Intelligent carbon brick, preparation method thereof, and carbon brick residual thickness measurement method and system

Abstract

The application discloses an intelligent carbon brick, a preparation method thereof, and a carbon brick residual thickness measuring method and system. The intelligent carbon brick comprises a carbon brick body and a thin film type electrical sensor fixed on the surface of the carbon brick body. The thin film type electrical sensor is a multilayer hetero thin film structure, comprising a first insulating protective layer, a metal functional layer, a second insulating protective layer and a second transition connecting layer in sequence. The metal functional layer is a patterned thin film resistor. The thin film resistor extends from one end of the carbon brick body to the other end. The intelligent carbon brick is stacked layer by layer along the periphery of the internal furnace wall of the furnace body. In the production process, the thin film resistor will be corroded synchronously with the carbon brick body, and the output resistance value will change accordingly. The residual thickness of the carbon brick body can be directly reflected according to the size of the output resistance value and the change condition, so that the real service life of the furnace body can be more accurately and reliably detected online, and the ironmaking production safety is ensured.

Description

Technical Field

[0001] This application relates to the field of metallurgical technology, specifically to the monitoring of furnace lining erosion in ironmaking production, and particularly to a smart carbon brick and its preparation method, as well as a method and system for measuring the excess thickness of the carbon brick using the smart carbon brick. Background Technology

[0002] Carbon bricks are high-temperature resistant, neutral refractory materials made primarily from coke, anthracite, and graphite, bound with organic materials such as pitch, tar, and anthracene oil. Carbon bricks possess high refractoriness, high thermal and electrical conductivity, and excellent slag resistance; they also exhibit good thermal stability, a low coefficient of thermal expansion, high high-temperature strength, high temperature resistance, good wear resistance, and resistance to corrosion from various acids, alkalis, salts, and organic solvents. Carbon bricks are widely used in the metallurgical industry; the hearth, hearth, and waist of many blast furnaces are constructed using carbon brick lining. Inside the blast furnace lining, one end of the carbon brick contacts the iron-making reaction zone, while the other end is connected to the furnace shell through a thin layer of rammed earth. The carbon brick forms a confining vessel for the reaction within the blast furnace, playing a crucial role in maintaining blast furnace production and ensuring its safety.

[0003] During blast furnace production, the carbon bricks gradually thin due to the continuous erosion caused by the ironmaking reaction raw materials and byproducts. Their thickness is considered a crucial factor in blast furnace maintenance and ensuring safe production. Therefore, monitoring the thickness of blast furnace carbon bricks is a core issue for blast furnace production and safety assurance.

[0004] Due to the extremely high temperatures and harsh environment inside the blast furnace, current methods for monitoring the thickness of carbon bricks primarily involve drilling blind holes of varying depths into the carbon bricks, inserting temperature sensors such as armored thermocouples, measuring the temperature at each depth, and then indirectly deriving the carbon brick thickness using a heat transfer simulation model. This process requires drilling blind holes through the furnace shell and inserting temperature sensors. Because of inherent errors in temperature measurement, coupled with the difficulty in achieving perfectly accurate boundary conditions for the heat transfer model, the obtained carbon brick thickness often deviates significantly from the actual thickness. False alarms and missed alarms regarding excess carbon brick thickness can cause substantial losses to the safe operation of the blast furnace. Therefore, blast furnace production urgently needs a direct, accurate, and reliable method for measuring the excess carbon brick thickness. Summary of the Invention

[0005] In view of the shortcomings of the prior art described above, the purpose of this application is to provide a smart carbon brick and its preparation method, as well as a method and system for measuring the remaining thickness of the carbon brick using the smart carbon brick. By integrating a thin-film electrical sensor in situ onto the surface of the carbon brick, the corresponding output resistance change during synchronous erosion can be used to directly reflect the erosion status of the furnace lining inside the furnace body. This provides a direct, accurate, and reliable method for measuring the remaining thickness of the carbon brick in blast furnace ironmaking and other production processes, helps to correct the prediction accuracy of the mathematical model of hearth erosion, comprehensively and truly understands the internal lifespan status of the furnace body, and ensures the safety and reliability of ironmaking production.

[0006] To achieve the above and other related objectives, the first aspect of this application provides a smart carbon brick, comprising a carbon brick body and a thin-film electrical sensor fixed to the surface of the carbon brick body. The thin-film electrical sensor is a multilayer heterogeneous thin-film structure, comprising a first insulating protective layer, a metal functional layer, a second insulating protective layer, and a second transition connection layer. The first insulating protective layer is a thin film formed by depositing inorganic insulating material. The metal functional layer is a patterned thin-film resistor deposited on the first insulating protective layer, extending from one end of the carbon brick body to the other end. The second insulating protective layer is a thin film formed by depositing inorganic insulating material on the first insulating protective layer and the metal functional layer. The second transition connection layer is a thin film attached to the second insulating protective layer and made of organic insulating material, with the other side of the second transition connection layer attached to the surface of the carbon brick body.

[0007] Furthermore, the inorganic insulating material is selected from at least one of silicon oxide (SiO), silicon dioxide, silicon nitride, aluminum oxide, aluminum nitride, and boron nitride.

[0008] Furthermore, the raw materials for preparing the metal functional layer are selected from at least one of chromium, platinum, and chromium-platinum alloys.

