Digital tapping channel and optimization method thereof

Abstract

The invention discloses a digital tapping channel and an optimization method thereof, and belongs to the technical field of operation and maintenance of blast furnace tapping channels.The digital tapping channel is provided with a temperature sensor and a warning interlayer, dual monitoring of the tapping channel is achieved, when the tapping channel is in an abnormal working state, an alarm is given in time, and the safety of the tapping channel is improved. Therefore, the working layer of the tapping channel is prevented from being eroded and perforated to damage the steel tank structure and the permanent layer. Compared with the mode that the service cycle of the working layer is set according to experience habits and the working layer is directly replaced after the service cycle is reached in the prior art, the working layer can be utilized to the maximum extent on the premise that safety is guaranteed by reasonably arranging the warning interlayer and adjusting the distance between the warning interlayer and the permanent layer, and the service life of the working layer is prolonged. Therefore, the effect of reducing the time cost and the economic cost of operation and maintenance of the tapping channel is achieved.

Description

Technical Field

[0001] The present invention belongs to the technical field of blast furnace tapping channel operation and maintenance, and specifically relates to a digital tapping channel and an optimization method thereof. Background Art

[0002] The main iron trough is part of the blast furnace process, used to transport molten iron and slag from the tap hole to the diversion area. In a high temperature environment, the refractory material of the iron trough is easily corroded, causing safety hazards and high maintenance costs.

[0003] The main iron groove generally includes a permanent layer and a working layer. The working layer is generally preset with a usage time or usage cycle based on experience, and is replaced at regular intervals or cycles to avoid damage to the permanent layer caused by erosion and perforation of the working layer. On the one hand, this method cannot monitor the working layer in real time, and cannot respond and handle problems such as erosion and perforation that may cause destructive damage to the permanent layer in a timely manner. On the other hand, since the replacement is carried out according to the prescribed time and cycle, the working layer cannot be fully utilized, resulting in an increase in the economic cost of replacing the working layer and the maintenance time cost, all of which are not conducive to cost reduction and efficiency improvement of the blast furnace process. In order to solve the above problems, the present invention provides the following technical solutions. Summary of the invention

[0004] The purpose of the present invention is to provide a digital iron outlet groove and its optimization method, so as to solve the problem of increased economic and time costs caused by the method in the prior art that the working layer is generally preset with a usage time or usage cycle based on experience and is replaced at regular intervals or cycles.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] Digital tapping channel, including main structure layer, permanent layer and working layer arranged from outside to inside;

[0007] An air duct is formed between the permanent layer and the main structural layer;

[0008] A warning interlayer is provided in the working layer, and the warning interlayer outputs a relevant signal after contacting molten iron. When the controller receives and identifies the relevant signal, it considers that the working layer has a large loss and needs to be replaced.

[0009] Furthermore, at least one fan is arranged in the air duct along the length direction.

[0010] Furthermore, an air duct cover is provided on the top of the air duct.

[0011] Furthermore, the warning interlayer is a laid layer of optical fiber network or conductive material.

[0012] Furthermore, when the temperature detection value of at least one temperature sensor is greater than or equal to its corresponding preset threshold value Ty, it is considered that there is an abnormality at the position detected by the corresponding temperature sensor.

[0013] Furthermore, the optimization method of the digital iron trough includes the following steps:

[0014] Establish a temperature field simulation model of the digital iron outlet channel when it is working, analyze and process the temperature field simulation model, obtain the temperature contour line corresponding to the preset temperature threshold Ty1, and mark the temperature contour line as the first temperature alarm line;

[0015] Obtain the temperature distribution area between the first temperature alarm line and the temperature contour line corresponding to Ty1-Tw, and mark the temperature distribution area as the first warning area, where Tw is a preset temperature difference;

[0016] When laying the warning interlayer, lay the warning interlayer within the coverage of the first warning area, or

[0017] The warning interlayer is laid on a continuous surface where the distance between each point in the working layer and the permanent layer is d, and d is the distance between the point closest to the permanent layer in the first warning area and the permanent layer.

