CFD-based blast furnace tuyere temperature field online monitoring and visualization system

Abstract

The invention relates to a CFD-based blast-furnace tuyere temperature field on-line monitoring and visualization system. The system comprises a data automatic acquisition module, a three-dimensional automatic modeling module, a space automatic discretization module, an iteration automatic solving module, a data visualization module and a chart analysis module. The iteration automatic solving module is used for a CFD solver to carry out parameterization automatic iteration solving according to the boundary conditions and the grid data file, and an air outlet temperature field is calculated; and the data visualization module is used for performing simulation display on the air outlet temperature field result of the iteration automatic solving module on a client interface. On-line simulation is carried out on the basis of on-site process parameters and equipment parameters, which is equivalent to digital twinning of the blast furnace tuyere working state, so that a'black box 'state of a blast furnace can be opened, and the digitization and visualization level of the blast furnace is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of blast furnace ironmaking, and in particular to a CFD-based blast furnace tuyere temperature field online monitoring and visualization system. Background Art

[0002] The tuyere of a blast furnace is an important medium for hot air to enter the blast furnace. The tuyere not only has to contact with high-temperature hot air at about 1250℃, but also has to withstand the radiation heat exchange of high-temperature coal gas at about 2400℃. Therefore, the tuyere must be cooled to extend its life. The tuyere is generally cast from copper, and its recrystallization temperature is generally between 200℃ and 400℃. With the occurrence of tuyere recrystallization, the thermal conductivity will further decrease, which will lead to a gradual increase in the maximum temperature of the tuyere and a shortening of the tuyere life, affecting the normal production of the blast furnace. Nowadays, with the rapid development of computational physics, the use of CFD technology combined with on-site hardware sensors to monitor the temperature field of the blast furnace tuyere online can realize an early warning of excessive temperature at the blast furnace tuyere, which is also conducive to opening the "black box" state of the blast furnace and improving the digitalization and visualization level of the blast furnace. Summary of the invention

[0003] In view of the lack of tuyere temperature field status monitoring during the normal production process of the blast furnace, it is difficult to judge the working status of the blast furnace tuyere. The present invention provides a blast furnace tuyere temperature field online monitoring and visualization system based on CFD. The method realizes automatic online calculation of the blast furnace tuyere temperature field through an automatic data acquisition module, a three-dimensional automatic modeling module, a spatial automatic discretization module, and an iterative automatic solution module. Finally, the three-dimensional visualization of the blast furnace tuyere temperature field is realized by developing a data visualization client.

[0004] A CFD-based blast furnace tuyere temperature field online monitoring and visualization system comprises an automatic data acquisition module, a three-dimensional automatic modeling module, a spatial automatic discretization module, an iterative automatic solution module, a data visualization module and a chart analysis module, wherein: the automatic data acquisition module comprises online acquisition of the tuyere whirlpool temperature monitored by a tuyere thermal imager and the tuyere cooling water flow monitored by a flowmeter as boundary conditions through communication protocols such as OPC or Modbus, and accesses a field database through a TCP protocol to obtain tuyere structural parameters such as tuyere length, tuyere diameter and tuyere downward inclination angle.

[0005] The three-dimensional automatic modeling module includes writing a modeling script using the three-dimensional modeling software FreeCAD or Blender, and then performing parametric automatic modeling using the three-dimensional model structure parameters (air outlet length, air outlet diameter, and air outlet downward angle) obtained by the data acquisition module, and automatically exporting a general stl format three-dimensional model file.

[0006] The space automatic discretization module includes using the meshing software Gmsh or Cfmesh to write a meshing script, parameterizing and automatically meshing the automatically exported general stl format three-dimensional model file, and automatically exporting the mesh data file.

[0007] The iterative automatic solution module includes using the CFD solver OpenFOAM or SU2 to write an iterative calculation script, performing parameterized automatic iterative solution on the boundary conditions obtained by the data acquisition module and the automatically generated grid file, and automatically exporting the calculation results of the tuyere temperature field.

[0008] The data visualization module includes three-dimensional visualization of CFD calculation results, and can realize visualization functions such as mouse rotation, zooming, slicing, and splitting.