[0009] Furthermore, the organic insulating material is selected from at least one of polyimide, polyethylene, polyvinylidene fluoride, and polytetrafluoroethylene.

[0010] Furthermore, the first insulating protective layer and the second insulating protective layer are formed by physical vapor deposition (PVD) or chemical vapor deposition (CVD) processes.

[0011] Furthermore, the patterned thin-film resistor is deposited using a combination of physical vapor deposition (PVD) or chemical vapor deposition (CVD) and hard mask etching.

[0012] Furthermore, the second transition bonding layer is prepared by a spin coating process.

[0013] Furthermore, the second transition bonding layer is attached to the surface of the carbon brick body using an adhesive through hot rolling curing, so that the thin-film electrical sensor is fixed on the surface of the carbon brick body.

[0014] Furthermore, the method for fixing the thin-film electrical sensor to the surface of the carbon brick body includes:

[0015] A thin film is prepared on a substrate using an organic insulating material as the first transition bonding layer;

[0016] The first insulating protective layer, the metal functional layer, the second insulating protective layer, and the second transition connection layer are sequentially prepared on the first transition connection layer.

[0017] The second transition bonding layer is attached to the surface of the carbon brick body by using an adhesive and hot rolling curing method;

[0018] The substrate is separated from the first transition connection layer, and then the first transition connection layer is removed, so that the thin-film electrical sensor is fixed on the surface of the carbon brick body.

[0019] Furthermore, the substrate is selected from any one of glass substrates, microcrystalline glass substrates, glazed ceramic substrates, sapphire substrates, and single-crystal silicon substrates.

[0020] Furthermore, the method of separating the substrate from the first transition connection layer includes: immersing the substrate and the first transition connection layer in warm water, and then peeling the first transition connection layer off the substrate.

[0021] Furthermore, the first transition connection layer is removed by plasma etching.

[0022] Furthermore, the method of separating the substrate from the first transition connection layer and then removing the first transition connection layer includes: immersing the substrate and the first transition connection layer in warm water, then peeling the first transition connection layer off the substrate, drying it, and then removing the first transition connection layer by a plasma etching process.

[0023] Furthermore, the thickness of the thin-film electrical sensor is 0.4–80 micrometers.

[0024] Furthermore, the thickness of the first transition connection layer is 0.1 to 20 micrometers.

[0025] Furthermore, the thickness of the first insulating protective layer is 0.1 to 20 micrometers.

[0026] Furthermore, the thickness of the metal functional layer is 0.1 to 20 micrometers.

[0027] Furthermore, the thickness of the second insulating protective layer is 0.1 to 20 micrometers.

[0028] Further, the thickness of the second transition connection layer is 0.1 to 20 micrometers.

[0029] Further, the patterned thin-film resistor includes a plurality of first thin-film resistors and a plurality of second thin-film resistors. The plurality of first thin-film resistors are arranged at intervals along one end to the other end of the carbon brick body and are connected in parallel. One second thin-film resistor is arranged between two adjacent first thin-film resistors, and the second thin-film resistor is connected in series with the adjacent first thin-film resistor.

[0030] Further, if the resistance value of the first thin-film resistor is much larger than the resistance value of the second thin-film resistor, the equivalent resistance of the patterned thin-film resistor satisfies the following conditions:

[0031]

[0032] In the formula, R out is the equivalent resistance of the patterned thin-film resistor, R h and n is the number of the first thin-film resistors. is the resistance value of the first thin-film resistor.

[0033] Further, the ratio of the resistance value of the first thin-film resistor to the resistance value of the second thin-film resistor is not less than 100.

[0034] Further, both the first thin-film resistor and the second thin-film resistor are strip-shaped. The plurality of first thin-film resistors are arranged at intervals and in parallel along one end to the other end of the carbon brick body. Two second thin-film resistors distributed at intervals are arranged in the gap between two adjacent first thin-film resistors. Two adjacent first thin-film resistors and two second thin-film resistors located between them form a "square" pattern, so that the plurality of first thin-film resistors are connected in parallel, and the second thin-film resistor is connected in series with the adjacent first thin-film resistor.

[0035] Further, both the first thin-film resistor and the second thin-film resistor are rectangular thin-film resistors and have the same material.

[0036] The second aspect of the present application provides a preparation method of the intelligent carbon brick according to the first aspect, including the following steps:

[0037] Prepare a thin film on a substrate with an organic insulating material as the first transition connection layer;

[0038] Deposit a thin film on the first transition connection layer with an inorganic insulating material as the first insulating protection layer;

[0039] Deposit a patterned thin-film resistor on the first insulating protection layer as the metal functional layer;

[0040] An inorganic insulating material is deposited on the first insulating protective layer and the metal functional layer to form a thin film, which serves as the second insulating protective layer.

[0041] An organic insulating material is deposited on the second insulating protective layer to form a thin film as the second transition connection layer; an adhesive is coated on the second transition connection layer and / or the surface of the carbon brick body, and the second transition connection layer is bonded to the surface of the carbon brick body by hot rolling curing.

[0042] The substrate is separated from the first transition connection layer, and then the first transition connection layer is removed to obtain the smart carbon brick.