[0018] Furthermore, the optimization method of the digital iron trough includes the following steps:

[0019] By analyzing and processing the temperature field simulation model, a temperature contour line corresponding to a preset temperature threshold Ty2 is obtained, and the temperature contour line is marked as a second temperature alarm line;

[0020] Obtain the temperature distribution area between the second temperature alarm line and the temperature contour line corresponding to Ty2-Tw, and mark the temperature distribution area as the second warning area;

[0021] When installing the temperature sensor, set the temperature acquisition port of the temperature sensor on a continuous surface where each point is at the same distance from the working layer or in the second warning area;

[0022] When the temperature acquisition ports of the temperature sensors are arranged on a continuous surface where the distances from each point to the working layer are the same, the temperature range of the location of the temperature acquisition ports of each temperature sensor is obtained according to the temperature field simulation model, and the preset temperature threshold Ty corresponding to each temperature sensor is determined within the temperature range;

[0023] When the temperature acquisition port of the temperature sensor is set in the second warning area, the temperature range corresponding to the second warning area is obtained, and the preset threshold value Ty corresponding to each temperature sensor is determined in the temperature range.

[0024] Furthermore, the optimization method of the digital iron trough includes the following steps:

[0025] Establish a flow simulation model for the digital tapping channel when tapping molten iron and slag;

[0026] Obtain the shear stress variation over time at the bottom and side of the iron outlet channel;

[0027] For areas where the shear stress is greater than the preset value, the service life of the working layer at the corresponding position can be increased by reshaping the shape, replacing the working layer material with a more corrosion-resistant material, and increasing the thickness of the working layer.

[0028] Furthermore, the optimization method of the digital iron outlet groove includes: taking the position where the molten iron enters and impacts the iron outlet groove as the center, transforming the side parts of the iron outlet groove on both sides of the center into arcs with a diameter greater than the width of the iron outlet groove.

[0029] Further, the optimization method of the digital iron trough includes:

[0030] Divide the iron trough into n sections along the length direction;

[0031] Obtain the maximum shear stress of the working layer within each section of the iron outlet channel after the molten iron flow state is stabilized;

[0032] The material and / or thickness of the working layer of each section is adjusted according to the maximum shear stress, and the greater the corresponding maximum shear stress, the more corrosion-resistant the material of the working layer is and / or the greater the thickness of the working layer is.

[0033] Beneficial effects of the present invention:

[0034] 1. The present invention realizes dual monitoring of the iron outlet trough by arranging temperature sensors and warning interlayers. When the iron outlet trough is in abnormal working state, an alarm is given in time, thereby avoiding erosion and perforation of the working layer of the iron outlet trough and damage to the steel trough structure and the permanent layer.

[0035] 2. Compared with the prior art method of setting the use cycle of the working layer according to experience and practice, and directly replacing it after the use cycle is reached, the present invention can maximize the use of the working layer while ensuring safety by reasonably arranging the warning interlayer and adjusting the distance between the warning interlayer and the permanent layer, thereby achieving the effect of cost saving.

[0036] 3. By optimizing the setting position of the warning layer, the present invention can greatly improve the utilization rate of the working layer while ensuring the normal and safe operation of the working layer, thereby reducing the replacement cost of the working layer.

[0037] 4. The present invention can optimize the alarm timing of the temperature sensor by optimizing the setting position of the temperature sensor or optimizing the warning temperature, thereby improving the accuracy of the temperature sensor alarm.

[0038] 5. By optimizing the shape and structure of the working layer, the service life of the areas that are more prone to erosion can be ensured, thereby improving the overall service life of the working layer, improving the utilization rate of the working layer, and reducing the time and economic costs of iron ditch operation and maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The present invention will be further described below in conjunction with the accompanying drawings.