[0009] The chart analysis includes drawing a two-dimensional curve of the CFD calculation results, and can perform data analysis on the historical maximum temperature of the tuyere.

[0010] Compared with the prior art, the present invention has at least the following advantages:

[0011] The present invention develops an online visualization system of the blast furnace tuyere temperature field based on CFD, connects the system with field sensors and databases, and can realize online calculation and visualization of the blast furnace tuyere temperature field. The invention performs online simulation based on field process parameters and equipment parameters, which is equivalent to the digital twin of the blast furnace tuyere working state, which is conducive to opening the "black box" state of the blast furnace and improving the digitization and visualization level of the blast furnace. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 The framework diagram of the online visualization system of blast furnace tuyere temperature field based on CFD DETAILED DESCRIPTION

[0013] The present invention is described in further detail below.

[0014] The present invention is an online monitoring and visualization system for the temperature field of a blast furnace tuyere based on computational fluid dynamics (CFD). The system uses an actual blast furnace tuyere drawing as a virtual physical model, collects the tuyere whirlpool temperature and tuyere cooling water flow rate monitored by a tuyere infrared thermal imager in real time as boundary conditions, collects tuyere structural parameters in real time to perform three-dimensional automatic modeling modules and spatial discretization, solves the blast furnace tuyere temperature field based on a CFD solver, and develops a visualization system to perceive the tuyere working state in real time, and monitors and warns the maximum temperature of the blast furnace tuyere.

[0015] Example 1: Figure 1As shown, the online visualization system of the blast furnace tuyere temperature field is composed of an automatic data acquisition module, a three-dimensional automatic modeling module, an automatic spatial discretization module, an iterative automatic solution module, a data visualization module and a chart analysis module.

[0016] The data acquisition module collects the temperature of the tuyere whirlpool area monitored by the tuyere thermal imager and the tuyere cooling water flow monitored by the ultrasonic flowmeter online as boundary conditions through the OPC or Modbus communication protocol, and accesses the on-site database through the TCP protocol to obtain the tuyere structural parameters, such as the tuyere length, tuyere diameter and tuyere downward inclination angle. It should be pointed out that the data acquisition method is not limited to the above method, as long as the required data can be obtained. In addition, if the on-site secondary system database does not have the above structural dimension data and process parameter data, it needs to be manually input on the client.

[0017] The 3D automatic modeling module uses the 3D modeling software FreeCAD or Blender to write the modeling script, and then uses the 3D model structure parameters (air outlet length, air outlet diameter, air outlet downslope angle) obtained from data collection to perform parametric automatic modeling, and automatically exports the 3D model file in the general STL format. It should be pointed out that if the production site has other modeling software copyrights, commercial modeling software can be used for automated parameter modeling.

[0018] The spatial automatic discretization module uses the meshing software Gmsh or Cfmesh to write a meshing script, perform parameterized automatic meshing on the automatically exported general stl format 3D model file, and automatically export the mesh data file. It should be pointed out that the format of the exported mesh data file should match the CFD solver in the iterative automatic solution module. In addition, if the production site has other meshing software copyrights, commercial meshing software can be used for automatic meshing.

[0019] The iterative automatic solution module uses the CFD solver OpenFOAM or SU2 to write iterative calculation scripts, performs parameterized automatic iterative solutions to automatically acquired boundary conditions and automatically generated mesh data files, automatically exports the calculation results of the tuyere temperature field, and feeds back the solution process log and solution results to the client.

[0020] The iterative automatic solution module uses the CFD solver OpenFOAM or SU2 to write an iterative calculation script based on the boundary conditions obtained by the client, and uses the SIMPLE algorithm to perform simultaneous iterative steady-state solutions to the fluid mass conservation equation, momentum conservation equation, turbulent kinetic energy equation and turbulent kinetic energy dissipation equation. After the solution is completed, the calculation results of the tuyere temperature field are automatically derived, and the solution process log and solution results are fed back to the client.

[0021] It should be pointed out that the format of the exported calculation results should match the data visualization module. In addition, if the production site has other CFD commercial software copyrights, commercial CFD software (Fluent or CFX) can be used for automated iterative solutions.