[0043] The third aspect of this application provides a method for measuring the excess thickness of carbon bricks, comprising the following steps: stacking intelligent carbon bricks as described in the first aspect layer by layer along the inner wall of the furnace body; monitoring the output resistance value of the patterned thin film resistors on all intelligent carbon bricks; determining the erosion status of the intelligent carbon bricks based on the magnitude and changes of the output resistance value; and determining the excess thickness of the carbon brick body based on the erosion status of the intelligent carbon bricks.

[0044] Furthermore, the erosion situation includes the erosion location, which is the position of the eroded smart carbon brick inside the furnace body. The method for determining the erosion location includes: numbering and locating each smart carbon brick stacked inside the furnace body, determining the eroded smart carbon brick based on the change in output resistance value, and determining the location of the eroded smart carbon brick based on the number.

[0045] Furthermore, the erosion situation also includes the severity of erosion, which refers to the severity of erosion of the carbon brick body of the eroded smart carbon brick. The severity of erosion is determined by: after the smart carbon bricks are stacked, the extension direction of the patterned thin film resistor on them is consistent with the horizontal direction; the remaining effective length of the patterned thin film resistor is determined according to the output resistance value; the remaining thickness of the carbon brick body is determined according to the remaining effective length; the remaining effective length is positively correlated with the remaining thickness of the carbon brick body; and the remaining thickness of the carbon brick body is negatively correlated with the severity of erosion.

[0046] Furthermore, patterned thin-film resistors are connected by wires to monitor the output resistance values ​​of the patterned thin-film resistors on all smart carbon bricks.

[0047] The fourth aspect of this application provides a carbon brick thickness measurement system, comprising several intelligent carbon bricks as described in the first aspect, wherein the intelligent carbon bricks are stacked layer by layer along the perimeter of the inner wall of the furnace body.

[0048] It also includes a monitoring module, which is used to monitor the output resistance value of the patterned thin film resistors on all smart carbon bricks, determine the erosion status of the smart carbon bricks based on the magnitude and changes of the output resistance value, and determine the remaining thickness of the carbon brick body based on the erosion status of the smart carbon bricks.

[0049] Furthermore, after the smart carbon bricks are stacked, the extension direction of the patterned thin-film resistors on them is consistent with the horizontal direction.

[0050] Furthermore, the carbon brick thickness measurement system also includes several wires for connecting the patterned thin-film resistors, so that the monitoring module can obtain the output resistance values ​​of the patterned thin-film resistors on all smart carbon bricks.

[0051] As described above, the intelligent carbon brick and its preparation method, as well as the carbon brick thickness measurement method and system of this application, have the following beneficial effects:

[0052] The intelligent carbon brick provided in this application integrates a thin-film electrical sensor in situ onto the surface of the carbon brick body. When the intelligent carbon brick is installed on the furnace wall inside the furnace body, the carbon brick body will be corroded and worn during the production process due to contact with high-temperature molten iron. The thin-film electrical sensor will corrode synchronously with the carbon brick, and its output resistance value will also change accordingly. The remaining thickness of the carbon brick body can be directly reflected according to the change law of the output resistance value.

[0053] This application utilizes the change in output resistance of a thin-film electrical sensor during synchronous erosion to directly reflect the real-time high-temperature corrosion of the refractory material inside the furnace wall. Compared with the traditional indirect monitoring method of inserting armored thermocouples into blind holes for temperature measurement and combining it with heat transfer model derivation, this method has better accuracy, reliability, and rationality. It can provide more timely and direct feedback on the location and severity of erosion, providing important technical support for ensuring the safety of blast furnace and other ironmaking production and correcting the prediction accuracy of hearth erosion models. In addition, the intelligent carbon brick and carbon brick thickness monitoring method and system provided in this application are not only applicable to ironmaking scenarios such as blast furnaces, but also applicable to other scenarios that require refractory bricks and temperature monitoring. Attached Figure Description

[0054] Figure 1 The diagram shown is a structural schematic of the smart carbon brick in an embodiment of this application.

[0055] Figure 2 The diagram shown is a schematic diagram of the film structure when fabricating a thin-film electrical sensor on a substrate in an embodiment of this application.

[0056] Figure 3 The diagram shown is a schematic diagram of the film layer structure of the integrated carbon brick formed after the thin-film electrical sensor is fixed on the carbon brick body in the embodiment of this application.

[0057] Figure 4 The diagram shown is an equivalent circuit diagram of a patterned thin-film resistor in a smart carbon brick according to an embodiment of this application.

[0058] Figure 5 The diagram shown is a schematic representation of the patterned thin-film resistor in a smart carbon brick according to an embodiment of this application.

[0059] Figure 6 The diagram shown is an equivalent circuit diagram of the output resistance of the metal functional layer of the smart carbon brick when it is in good condition, as described in this application embodiment.

[0060] Figure 7 The diagram shown is an equivalent circuit diagram of the output resistance of the metal functional layer of the smart carbon brick when it is eroded in the embodiment of this application. Detailed Implementation

[0061] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. This application can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application.

[0062] like Figure 1 As shown, one embodiment of this application provides a smart carbon brick, including a carbon brick body and a thin-film electrical sensor fixed on the surface of the carbon brick body. The thin-film electrical sensor is a multilayer heterogeneous thin-film structure, including a first insulating protective layer, a metal functional layer, a second insulating protective layer, and a second transition connection layer. The first insulating protective layer is a thin film formed by depositing inorganic insulating material. The metal functional layer is a patterned thin-film resistor deposited on the first insulating protective layer. The patterned thin-film resistor extends from one end of the carbon brick body to the other end. The second insulating protective layer is a thin film formed by depositing inorganic insulating material on the first insulating protective layer and the metal functional layer. The second transition connection layer is a thin film attached to the second insulating protective layer and made of organic insulating material. The other side of the second transition connection layer is attached to the surface of the carbon brick body.