[0040] Figure 1 It is a structural schematic diagram of a digital iron outlet channel of the present invention;

[0041] Figure 2 It is a temperature field simulation model of the positive cross section of the digital iron outlet channel of the present invention;

[0042] Figure 3 It is a flow simulation model of the digital iron outlet channel of the present invention;

[0043] Figure 4 It is a simulation diagram of the shear stress at the bottom of the iron ditch changing with time;

[0044] Figure 5 It is a simulation diagram of the shear stress on the side of the iron groove changing with time. DETAILED DESCRIPTION

[0045] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0046] A digital iron channel, such as Figure 1 As shown, it includes a main structure layer 1, a permanent layer 3, and a working layer 4 arranged in sequence from the outside to the inside;

[0047] A certain gap is left between the permanent layer 3 and the main structure layer 1 to form an air duct 2. When working, the heat dissipation is accelerated by creating a flowing air condition in the air duct 2. In a specific solution, at least one fan can be arranged along the length direction of the air duct 2 to promote the air flow in the air duct 2, thereby achieving heat dissipation;

[0048] In order to ensure safety and prevent debris from entering the air duct 2, an air duct cover plate 5 is also provided on the top of the air duct 2 formed between the permanent layer 3 and the main structure 1;

[0049] The permanent layer 3 is supported and fixed on the main structure layer 1 by a steel trough structure, the positive cross section of the steel trough structure is U-shaped, and the outer side of the steel trough structure is fixedly installed on the main structure layer 1 by a connecting piece;

[0050] In a specific embodiment, the connecting member includes a plurality of rows of first connecting members arranged on two sides of the steel channel structure close to the main structure 1, and two ends of the first connecting members are respectively fixedly connected to the outer surface of the steel channel structure and the main structure layer 1;

[0051] The connecting piece also includes a plurality of second connecting pieces fixed to the bottom of the steel trough structure and laid along the length direction of the iron outlet groove, with a certain gap left between two adjacent second connecting pieces, so as to ensure ventilation and heat dissipation at the bottom of the steel trough structure;

[0052] In a specific solution of the present invention, the digital iron outlet groove further includes distributed temperature sensors 6, which are used to detect the temperature of a part of the iron outlet groove. The temperature sensors 6 are arranged in a manner that a row of temperature sensors are arranged on both side walls of the permanent layer 3 close to the main structure 1, respectively, so as to ensure that the arranged temperature sensors 6 can cover the entire iron outlet groove;

[0053] During operation, when the temperature detection value of at least one temperature sensor 6 is greater than or equal to its corresponding preset threshold value Ty, it is considered that the position detected by the corresponding temperature sensor 6 is abnormal;

[0054] The working layer 4 is provided with a warning interlayer. When the working layer 4 is eroded due to long-term operation or other reasons, and when the erosion reaches a certain degree (generally when the working layer is damaged to the point where there is a high risk of perforation during the next operation), the molten iron will contact the warning interlayer in the working layer 4. After contacting the molten iron, the warning interlayer outputs a relevant signal. When the controller receives and identifies the relevant signal, it considers that the working layer 4 is damaged greatly and needs to be replaced.

[0055] The warning interlayer may be a layer of optical fiber network or conductive material laid out, so as to identify the burn-through phenomenon and the burn-through position of the working layer;

[0056] Specifically, the setting position of the warning interlayer (i.e., the distance between the warning interlayer and the permanent layer 3) can also be adjusted as needed, so as to determine the replacement timing of the working layer 4; for ease of understanding, an example is given below:

[0057] The production party has the conditions to replace the working layer 4 after the controller receives and identifies the relevant signal and the molten iron discharge work in the current cycle is completed, or

[0058] After the controller receives and identifies the relevant signal, the producer can still carry out several cycles of molten iron discharge work before replacing the working layer 4; generally speaking, under the same other conditions, the distance between the warning interlayer and the permanent layer 3 set in the latter is greater than the distance between the warning interlayer and the permanent layer 3 set in the former. The specific setting method can be determined according to the actual situation and needs of the producer.

[0059] In order to facilitate the intuitive expression of the alarm, the present invention also provides an alarm method for a digital iron outlet channel, which specifically includes the following steps:

[0060] A model of the iron outlet channel is established on the human-machine interaction interface. The model may be a plane model or a three-dimensional model that can display the layout positions of the temperature sensor 6 and / or the warning interlayer;

[0061] When an alarm message is issued at a certain position of the corresponding temperature sensor 6 and / or the warning interlayer, the corresponding position of the temperature sensor 6 and / or the warning interlayer is highlighted on the model (such as changing color, etc.), and a warning is given through sound and light alarms.

