Device and method for monitoring submerged arc furnace on line in real time

Abstract

The invention discloses a device and a method for monitoring a submerged arc furnace on line in real time. The device comprises a thermocouple array, a main junction box, a data acquisition device and a data processing device. The thermocouple array is buried in the furnace bottom and the furnace wall of the submerged arc furnace according to a point distribution rule, is used for collecting temperature data and is connected with the main junction box, the main junction box converts the data and sends the data to the data collecting device, the data collecting device preprocesses and stores the data, and the data processing device is connected with the data collecting device and analyzes and processes the data. And displaying the real-time state of the furnace bottom and the furnace wall of the submerged arc furnace during smelting. The problem that the temperature and the erosion state of the furnace bottom and the furnace wall in an existing submerged arc furnace cannot be monitored on line in real time is solved. The erosion state, the electrode height and the molten pool morphology can be predicted in real time, safety accidents can be effectively prevented, and the safety of the production process is ensured; manual inspection frequency is reduced, maintenance cost is reduced, and production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of metallurgical industry, and in particular to a device and method capable of online real-time monitoring of the erosion state of a furnace bottom and furnace wall of an ore-bearing furnace, aiming to realize accurate prediction of the residual lining thickness and erosion state of the furnace bottom and furnace wall, electrode height and molten pool morphology by real-time monitoring of furnace lining temperature data in the furnace and by mathematical model simulation calculation, so as to provide a scientific basis for the safe operation and efficient maintenance of the ore-bearing furnace. Background Art

[0002] Submerged arc furnace is a kind of equipment used to refine metal ores. It mainly uses carbonaceous reducing agents and solvents to reduce and smelt ores to produce ferrosilicon, ferromanganese, ferrochrome, ferrotungsten, silicon-manganese alloy and other ferroalloys. Ferroalloys are important raw materials in the metallurgical chemical industry. As an important equipment in the smelting industry, the furnace bottom and furnace wall of the submerged arc furnace work in a high temperature and corrosive environment for a long time, which is prone to erosion, affecting the service life of the furnace; the electrode height and the morphology of the molten pool directly affect its production capacity and efficiency. The traditional monitoring method relies on manual inspection and regular inspection, which is a lagging and non-continuous measure. There are problems such as long monitoring cycle and inaccurate data. It is difficult to achieve real-time feedback on the operation and maintenance of the submerged arc furnace, resulting in an increased risk of production interruption and safety accidents. Therefore, it is of great significance to develop a device and method that can monitor the erosion state of the furnace bottom and furnace wall, electrode height and molten pool morphology online and in real time to improve the operation safety and production efficiency of the submerged arc furnace.

[0003] The Chinese authorized patent document with publication number CN218723239U discloses a submerged arc furnace with a temperature monitoring function. SMD thermocouples are arranged at intervals along the circumferential outer wall of the submerged arc furnace body and connected to a display through wires, so that real-time temperature monitoring of the outer wall temperature of the submerged arc furnace body can be realized. However, only the temperature change of the outer wall of the submerged arc furnace body is monitored, and the temperature change of the furnace lining inside the submerged arc furnace is not monitored, and the electrode height and the morphology of the molten pool cannot be monitored. The bottom of the submerged arc furnace, especially the area below the bottom electrode, below the electrode circle and the area around the iron mouth on the furnace wall are the weak links that are most easily corroded during the production process of the submerged arc furnace. Summary of the invention

[0004] To this end, the present invention provides an online real-time monitoring device and method for an ore-fired furnace to solve the problem that the temperature and erosion state of the furnace bottom and furnace wall, electrode height and molten pool morphology of the existing ore-fired furnace cannot be monitored in real time.

[0005] In a first aspect, the present invention provides a device for online real-time monitoring of a submerged arc furnace, which adopts the following technical solution: A device for online real-time monitoring of an ore-fired furnace comprises: a thermocouple array, a main junction box, a data acquisition device and a data processing device, wherein the thermocouple array is buried in the furnace bottom and furnace wall of the ore-fired furnace, the thermocouple array is connected to the main junction box via a compensation wire, the main junction box converts the data obtained by the thermocouple array and sends it outward via a wired or wireless network, the data acquisition device receives the data sent by the main junction box via a wired or wireless network, the data processing device is connected to the data acquisition device via a wired or wireless network, the data processing device analyzes and processes the data, and displays the temperature change and erosion state of the furnace bottom and furnace wall of the ore-fired furnace as well as the electrode height and the morphology of the molten pool in real time.

