided into n (generally n = 4-6), and the temperature of each range is denoted as T. n The m-th time entering the temperature range T will be measured. n The thickness measured at that time is denoted as L. n -E m The thickness L measured when the wall temperature jumps out of this temperature range n -O m The duration is denoted as t. n-m ;

[0061] Statistical analysis of the total operating time of the copper wall body within a certain temperature range T1 and total wear thickness Calculate the wear rate υ of the copper wall in various temperature ranges. n ,but,

[0062]

[0063] The overall wear rate of the copper wall over the total statistical period for:

[0064]

[0065] Step d involves dynamically estimating the remaining lifespan range and overall remaining lifespan of the copper wall based on the copper wall thickness data. This information is then used to guide adjustments to the furnace charge structure near the copper wall, thereby reducing wear.

[0066] The calculation of the remaining lifetime range includes the following:

[0067] Statistics show that within a certain temperature range T of the copper wall of a blast furnace over a period of time (h). n Wear rate υ n And estimate the temperature T that the copper cooling wall remains at. n The remaining working capacity when working within a range is as follows:

[0068] Among them, △L n Let be the remaining thickness from the worn surface of the copper wall to the cooling wall channel. From this, the maximum remaining lifespan of the copper wall can be calculated as follows:

[0069] MaxD = {D1, D2, ..., D} n},

[0070] The remaining minimum lifetime of the copper wall is: MinD = {D1, D2, ..., D} n},

[0071] The remaining working life of the cooling wall is: MinD~MaxD.

[0072] The calculation of the overall remaining life of copper walls includes the following:

[0073] Calculate the overall wear rate of a certain part of the copper wall of a blast furnace over a period of time (h). The overall wear rate of the copper wall over the preceding h-hour period was then calculated weekly and recorded as follows: Then, using the obtained wear rate data, a method is used to regress and predict the relationship between the overall wear rate and time of the wall:

[0074]

[0075] The overall remaining life x of the copper wall satisfies the equation:

[0076]

[0077] The obtained x is the total remaining life of the wall.

[0078] Example 1

[0079] The temperature range is divided into 5 zones: T1, T2...T5. The wear rates in different temperature zones are as follows:

[0080] The wear rate υ1 when the temperature of the blast furnace copper wall is ≤80℃ is expressed as:

[0081]

[0082] The wear rate υ2 of the copper wall at 80℃~100℃ is expressed as:

[0083]

[0084] The wear rate υ3 of the copper wall at 100℃~120℃ is expressed as:

[0085]

[0086] The wear rate υ4 of the copper wall at 120℃~140℃ is expressed as:

[0087]

[0088] The wear rate υ5 of the copper wall at a temperature >140℃ is expressed as:

[0089]

[0090] The overall wear rate of the copper wall over the total statistical period for:

[0091] The following table shows the statistical data on the wear and tear of the copper cooling wall in different temperature ranges during the later stages of furnace operation.

[0092] Table 1

[0093]

[0094]

[0095] The remaining life range and overall remaining life of the furnace wall are dynamically estimated based on thickness measurement data, which guides the adjustment of the burden structure near the furnace wall to reduce wear.

[0096] 1. Calculation of the remaining working life of the blast furnace copper cooling wall

[0097] Calculation of the remaining working life of the blast furnace copper wall in different temperature ranges. By statistically analyzing the wear rate υ1 (mm / h) of a certain part of the blast furnace copper wall within a certain period of time (3-4 months) at temperature T1 (≤80℃), the remaining working capacity of the copper cooling wall while maintaining operation within temperature T1 is estimated, as shown in the following formula:

[0098] Similarly, the remaining working capacity of the wall within the temperature ranges T2, T3, T4, and T5 can be obtained as follows:

[0099]

[0100]

[0101] Among them, △L n Let be the remaining thickness from the worn surface of the copper wall to the cooling wall channel. From this, the maximum remaining lifespan of the copper wall can be calculated as follows:

[0102] MaxD={D1, D2, D3, D4, D5},

[0103] The remaining minimum lifetime of the copper wall is: MinD = {D1, D2, D3, D4, D5}.

[0104] The remaining working life range of the cooling wall is: MinD~MaxD. Based on this result, the blast furnace takes corresponding measures to control the working time of the wall within the temperature range corresponding to MinD.

[0105] 2. Overall wall wear rate and overall remaining service life

[0106] By calculating the comprehensive wear rate of a certain part of the copper wall of the blast furnace over a period of time (h). The overall wear rate of the copper wall over the preceding h-hour period was then calculated weekly and recorded as follows: (x = 6~10), and then the obtained wear rate data is used to regress the predictive method of the overall wear rate and time of the wall:

[0107]

[0108] The overall remaining life x of the copper wall satisfies the equation:

[0109]

[0110] The obtained x is the total remaining life of the wall.

[0111] Based on the calculation results of the remaining life of the copper wall, the blast furnace burden structure and operation mode are adjusted, and after 5 to 10 weeks, the calculation is repeated to obtain new comprehensive wear rate data. The regression equation is then recalculated, and it is estimated whether the current operating parameters are conducive to extending the remaining life X of the wall. This method is used to obtain the most favorable operating system for extending the working life of the blast furnace wall.