[0062] This method can intuitively express the location of abnormalities in the iron outlet ditch, making it convenient for staff to quickly and accurately locate abnormalities.

[0063] The present invention realizes dual monitoring of the iron outlet channel by providing a temperature sensor 6 and a warning interlayer, and promptly issues an alarm when the iron outlet channel is in an abnormal working state, thereby preventing the working layer 4 of the iron outlet channel from being corroded and perforated, and damaging the steel channel structure and the permanent layer 3;

[0064] In addition, compared with the prior art method of setting the service life of the working layer 4 according to experience and practice, and directly replacing it after the service life is reached, the present invention can maximize the use of the working layer 4 while ensuring safety by reasonably arranging the warning interlayer and adjusting the distance between the warning interlayer and the permanent layer, thereby achieving the effect of cost saving.

[0065] The digital iron tapping ditch optimization method based on the digital iron tapping ditch comprises the following steps:

[0066] S1. Establish a temperature field simulation model of the digital iron outlet channel during operation. The temperature field simulation model is as follows: Figure 2 As shown, by analyzing and processing the temperature field simulation model, the temperature regional distribution of the iron outlet channel cross section is obtained, the temperature contour line corresponding to the preset temperature threshold Ty1 is obtained, and the temperature contour line is marked as the first temperature alarm line;

[0067] The part where the temperature of the iron outlet channel is greater than the temperature threshold Ty1 will experience more obvious and rapid erosion, and its specific setting is set according to the material of the working layer, etc.

[0068] Obtain the temperature distribution area between the first temperature alarm line and the temperature contour line corresponding to Ty1-Tw, and mark the temperature distribution area as the first warning area, where Tw is a preset temperature difference;

[0069] When laying the warning interlayer, lay the warning interlayer within the coverage of the first warning area, or

[0070] First, obtain the distance d between the point closest to the permanent layer 3 in the first warning area and the permanent layer 3. When laying the warning interlayer, lay the warning interlayer on a continuous surface where the distance between each point in the working layer 4 and the permanent layer 3 is d;

[0071] The latter is more convenient to construct and has lower construction cost. When a molten iron contact signal is detected at the corresponding point on the warning interlayer (generally speaking, the point closest to the permanent layer 3 in the first warning area), it is considered that the corresponding working layer 4 cannot continue to work normally. The working layer 4 is replaced after the current molten iron discharge cycle is completed or after a preset number of cycles after the current molten iron discharge cycle is completed. This can greatly improve the utilization rate of the working layer 4 while ensuring the normal and safe operation of the working layer 4, thereby reducing the replacement cost of the working layer 4.

[0072] For the former (laying the warning interlayer within the coverage of the first warning area), the construction is more difficult, but compared with the method of laying the warning interlayer on a continuous surface with each point at an equal distance from the permanent layer 3, it can improve safety. Specifically: the latter laying method focuses on those points with the most serious erosion. At these points, when the dangerous erosion points cannot be accurately and timely detected due to reasons such as detection accuracy and warning interlayer coverage density, there will be a risk of damaging the permanent layer 3. The former laying method can comprehensively consider the erosion rate of each point, thereby having higher safety.

[0073] S2. Establish a temperature field simulation model of the digital iron outlet channel when it is working, and obtain the temperature area distribution of the iron outlet channel cross section by analyzing and processing the temperature field simulation model;

[0074] Obtain a temperature contour line corresponding to a preset temperature threshold value Ty2, and mark the temperature contour line as a second temperature alarm line;

[0075] Obtain the temperature distribution area between the second temperature alarm line and the temperature contour line corresponding to Ty2-Tw, and mark the temperature distribution area as the second warning area;

[0076] When installing the temperature sensor 6, the temperature acquisition port of the temperature sensor 6 can be set on a continuous surface where each point is at the same distance from the working layer or