[0063] The charcoal brick body in this application embodiment refers to existing charcoal bricks, i.e., common refractory bricks, which are made of refractory materials.

[0064] Generally, the carbon brick body is square in shape. A thin-film electrical sensor can be fixed on any side of the carbon brick body, such as the top surface, bottom surface, front side, rear side, left side, and right side, depending on the actual needs.

[0065] In this embodiment, a thin-film electrical sensor is in situ integrated onto the surface of a carbon brick body (i.e., a traditional carbon brick). The thin-film electrical sensor has a multilayer heterogeneous thin-film structure, including a first insulating protective layer, a metal functional layer, a second insulating protective layer, and a second transition connection layer. The first and second insulating protective layers are both thin films formed by the deposition of inorganic insulating materials, which encapsulate the metal functional layer and provide good insulation, protecting the metal functional layer. The second transition connection layer is formed by the deposition of organic insulating materials and is located between the second insulating protective layer and the surface of the carbon brick body. It has good adhesion to the surface of the carbon brick body and can achieve tight adhesion between the thin-film electrical sensor and the surface of the carbon brick body. The metal functional layer is a patterned thin-film resistor that extends from one end of the carbon brick body to the other. During the production process, the carbon brick body is corroded by high-temperature molten iron, and the thin-film electrical sensor will corrode synchronously with the carbon brick body. The output resistance value of its metal functional layer, i.e., the patterned thin-film resistor, will also change accordingly. The remaining thickness of the carbon brick body can be directly reflected by the magnitude and change of the output resistance value. Therefore, by replacing traditional carbon bricks with intelligent carbon bricks in this embodiment, the real-time high-temperature corrosion of the refractory material inside the blast furnace can be directly reflected by the corresponding output resistance change when synchronous erosion occurs. This overcomes the blind zone problem caused by the inability to continuously arrange detection points, which is a problem in the traditional method of using sheathed thermocouples to detect temperature and feedback the corrosion of the furnace wall. At the same time, it can also avoid detection failure caused by thermocouple damage or poor contact. Compared with the traditional method of indirectly monitoring by inserting sheathed thermocouples into blind holes to measure temperature and combining it with heat transfer model derivation, it has better accuracy, reliability and rationality. It can more timely and directly reflect the location and severity of erosion, providing important technical support for the safety assurance of blast furnace and other ironmaking production and the correction of the prediction accuracy of hearth erosion model. It is worth promoting and applying in blast furnace and other ironmaking production.

[0066] Regarding the raw materials used in preparing the first insulating protective layer, the metallic functional layer, the second insulating protective layer, and the second transition bonding layer:

[0067] In some embodiments of this application, the inorganic insulating material is selected from materials that can maintain good insulation performance at high temperatures of 1000°C and above, including but not limited to silicon oxide (SiO), silicon dioxide (SiO2), silicon nitride, aluminum oxide, aluminum nitride, boron nitride, etc. Furthermore, the aforementioned inorganic insulating materials can also maintain good bonding with the carbon brick body at high temperatures of 1000°C and above.

[0068] In some embodiments of this application, the raw materials for preparing the metal functional layer include, but are not limited to, at least one of chromium, platinum, and chromium-platinum alloys. These two metallic materials possess stable electrical properties, with melting points of 1907°C and 1769°C (1772°C), respectively; temperature coefficients of resistivity of 0.003 ppm / °C (0–100°C) and 0.00374 ppm / °C (0–60°C), respectively; and resistivity at room temperature of 12.9 × 10⁻⁶, respectively. -8 Ωm and 10.6×10 -8 For Ω m, Cr is the better choice considering signal significance and high-temperature stability. Besides Cr, other thin-film resistor materials with certain resistivity and good high-temperature stability can also be used, such as nickel, tungsten, copper, and their alloys.

[0069] In some embodiments of this application, the organic insulating material is selected from materials that have good insulation performance at high temperatures of 1000°C and below and good bonding with the carbon brick body, including but not limited to polyimide, polyethylene, polyvinylidene fluoride, polytetrafluoroethylene, etc.

[0070] The first insulating protective layer, the metal functional layer, the second insulating protective layer, and the second transition connection layer in the embodiments of this application are all processed by MEMS (Microelectromechanical systems) manufacturing process.

[0071] In some embodiments of this application, the first insulating protective layer and the second insulating protective layer are formed by physical vapor deposition (PVD) or chemical vapor deposition (CVD) processes.

[0072] In some embodiments of this application, the patterned thin-film resistor is deposited using a combination of physical vapor deposition (PVD) or chemical vapor deposition (CVD) and hard mask etching. Specifically, a thin film is first deposited on a first insulating protective layer using a PVD / CVD process, and then a sensor pattern is generated using a hard mask etching process, thus completing the fabrication of the patterned thin-film resistor.

[0073] In some embodiments of this application, the second transition bonding layer is prepared by a spin coating process.