[0112] This invention is based on the fact that copper structures can wear synchronously with the copper wall of a blast furnace, and that pure copper transmits energy wave signals clearly. It involves installing a copper wall synchronous wear device on the copper cooling wall of a blast furnace during the later stages of its service life. Combined with corresponding automatic monitoring devices, installation and usage methods, and data analysis methods, this invention aims to measure and track the wear rate of the copper wall under different smelting conditions and predict its remaining lifespan online. This, in turn, guides blast furnace operation adjustments, improves smelting conditions at the worn areas, and extends the service life of the copper wall.

Claims

1. A device for measuring the thickness of copper wall in the later stage of blast furnace service, characterized in that, The system includes a synchronous wear mechanism, a coupling agent self-adjustment mechanism, and a measuring probe mechanism. The synchronous wear mechanism is horizontally installed on the blast furnace cooling wall, with its first end flush with the inner surface of the copper wall and its last end connected to one end of the coupling agent self-adjustment mechanism. The measuring probe mechanism is located within the coupling agent self-adjustment mechanism and is connected to an external computer via a data cable to record measurement data. The synchronous wear mechanism includes a synchronous wear column made of the same material as the copper wall, with a sealing ring on the column. The first end of the synchronous wear column is inserted into the blast furnace cooling wall, and the sealing ring abuts against the blast furnace shell, thus achieving synchronous wear. The tail end of the column is exposed outside the blast furnace and connected to the self-adjusting coupling agent mechanism. The self-adjusting coupling agent mechanism includes a coupling agent adjusting cylinder and a bellows expander. The coupling agent adjusting cylinder is filled with coupling agent. A connecting flange is provided at the center of the front end face, and a conduit extending backward is provided at the center of the rear end face. The tail end of the synchronous wear column is connected to the connecting flange. The tail end face of the synchronous wear column is flush with the inner wall of the front end face of the coupling agent adjusting cylinder. The measuring probe mechanism extends into the coupling agent adjusting cylinder, and the data line passes through the conduit. The bellows expander is installed on the top of the coupling agent adjusting cylinder and is connected through a through hole.

2. The copper wall thickness measuring device in the later stage of blast furnace service according to claim 1, characterized in that, The measuring probe mechanism includes an ultrasonic probe and a probe displacement drive. The ultrasonic probe is placed inside the coupling agent adjustment cylinder and connected to an external computer via a data cable. The probe displacement drive is located outside the coupling agent adjustment cylinder and is tightly fitted to the conduit, driving the ultrasonic probe to move back and forth.

3. A device for measuring the thickness of copper wall in the later stage of blast furnace service according to claim 1 or 2, characterized in that, The tail end of the synchronous wear column is provided with a snap-fit ​​protrusion, and the snap-fit ​​protrusion is provided with connecting lugs on both sides. The snap-fit ​​protrusion is snapped into the connecting flange, and the connecting lugs are connected and fastened to the connecting flange by bolts.

4. The copper wall thickness measuring device in the later stage of blast furnace service according to claim 2, characterized in that, The probe displacement drive includes a drive motor, a rotating screw, and an adjusting nut. One end of the rotating screw is connected to the ultrasonic probe, and the other end passes through the conduit and is connected to the drive motor. The adjusting nut is fixed to the tail of the conduit and is configured with the rotating screw.

5. The method of using the copper wall thickness measuring device in the later stage of blast furnace service as described in claim 4, characterized in that, Includes the following steps: Step a: Drill a mounting hole in the cooling wall between the two water channels, close to the thermocouple of the cooling wall. Measure the length of the wall material at the drilling location. Cut the synchronous wear column so that the length of the insertion part is the same as the depth of the mounting hole. Insert the synchronous wear column into the mounting hole and seal it by pouring in refractory liquid slurry. Connect the front end of the coupling agent adjustment cylinder to the tail end of the synchronous wear column with bolts. Then connect the probe displacement drive to the ultrasonic probe. Step b: During use, the probe displacement drive is activated to propel the ultrasonic probe forward. Simultaneously, the couplant inside the cylinder is squeezed into the bellows expander through the through-hole, causing it to expand. When the ultrasonic probe moves and fits against the tail of the synchronous wear column, it stops moving forward, and the couplant achieves automatic lubrication. High-definition ultrasonic thickness signal measurement is performed on the synchronous wear column. After the measurement is completed, the ultrasonic probe retracts to its original position, and the couplant inside the bellows expander flows back into the couplant adjustment cylinder. Step c: Based on the measured copper wall thickness data and cooling wall temperature data, calculate the wear rate law of the blast furnace copper wall under different temperature conditions. Step d involves dynamically estimating the remaining lifespan range and overall remaining lifespan of the copper wall based on the copper wall thickness data. This information is then used to guide adjustments to the furnace charge structure near the copper wall, thereby reducing wear.

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