[0022] The data visualization module includes three-dimensional visualization of CFD calculation results, which can realize visualization functions such as mouse rotation, zooming, slicing, and splitting. It should be pointed out that the visualization of CFD calculation results can be realized using OpenGL or VTK library.

[0023] The chart analysis module includes drawing two-dimensional curves based on CFD calculation results. It can generate customized two-dimensional curves according to different application scenarios, and users can also input data for custom curves. It should be pointed out that two-dimensional chart analysis can also be implemented using the VTK library.

[0024] When all the above processes are completed, the cycle can be re-entered, that is, the temperature field of the tuyere is calculated and analyzed regularly to realize the "digital twin" of the working state of the tuyere. The present invention has developed an online visualization system for the blast furnace tuyere temperature field based on CFD, which can quantitatively evaluate the working state of the blast furnace tuyere temperature field. Secondly, the invention is simulated based on on-site equipment parameters and process parameters, which is equivalent to the digital twin of the local area of ​​the blast furnace tuyere, which is conducive to opening the "black box" state of the blast furnace and improving the digitization and visualization level of the blast furnace.

[0025] Utilizing the technical solution described in the present invention, or those skilled in the art designing a similar technical solution inspired by the technical solution of the present invention to achieve the above-mentioned technical effects, all fall within the protection scope of the present invention.

[0026] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution of the present invention, which should be included in the scope of the claims of the present invention.

Claims

1. A CFD-based blast furnace tuyere temperature field online monitoring and visualization system, characterized by: It includes automatic data acquisition module, 3D automatic modeling module, space automatic discretization module, iterative automatic solution module, data visualization module and chart analysis module, among which: The automatic data acquisition module is used to collect the temperature of the tuyere raceway and the cooling water flow rate of the tuyere online as boundary conditions through the communication protocol, and access the on-site database to obtain the tuyere structure parameters; The three-dimensional automatic modeling module is used to obtain the tuyere structure parameters for modeling and automatically export the three-dimensional model file in a general STL format. The space automatic discretization module is used to parameterize and automatically divide the grid of the general STL format three-dimensional model file, and automatically export the grid data file. The format of the automatically exported general STL format three-dimensional model file matches the CFD solver in the iterative automatic solution module. The iterative automatic solution module is used for the CFD solver to perform parameterized automatic iterative solution according to the boundary conditions and the grid data file, calculate the outlet temperature field, and export the calculation result format to match the data visualization module. The data visualization module is used to simulate and display the air outlet temperature field results of the iterative automatic solution module on the client interface.

2. The CFD-based online monitoring and visualization system for blast furnace tuyere temperature field according to claim 1, characterized in that: The 3D automatic modeling module uses the 3D modeling software FreeCAD or Blender to write a modeling script, and then uses the 3D model structure parameters obtained by data collection, namely the tuyere length, tuyere diameter and tuyere downslope angle, to perform parametric automatic modeling, and automatically exports the 3D model file in a general stl format.

3. The CFD-based online monitoring and visualization system for blast furnace tuyere temperature field according to claim 2, characterized in that: The space automatic discretization module uses the meshing software Gmsh or Cfmesh to write a meshing script, performs parameterized automatic meshing on the automatically exported general stl format three-dimensional model file, and automatically exports the mesh data file.

4. The CFD-based online monitoring and visualization system for blast furnace tuyere temperature field according to claim 3, characterized in that: The iterative automatic solution module uses the CFD solver OpenFOAM or SU2 to write an iterative calculation script, performs parameterized automatic iterative solution on the boundary conditions and mesh data files, automatically exports the calculation results of the tuyere temperature field, and feeds back the solution process log and solution results to the client.

5. The CFD-based online monitoring and visualization system for blast furnace tuyere temperature field according to claim 4, characterized in that: The data visualization module is used to visualize the CFD calculation results in three dimensions using OpenGL or VTK library, and realize mouse rotation, zooming, slicing and splitting.

6. The CFD-based online monitoring and visualization system for blast furnace tuyere temperature field according to claim 4, characterized in that: It also includes a chart analysis module, which is used to draw a two-dimensional curve based on the CFD calculation results.

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