[0006] Furthermore, the thermocouple array is configured by arranging thermocouples at key positions of the furnace bottom and furnace wall for real-time acquisition of temperature data. The top of each thermocouple contacts the brick lining of the furnace bottom and furnace wall of the electric arc furnace, and each thermocouple is connected to the main junction box via a compensation wire.

[0007] Furthermore, the main junction box is installed on the outside of the furnace shell of the electric arc furnace, a pad is arranged between the main junction box and the furnace shell of the electric arc furnace, a protective shell is installed on the outside of the main junction box, a compensation wire entrance is opened on the protective shell, a digital-to-analog converter and a wireless communication module are arranged in the main junction box, the digital-to-analog converter is connected to each thermocouple in the thermocouple array through the compensation wire, the wireless communication module is connected to the digital-to-analog converter through a data line, and the wireless communication module sends the converted data to the data acquisition device through a wired or wireless network.

[0008] Furthermore, a memory is provided in the data acquisition device, and the data collected by the data acquisition device is stored in the memory and preliminarily preprocessed.

[0009] Furthermore, the data processing device is connected to the data acquisition device via a wired or wireless network, and includes a data processing module and a display device. The data processing module analyzes and processes the preprocessed data, and the processing results are displayed through the display device to achieve real-time display of data.

[0010] Furthermore, the display device also includes a buzzer, which is connected to the display device via a data line, and is used to make a sound to warn the staff when the residual lining thickness of the furnace bottom and the furnace wall reaches a threshold thickness.

[0011] In a second aspect, the present invention discloses a method for online real-time monitoring of a submerged arc furnace, which measures the temperature of the furnace bottom and furnace wall of the submerged arc furnace by thermocouples, combines heat transfer principles and numerical calculation methods, and inversely solves the temperature field distribution of the furnace bottom and furnace wall, thereby predicting the erosion state of the furnace bottom and furnace wall, the electrode height, and the morphology of the molten pool. The method comprises the following steps: Temperature data collection: Arrange thermocouple arrays at key locations on the bottom and wall of the submerged arc furnace to obtain real-time temperature data of the bottom and wall of the submerged arc furnace; Data preprocessing: preprocess the collected temperature data. On the one hand, filter the data to reduce noise interference, and on the other hand, reasonably process or complete abnormal data or missing data. Establishing the model: Based on the mathematical model of Fourier's law (q = -λ(dT / dx), where q represents heat flux, λ is thermal conductivity, and dT / dx is temperature gradient) and the principle of energy conservation, and according to the principle that heat flux is proportional to temperature gradient and the direction of heat transfer is opposite to the direction of temperature increase, a mathematical model of temperature field is established based on the geometric shape, material properties and boundary conditions of the lining inside the submerged arc furnace. The model includes key information such as the thermal conductivity characteristics of the lining, heat source distribution, and boundary conditions; Calculate and predict the temperature field distribution and erosion state of the furnace bottom and furnace wall, as well as the electrode height and molten pool morphology: Use the finite difference method to divide the furnace lining into a finite number of small units, and use Fourier's law to calculate the temperature gradient of each unit by setting initial conditions and boundary conditions, and then obtain the heat flux density; through iterative calculation, continuously adjust the temperature field distribution in the model; by analyzing the thermal conductivity characteristics of the furnace lining material and determining the position of specific isotherms, the hot spot position, erosion state, electrode height and molten pool morphology of the furnace bottom and furnace wall can be obtained; Visual interface and alarm mechanism: Real-time display of the isotherm distribution diagram of the furnace bottom and furnace wall, the lining erosion status diagram of the furnace bottom and furnace wall, the electrode height information, the molten pool morphology and other information calculated through the above steps. At the same time, an alarm mechanism is set up. When an abnormal situation is monitored, the alarm is automatically triggered to remind the operator to take timely measures.