[0074] Regarding the fixing method of the thin-film electrical sensor, in some embodiments of this application, an adhesive is used to attach the second transition connection layer to the surface of the carbon brick body through hot rolling curing, so that the thin-film electrical sensor is fixed to the surface of the carbon brick body. Specifically, an adhesive is applied to the surface of the second transition connection layer and / or the surface of the carbon brick body. While they are still wet, the two are brought together, softened, and then cured by hot rolling to avoid air bubble capture and enhance interaction, thereby achieving a tight adhesion between the two. Then, they are cooled to room temperature. The adhesive is selected as an adhesive with good insulation properties at high temperatures of 1000°C and below, such as negative photoresist SU8-2000.5.

[0075] In one specific embodiment of this application, the method for fixing a thin-film electrical sensor to the surface of a carbon brick body includes the following steps:

[0076] Combination Figure 2 As shown, an organic insulating material is used to prepare a thin film on the substrate as the first transition connection layer; a first insulating protective layer, a metal functional layer, a second insulating protective layer, and a second transition connection layer are sequentially prepared on the first transition connection layer.

[0077] The second transition layer is attached to the surface of the carbon brick body using an adhesive through hot rolling curing, resulting in an integrated carbon brick membrane structure as follows: Figure 3 As shown;

[0078] The substrate is separated from the first transition bonding layer, and then the first transition bonding layer is removed to fix the thin-film electrical sensor onto the surface of the carbon brick body. This transfers the sensor from the substrate to the surface of the carbon brick body, ultimately obtaining... Figure 1 The smart carbon brick shown.

[0079] In some embodiments of this application, the substrate includes, but is not limited to, glass substrates, microcrystalline glass substrates, glazed ceramic substrates, sapphire substrates, and single-crystal silicon substrates. The substrate size is comparable to the surface area of ​​the carbon brick body to which the thin-film electrical sensor is to be attached, for example, 30cm × 80cm.

[0080] In some embodiments of this application, the method of separating the substrate from the first transition connection layer includes immersing the substrate and the first transition connection layer in warm water, and then peeling the first transition connection layer off the substrate. Specifically, the substrate and the first transition connection layer are immersed in a warm water bath. The substrate has relatively better hydrophilicity and tends to attract water molecules, thus allowing water to enter the interface between the substrate and the first transition connection layer, thereby peeling the composite film material off the substrate. Then, it is dried to achieve the separation of the substrate and the first transition connection layer. The warm water is preferably deionized water, but pure water, purified water, ultrapure water, etc., can also be used.

[0081] To facilitate the separation of the substrate and the first transition connection layer, the first transition connection layer is also prepared by a spin coating process using an organic insulating material. The organic insulating material used is preferably a material with poor hydrophilicity, including but not limited to polyimide, polyethylene, polyvinylidene fluoride, polytetrafluoroethylene, etc.

[0082] In some embodiments of this application, the first transition connection layer can be removed by plasma etching.

[0083] In some embodiments of this application, the method of separating the substrate from the first transition connection layer and then removing the first transition connection layer includes: immersing the substrate and the first transition connection layer in warm water, then peeling the first transition connection layer off the substrate, drying it, and then removing the first transition connection layer by a plasma etching process.

[0084] The embodiments described above in this application transfer a thin-film electrical sensor onto the surface of the carbon brick body through hot rolling curing and warm water immersion, forming an integrated smart carbon brick. This method has the advantages of simple preparation and easy operation.

[0085] Regarding the total thickness of the thin-film electrical sensor and the thicknesses of the first transition connection layer, the first insulating protective layer, the metallic functional layer, the second insulating protective layer, and the second transition connection layer:

[0086] In some embodiments of this application, the thickness of the thin-film electrical sensor is 0.4 to 80 micrometers, preferably 2.4 to 64 micrometers, and more preferably 4 to 40 micrometers.

[0087] In some embodiments of this application, the thickness of the first transition connection layer is 0.1 to 20 micrometers, preferably 0.6 to 16 micrometers, more preferably 1 to 10 micrometers, for example 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 9.0, and 10.0 micrometers.

[0088] In some embodiments of this application, the thickness of the first insulating protective layer is 0.1 to 20 micrometers, preferably 0.6 to 16 micrometers, more preferably 1 to 10 micrometers, for example 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 9.0, and 10.0 micrometers.

[0089] In some embodiments of this application, the thickness of the metal functional layer is 0.1 to 20 micrometers, preferably 0.6 to 16 micrometers, more preferably 1 to 10 micrometers, for example 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 9.0, and 10.0 micrometers.

[0090] In some embodiments of this application, the thickness of the second insulating protective layer is 0.1 to 20 micrometers, preferably 0.6 to 16 micrometers, more preferably 1 to 10 micrometers, for example 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 9.0, and 10.0 micrometers.

[0091] In some embodiments of this application, the thickness of the second transition connection layer is 0.1 to 20 micrometers, preferably 0.6 to 16 micrometers, more preferably 1 to 10 micrometers, for example 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 9.0, and 10.0 micrometers.

[0092] The physical vapor deposition (PVD), chemical vapor deposition (CVD), hard mask etching, spin coating, and plasma etching processes mentioned in the above embodiments of this application are all common preparation methods for thin film materials. The specific process parameters and other details can be adjusted according to actual needs such as thin film thickness, and will not be described in detail here.