[0077] When installing the temperature sensor 6, the temperature collection port of the temperature sensor 6 can be set in the second warning area;

[0078] When the temperature acquisition port of the temperature sensor 6 is set on a continuous surface where the distance from each point to the working layer is the same, the laying cost is the lowest. At this time, the temperature range of the location of the temperature acquisition port of each temperature sensor 6 is obtained according to the temperature field simulation model of the digital iron outlet channel when it is working, and the warning temperature corresponding to each temperature sensor 6 is determined according to the temperature range, that is, the preset temperature threshold Ty mentioned above. At this time, the warning temperature corresponding to each temperature sensor 6 will be different according to its position;

[0079] When the temperature acquisition port of the temperature sensor 6 is set in the second warning area, the temperature range corresponding to the second warning area is obtained, and the warning temperature corresponding to each temperature sensor 6 is determined according to the temperature range, that is, the preset threshold Ty mentioned above. At this time, the warning temperatures corresponding to each temperature sensor 6 are the same;

[0080] By optimizing the setting position of the temperature sensor 6 or optimizing the warning temperature, the alarm timing of the temperature sensor 6 can be optimized and guided, thereby improving the accuracy of the alarm of the temperature sensor 6.

[0081] S3. Establish a flow simulation model of the digital iron tapping channel when tapping molten iron and slag. The flow simulation model is as follows: Figures 3 to 5 As shown in the figure, the simulation model can show the molten iron flow in each cross section of the iron channel and the shear stress variation over time at the bottom and side of the iron channel.

[0082] The iron trough structure is optimized according to the flow simulation model.

[0083] The optimization method is as follows:

[0084] Obtain the shear stress variation over time at the bottom and side of the iron outlet channel;

[0085] For areas with large shear stress after the flow state stabilizes, various methods that can improve the erosion resistance can be used for transformation, such as shape modification, replacement of more erosion-resistant working layer materials, and increasing the thickness of the working layer.

[0086] For ease of understanding, specific examples are given below:

[0087] Taking the position where the molten iron enters and impacts the iron outlet groove as the center, the side parts of the iron outlet groove on both sides of the center are transformed into arcs with a diameter greater than the width of the iron outlet groove;

[0088] The position where the molten iron enters and impacts the iron outlet trough is taken as the center, and the bottom surface of the iron outlet trough covered by a circle with a radius of a preset value r1 and the center is taken as the center, and the working layer material with a more corrosion-resistant material or

[0089] The bottom surface of the iron outlet groove covered by a circle with a radius of a preset value r1 and the center of the circle is thickened. As a more detailed expansion plan, the thickness can be thickened in a manner that the greater the shear stress, the greater the corresponding thickness increase;

[0090] The circle with a radius of the preset value r1 can cover the area with large shear stress on the bottom surface of the iron outlet groove after the flow state stabilizes.

[0091] Here are some examples:

[0092] Divide the iron trough into n sections along the length direction;

[0093] Obtaining the maximum shear stress of the working layer 4 within each section of the iron outlet channel after the molten iron flow state is stabilized;

[0094] The material and / or thickness of each section of the working layer 4 is adjusted according to the maximum shear stress, and the greater the corresponding maximum shear stress, the more corrosion-resistant the material of the working layer 4 is and / or the greater the thickness of the working layer 4 is.

[0095] Through the optimization method in step S3, the present invention can reasonably optimize the working layer 4 at the local position of the iron outlet groove, so as to ensure the service life of the places more prone to erosion, thereby improving the overall service life of the working layer 4, improving the utilization rate of the working layer 4, and reducing the time cost and economic cost of the iron outlet groove operation and maintenance.

[0096] It should be noted that, under the condition of obtaining relevant data, the method of establishing a temperature field simulation model and a flow simulation model of the iron outlet channel belongs to the prior art, and thus will not be described in detail.

[0097] The above contents are merely examples and explanations of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the invention or exceed the scope defined by the claims, they shall all fall within the protection scope of the present invention.