[0012] Furthermore, the thermocouple array is arranged at the furnace bottom in the following manner to meet the requirements of temperature field calculation: Longitudinal point arrangement method of furnace bottom: the first layer of thermocouples is arranged at the joint between the furnace bottom electrode paste layer and the furnace bottom carbon brick layer, and the furnace bottom carbon brick layer is arranged downward in sequence at the joint of two layers of carbon bricks every 400mm, for a total of three layers, i.e. the second to fourth layers of thermocouples, and a layer of thermocouples is laid at the midpoint of the total thickness of the furnace bottom lining, i.e. the fifth layer of thermocouples; Circumferential distribution method of carbon brick layer at the bottom of furnace: A thermocouple is arranged at the core point of the furnace; The entire circumferential surface corresponds to three electrodes ABC. The 120° fan-shaped areas formed between every two electrodes are defined as AB area, BC area and CA area. The following uses AB area to explain the point distribution method. The point distribution methods of BC area and CA area are the same as those of AB area. On the radius line formed by connecting the furnace center point and the center point of the A electrode circle (called the first radius line): a thermocouple is arranged at the center point of the A electrode circle, a thermocouple is arranged at each of the inner and outer points of the A electrode circle, a thermocouple is arranged at a distance of 500mm from the furnace wall, and the rest of the thermocouples are arranged every 1000mm according to the distance on the radius; Push the 30° radius line clockwise from the center of electrode A (called the second radius line): arrange a thermocouple at the intersection with the polar center circle (the circle where the centers of the three electrodes ABC are located), arrange a thermocouple at a distance of 500mm from the furnace wall lining, and arrange the rest of the thermocouples every 1000mm according to the distance on the radius; Thermocouples are arranged on the radius line of 60° clockwise from the center of electrode A (called the third radius line) and the radius line of 90° clockwise from the center of electrode A (called the fourth radius line) in the same regular manner as the second radius line; On a circle with the furnace center as the center and 500 mm away from the furnace wall, a thermocouple is arranged at the middle point of the intersection with the first radius line and the intersection with the second radius line, the middle point of the intersection with the second radius line and the intersection with the third radius line, and the middle point of the intersection with the third radius line and the intersection with the fourth radius line; Arrange a thermocouple at the midpoint of the line segment connecting electrode A and electrode B; The distribution method of the BC and CA areas is the same as that of the AB area; A thermocouple is arranged at each of the left and right intersections of the polar center circle and the three electrode circles ABC; Circumferential distribution method of furnace bottom lining: A thermocouple is arranged at the core point of the furnace; Eight thermocouples are evenly arranged on a circle with the furnace center as the center and 500 mm away from the furnace wall lining.

[0013] Furthermore, the thermocouple array is arranged on the furnace wall in the following manner to obtain temperature data at two different depths of each layer: Method for longitudinal point arrangement of furnace wall: start arranging thermocouples at the joint between the first and second layers of brick lining at the upper edge of the taphole, and arrange one thermocouple every three layers of brick lining upwards until the top of the furnace wall; or arrange one thermocouple every three layers of brick lining upwards, after arranging five layers in total, arrange one thermocouple every six layers of brick lining upwards until the top of the furnace wall; arrange one thermocouple at the joint between the two layers of brick lining at the center line of the taphole; start arranging thermocouples at the joint between the first and second layers of brick lining at the lower edge of the taphole, and arrange one thermocouple every three layers of brick lining downwards until the bottom of the furnace wall; arrange one thermocouple at each layer at 300mm and 400mm from the furnace shell; Circumferential distribution method of furnace wall: In the circumferential direction of each layer, with the center line of the iron mouth as the starting point, the thermocouples are evenly arranged at certain angles on the two circles 300mm and 400mm away from the furnace shell. The closer to the iron mouth layer, the smaller the interval angle, and the farther away from the iron mouth layer, the larger the interval angle can be. The interval angle range is 10° to 30°.