[0093] Regarding patterned thin-film resistors, in one specific embodiment of this application, the patterned thin-film resistor includes a plurality of first thin-film resistors (i.e., Figure 4 R shown h ) and several second thin-film resistors (i.e. Figure 4 R shown l Several first thin-film resistors are arranged at intervals along one end of the carbon brick body to the other end and are connected in parallel. A second thin-film resistor is set between two adjacent first thin-film resistors and the second thin-film resistor is connected in series with the adjacent first thin-film resistor.

[0094] In some embodiments of this application, if the resistance value of the first thin-film resistor is much greater than the resistance value of the second thin-film resistor, then the equivalent resistance of the patterned thin-film resistor satisfies the following condition:

[0095]

[0096] In the formula, R out R is the equivalent resistance of a patterned thin-film resistor. h$R_1$ is the resistance value of the first thin-film resistor, and $n$ is the number of the first thin-film resistors.

[0097] In some embodiments of the present application, that the resistance value of the first thin-film resistor is much greater than the resistance value of the second thin-film resistor means that the ratio of the resistance value of the first thin-film resistor to the resistance value of the second thin-film resistor is not less than 100.

[0098] Regarding the pattern shape of the patterned thin-film resistor, in some embodiments of the present application, both the first thin-film resistor and the second thin-film resistor are strip-shaped. A plurality of first thin-film resistors are arranged in parallel at intervals from one end to the other end of the carbon brick body. Two second thin-film resistors distributed at intervals are arranged in the gap between two adjacent first thin-film resistors. Two adjacent first thin-film resistors and two second thin-film resistors located between them form a "square" pattern, so that a plurality of first thin-film resistors are connected in parallel, and the second thin-film resistor is connected in series with the adjacent first thin-film resistor.

[0099] As Figure 5 shown, in a specific embodiment of the present application, both the first thin-film resistor and the second thin-film resistor are rectangular thin-film resistors and have the same material. At this time, when the intelligent carbon brick is intact, the output resistance of its metal functional layer is equivalent to Figure 6 the electrical circuit shown in h . If the length $L_1$ of the first thin-film resistor $R_1$ is 200 mm and the width $B_1$ is 5 mm, and the length $L_2$ of the second thin-film resistor $R_2$ is 10 mm and the width $B_2$ is 25 mm, then there is: l

[0100]

[0101] In formula (1): $H$ is the thickness of the metal functional layer thin film, and $\rho$ m is the resistivity of the material used to prepare the thin-film resistor.

[0102] That is:

[0103] $R_1$ h >> $R_2$ l (2)

[0104] At this time, the output resistance $R_{eq}$ of the equivalent circuit out satisfies:

[0105]

[0106] In formula (3): $n$ is the number of all $R$ h resistors.

[0107] When the intelligent carbon brick is eroded, the output resistance of its metal functional layer is equivalent to Figure 7 the electrical circuit shown in the above figure, and actually is equivalent to Figure 7 the electrical circuit shown in the following figure.

[0108] The first and second thin-film resistors in the embodiments of this application can also be made of different materials. Their length and width can be designed and adjusted according to the size of the carbon brick body. The corresponding output resistance and its equivalent circuit can be analyzed and calculated with reference to the above formula. This application does not impose any restrictions on this.

[0109] Another embodiment of this application provides a method for preparing a smart carbon brick according to the above embodiments, comprising the following steps:

[0110] A thin film is prepared on a substrate using an organic insulating material as the first transition bonding layer;

[0111] An inorganic insulating material is deposited on the first transition connection layer to form a thin film, which serves as the first insulating protective layer.

[0112] A patterned thin-film resistor is deposited on the first insulating protective layer as a metal functional layer;

[0113] An inorganic insulating material is deposited on the first insulating protective layer and the metal functional layer to form a thin film, which serves as the second insulating protective layer.

[0114] An organic insulating material is deposited on the second insulating protective layer to form a thin film as a second transition connection layer; an adhesive is coated on the surface of the second transition connection layer and / or the carbon brick body, and the second transition connection layer is bonded to the surface of the carbon brick body by hot rolling curing.

[0115] The substrate is separated from the first transition connection layer, and then the first transition connection layer is removed to obtain the smart carbon brick.

[0116] It should be noted that the intelligent carbon brick preparation method provided in the above embodiments belongs to the same concept as the intelligent carbon brick provided in the above embodiments. The structure of the thin-film electrical sensor, the specific preparation process of each film layer and its key process parameters have been described in detail in the embodiments concerning intelligent carbon bricks, and will not be repeated here.

[0117] The embodiments of this application also provide a method for measuring the excess thickness of carbon bricks, including the following steps: stacking smart carbon bricks as described above layer by layer along the inner wall of the furnace body, monitoring the output resistance value of the patterned thin film resistors on all smart carbon bricks, determining the erosion status of the smart carbon bricks based on the magnitude and changes of the output resistance value, and determining the excess thickness of the carbon brick body based on the erosion status of the smart carbon bricks.

[0118] In this embodiment, intelligent carbon bricks are stacked layer by layer around the furnace wall. The thin-film electrical sensor will corrode synchronously with the carbon brick body, and its electrical state will be updated accordingly. By identifying the resistance output signal of the graphic thin-film resistor, the corrosion of the refractory material inside the furnace can be monitored online in an all-round way. This helps to correct the prediction accuracy of the mathematical model of blast furnace hearth erosion, fully and accurately understand the life status of the blast furnace, and ensure the safe and reliable production of blast furnace ironmaking.