Claims

1. The digital iron trough includes a main structure layer, a permanent layer, and a working layer arranged in sequence from the outside to the inside, and is characterized by: An air duct is formed between the permanent layer and the main structural layer; A warning interlayer is provided in the working layer, and the warning interlayer outputs a relevant signal after contacting molten iron. When the controller receives and identifies the relevant signal, it considers that the working layer has a large loss and needs to be replaced.

2. The digital iron outlet channel according to claim 1, characterized in that: At least one fan is arranged in the air duct along the length direction.

3. The digital iron outlet channel according to claim 1, characterized in that: An air duct cover plate is arranged on the top of the air duct.

4. The digital iron outlet channel according to claim 1, characterized in that: The warning interlayer is a layer of optical fiber network or conductive material laid out.

5. The digital iron outlet channel according to claim 1, characterized in that: It also includes distributed temperature sensors. When the temperature detection value of at least one temperature sensor is greater than or equal to its corresponding preset threshold Ty, it is considered that the position detected by the corresponding temperature sensor is abnormal.

6. The method for optimizing a digital iron channel according to claim 1, characterized in that: The steps include: Establish a temperature field simulation model of the digital iron outlet channel when it is working, analyze and process the temperature field simulation model, obtain the temperature contour line corresponding to the preset temperature threshold Ty1, and mark the temperature contour line as the first temperature alarm line; Obtain the temperature distribution area between the first temperature alarm line and the temperature contour line corresponding to Ty1-Tw, and mark the temperature distribution area as the first warning area, where Tw is a preset temperature difference; When laying the warning interlayer, lay the warning interlayer within the coverage of the first warning area, or The warning interlayer is laid on a continuous surface where the distance between each point in the working layer and the permanent layer is d, and d is the distance between the point closest to the permanent layer in the first warning area and the permanent layer.

7. The method for optimizing a digital iron channel according to claim 6, characterized in that: The steps include: By analyzing and processing the temperature field simulation model, a temperature contour line corresponding to a preset temperature threshold Ty2 is obtained, and the temperature contour line is marked as a second temperature alarm line; Obtain the temperature distribution area between the second temperature alarm line and the temperature contour line corresponding to Ty2-Tw, and mark the temperature distribution area as the second warning area; When installing the temperature sensor, set the temperature acquisition port of the temperature sensor on a continuous surface where each point is at the same distance from the working layer or in the second warning area; When the temperature acquisition ports of the temperature sensors are arranged on a continuous surface where the distances from each point to the working layer are the same, the temperature range of the location of the temperature acquisition ports of each temperature sensor is obtained according to the temperature field simulation model, and the preset temperature threshold Ty corresponding to each temperature sensor is determined within the temperature range; When the temperature acquisition port of the temperature sensor is set in the second warning area, the temperature range corresponding to the second warning area is obtained, and the preset threshold value Ty corresponding to each temperature sensor is determined in the temperature range.

8. The method for optimizing a digital iron channel according to claim 1, characterized in that: The steps include: Establish a flow simulation model for the digital tapping channel when tapping molten iron and slag; Obtain the shear stress variation over time at the bottom and side of the iron outlet channel; For areas where the shear stress is greater than the preset value, the service life of the working layer at the corresponding position can be increased by reshaping the shape, replacing the working layer material with a more corrosion-resistant material, and increasing the thickness of the working layer.

9. The method for optimizing a digital iron channel according to claim 8, characterized in that: include: Taking the position where molten iron enters and impacts the iron outlet groove as the center, the side parts of the iron outlet groove on both sides of the center are transformed into arcs with a diameter greater than the width of the iron outlet groove.

10. The method for optimizing a digital iron channel according to claim 8, characterized in that: include: Divide the iron trough into n sections along the length direction; Obtain the maximum shear stress of the working layer within each section of the iron outlet channel after the molten iron flow state is stabilized; The material and / or thickness of the working layer of each section is adjusted according to the maximum shear stress, and the greater the corresponding maximum shear stress, the more corrosion-resistant the material of the working layer is and / or the greater the thickness of the working layer is.

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