[0119] In one specific embodiment of this application, the erosion condition includes the erosion location, which is the position of the eroded smart carbon brick inside the furnace body. The erosion location is determined by: numbering and locating each smart carbon brick stacked inside the furnace body; identifying the eroded smart carbon brick based on changes in output resistance values; and determining the location of the eroded smart carbon brick based on its number. In this embodiment, by numbering and locating each brick, the erosion location can be determined through abnormal output resistance signals.

[0120] In one specific embodiment of this application, the erosion situation also includes the severity of erosion. The severity of erosion refers to the severity of erosion of the carbon brick body of the eroded smart carbon brick. The method for determining the severity of erosion includes: after the smart carbon bricks are stacked, the extension direction of the patterned thin film resistor on them is consistent with the horizontal direction. The remaining effective length of the patterned thin film resistor is determined according to the output resistance value. The remaining thickness of the carbon brick body is determined according to the remaining effective length. The remaining effective length is positively correlated with the remaining thickness of the carbon brick body, and the remaining thickness of the carbon brick body is negatively correlated with the severity of erosion.

[0121] In one specific embodiment of this application, patterned thin-film resistors are connected by wires to monitor the output resistance values ​​of the patterned thin-film resistors on all smart carbon bricks. Since the smart carbon bricks are stacked layer by layer around the furnace wall, the wires connecting the patterned thin-film resistors to each layer of thin-film electrical sensors can be bundled together, meaning the signals from each layer are concentrated and led out via wires to monitor the output resistance values ​​of all smart carbon bricks online. Furthermore, conductive silver paste can be used as the connecting material between the wires and the patterned thin-film resistors.

[0122] The embodiments of this application also provide a carbon brick thickness measurement system, including several smart carbon bricks as described in the above embodiments, which are stacked layer by layer along the inner wall of the furnace body; it also includes a monitoring module, which is used to monitor the output resistance value of the patterned thin film resistor on all smart carbon bricks, determine the erosion status of the smart carbon bricks based on the magnitude and changes of the output resistance value, and determine the carbon brick body thickness based on the erosion status of the smart carbon bricks.

[0123] In one specific embodiment of this application, after the smart carbon bricks are stacked, the extension direction of the patterned thin-film resistors on them is consistent with the horizontal direction. Generally, carbon bricks are laid horizontally; therefore, when the extension direction of the patterned thin-film resistors on the smart carbon bricks is consistent with the horizontal direction, the variation law of the remaining effective length of the patterned thin-film resistors can be consistent with the variation law of the remaining thickness of the carbon brick body.

[0124] In one specific embodiment of this application, the carbon brick thickness measurement system further includes several wires for connecting patterned thin-film resistors, so that the monitoring module can acquire the output resistance values ​​of the patterned thin-film resistors on all smart carbon bricks.

[0125] It should be noted that the carbon brick thickness measurement system and the carbon brick thickness measurement method provided in the above embodiments belong to the same concept. The specific operation methods of each module and unit have been described in detail in the method embodiments and will not be repeated here. In practical applications, the carbon brick thickness measurement system provided in the above embodiments can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. This is not a limitation here.

[0126] The intelligent carbon brick and carbon brick thickness measurement method and system mentioned in the above embodiments of this application are applicable not only to blast furnace scenarios, but also to other types of metallurgical reactors, such as various steelmaking furnaces, molten iron ladles, cupola furnaces, glass melting furnaces and other furnaces, and are also applicable to other scenarios that require the use of refractory bricks and temperature monitoring.

[0127] The above embodiments are merely illustrative of the principles and effects of this application and are not intended to limit this application. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this application should still be covered by the claims of this application.

Claims

1. A smart carbon brick, characterized in that, The device includes a carbon brick body and a thin-film electrical sensor fixed to the surface of the carbon brick body. The thin-film electrical sensor is a multilayer heterogeneous thin-film structure, including a first insulating protective layer, a metal functional layer, a second insulating protective layer, and a second transition connection layer. The first insulating protective layer is a thin film formed by depositing inorganic insulating material. The metal functional layer is a patterned thin-film resistor deposited on the first insulating protective layer, extending from one end of the carbon brick body to the other end. The second insulating protective layer is a thin film formed by depositing inorganic insulating material on the first insulating protective layer and the metal functional layer. The second transition connection layer is a thin film attached to the second insulating protective layer and made of organic insulating material, with the other side of the second transition connection layer attached to the surface of the carbon brick body.

2. The intelligent carbon brick according to claim 1, characterized in that: The inorganic insulating material is selected from at least one of silicon dioxide, silicon nitride, aluminum oxide, aluminum nitride, and boron nitride. And / or, the raw materials for preparing the metal functional layer are selected from at least one of chromium, platinum, and chromium-platinum alloys; And / or, the organic insulating material is selected from at least one of polyimide, polyethylene, polyvinylidene fluoride, and polytetrafluoroethylene; And / or, the first insulating protective layer and the second insulating protective layer are formed by physical vapor deposition or chemical vapor deposition. And / or, the patterned thin-film resistor is deposited by combining physical vapor deposition or chemical vapor deposition with hard mask etching. And / or, the second transition bonding layer is prepared by a spin coating process.

3. The intelligent carbon brick according to claim 1, characterized in that: The patterned thin-film resistor includes a plurality of first thin-film resistors and a plurality of second thin-film resistors. The plurality of first thin-film resistors are arranged at intervals along one end of the carbon brick body to the other end and are connected in parallel. A second thin-film resistor is disposed between two adjacent first thin-film resistors, and the second thin-film resistor is connected in series with the adjacent first thin-film resistor.

4. The intelligent carbon brick according to claim 3, characterized in that: If the resistance value of the first thin-film resistor is much greater than the resistance value of the second thin-film resistor, that is, the ratio of the resistance value of the first thin-film resistor to the resistance value of the second thin-film resistor is not less than 100, then the equivalent resistance of the patterned thin-film resistor satisfies the following condition: In the formula, The equivalent resistance of the patterned thin-film resistor is given. The resistance value of the first thin-film resistor. The number of the first thin-film resistors.

5. The intelligent carbon brick according to claim 1, characterized in that: The second transition bonding layer is attached to the surface of the carbon brick body by means of an adhesive and hot rolling curing, so that the thin film electrical sensor is fixed on the surface of the carbon brick body.

6. The intelligent carbon brick according to claim 5, characterized in that: The method for fixing the thin-film electrical sensor to the surface of the carbon brick body includes: A thin film is prepared on a substrate using an organic insulating material as the first transition bonding layer; The first insulating protective layer, the metal functional layer, the second insulating protective layer, and the second transition connection layer are sequentially prepared on the first transition connection layer. The second transition bonding layer is attached to the surface of the carbon brick body by using an adhesive and hot rolling curing method; The substrate is separated from the first transition connection layer, and then the first transition connection layer is removed, so that the thin-film electrical sensor is fixed on the surface of the carbon brick body.

7. The intelligent carbon brick according to claim 6, characterized in that: The substrate is selected from any one of glass substrates, glazed ceramic substrates, sapphire substrates, and single-crystal silicon substrates; And / or, the first transition interconnect layer is removed by plasma etching.

8. The intelligent carbon brick according to claim 7, characterized in that: The method of separating the substrate from the first transition connection layer includes: immersing the substrate and the first transition connection layer in warm water, and then peeling the first transition connection layer off the substrate.

9. The method for preparing intelligent carbon bricks according to any one of claims 1 to 8, characterized in that, Includes the following steps: A thin film is prepared on a substrate using an organic insulating material as the first transition bonding layer; An inorganic insulating material is deposited on the first transition connection layer to form a thin film, which serves as the first insulating protective layer. A patterned thin-film resistor is deposited on the first insulating protective layer as the metal functional layer; An inorganic insulating material is deposited on the first insulating protective layer and the metal functional layer to form a thin film, which serves as the second insulating protective layer. An organic insulating material is deposited on the second insulating protective layer to form a thin film, which serves as the second transition connection layer. An adhesive is applied to the second transition bonding layer and / or the surface of the carbon brick body, and the second transition bonding layer is bonded to the surface of the carbon brick body by hot rolling curing. The substrate is separated from the first transition connection layer, and then the first transition connection layer is removed to obtain the smart carbon brick.

10. A method for measuring the excess thickness of carbon bricks, characterized in that, The process includes the following steps: stacking the smart carbon bricks as described in any one of claims 1 to 8 layer by layer along the inner wall of the furnace body; monitoring the output resistance value of the patterned thin film resistors on all smart carbon bricks; determining the erosion status of the smart carbon bricks based on the magnitude and changes in the output resistance value; and determining the remaining thickness of the carbon brick body based on the erosion status of the smart carbon bricks.

11. The method for measuring the remaining thickness of carbon bricks according to claim 10, characterized in that, The erosion situation includes the erosion location, which is the position of the eroded smart carbon brick inside the furnace body. The method for determining the erosion location includes: numbering and locating each smart carbon brick stacked inside the furnace body, determining the eroded smart carbon brick based on the change in output resistance value, and determining the location of the eroded smart carbon brick based on the number.

12. The method for measuring the remaining thickness of carbon bricks according to claim 10, characterized in that, The corrosion situation also includes the degree of corrosion severity, which refers to the degree of corrosion of the carbon brick body of the eroded smart carbon brick. The method for determining the degree of corrosion severity includes: after the smart carbon bricks are stacked, the extension direction of the patterned thin film resistor on them is consistent with the horizontal direction. The remaining effective length of the patterned thin film resistor is determined according to the output resistance value. The remaining thickness of the carbon brick body is determined according to the remaining effective length. The remaining effective length is positively correlated with the remaining thickness of the carbon brick body, and the remaining thickness of the carbon brick body is negatively correlated with the degree of corrosion severity.

13. A system for measuring the excess thickness of carbon bricks, characterized in that: Includes several smart carbon bricks as described in any one of claims 1 to 8, wherein the smart carbon bricks are stacked layer by layer along the perimeter of the inner wall of the furnace body; It also includes a monitoring module, which is used to monitor the output resistance value of the patterned thin film resistors on all smart carbon bricks, determine the erosion status of the smart carbon bricks based on the magnitude and changes of the output resistance value, and determine the remaining thickness of the carbon brick body based on the erosion status of the smart carbon bricks.

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