[0014] The beneficial effects of the present invention are as follows: The present invention discloses an online real-time monitoring device and method for an ore-heating furnace. A thermocouple array is buried in the lining of the ore-heating furnace. The temperature information collected by the thermocouple is converted to digital through a data acquisition device and pre-processed before being transmitted to a data processing device. The data processing device establishes a mathematical model, and according to the measured temperature value, combines the heat transfer principle and the numerical calculation method, inversely solves the temperature field distribution of the furnace bottom and furnace wall, and then predicts the erosion state of the furnace bottom and furnace wall, thereby realizing online monitoring of the erosion state of the furnace bottom and furnace wall of the ore-heating furnace. Through online monitoring, the temperature data of the furnace bottom and furnace wall can be obtained in real time, and the erosion state, electrode height and molten pool morphology can be predicted in real time; a specific data processing algorithm is used, combined with temperature field calculation and heat flux intensity analysis, to realize accurate prediction of the erosion state of the furnace bottom and furnace wall; the erosion risk of the furnace bottom and furnace wall can be discovered and warned in time, effectively preventing the occurrence of safety accidents, and ensuring the safety of the production process; the frequency of manual inspections can be reduced, maintenance costs can be reduced, and production efficiency can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 : Schematic diagram of the overall structure of the device for online real-time monitoring of the ore-fired furnace.

[0016] Figure 2 : Schematic diagram of the circumferential thermocouple distribution method of the carbon brick layer at the bottom of the furnace.

[0017] Figure 3 : Schematic diagram of the circumferential thermocouple distribution method of the furnace bottom and furnace lining.

[0018] Figure 4 : Schematic diagram of the thermocouple distribution method along the circumference of the furnace wall.

[0019] Figure 5 : Flowchart of the method for online real-time monitoring of an ore-fired furnace.

[0020] In the figure: 1-thermocouple array, 2-main junction box, 21-digital-to-analog converter, 22-wireless communication module, 3-data acquisition device, 4-data processing device, 41-data processing module, 42-display device, 43-buzzer, 5-submerged arc furnace, 6-furnace bottom, 61-furnace bottom electrode paste layer, 62-furnace bottom carbon brick layer, 63-furnace bottom lining layer, 7-furnace wall, 8-iron mouth, 9-furnace shell. DETAILED DESCRIPTION

[0021] The following is a description of the implementation of the present invention by specific embodiments. People familiar with the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. Obviously, the described embodiments are 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.

[0022] The following is combined with Figure 1 -Attached Figure 5 Specific embodiments of the present invention are described in detail.

[0023] This embodiment provides a device for online real-time monitoring of a submerged arc furnace. Figure 1 As shown, the device includes: a thermocouple array 1, a main junction box 2, a data acquisition device 3 and a data processing device 4. The thermocouple array 1 is buried in the furnace bottom 6 and the furnace wall 7 of the ore-heating furnace. The thermocouple array 1 is connected to the main junction box 2 through a compensation wire. The main junction box 2 converts the data obtained by the thermocouple array 1 and sends it outward through a wireless network. The data acquisition device 3 receives the data sent by the main junction box 2 through a wireless network. The data processing device 4 is connected to the data acquisition device 3 through a wireless network. The data processing device 4 analyzes and processes the data to display the temperature change and erosion state of the furnace bottom 6 and the furnace wall 7 of the ore-heating furnace as well as the electrode height and the molten pool morphology in real time.

[0024] Furthermore, the thermocouple array 1 arranges thermocouples at key positions of the furnace bottom 6 and the furnace wall 7 for real-time acquisition of temperature data. The top of each thermocouple contacts the brick lining inside the furnace bottom 6 and the furnace wall 7 of the ore-heating furnace. Each thermocouple is connected to the main junction box 2 through a compensation wire. The outer side of the compensation wire is wrapped with a steel pipe for protection. The steel pipe model is DN35 and the outer diameter is 38mm. The steel pipe is made of Inconel 600 nickel-chromium alloy, which has high temperature resistance, corrosion resistance, oxidation resistance, nitridation resistance, carburization resistance, creep rupture strength resistance, good mechanical properties, and can withstand a high temperature of up to 1100°C. The thermocouple array 1 is composed of high-quality armored flexible thermocouples with high temperature resistance, oxidation resistance, high temperature creep resistance, and alternating thermal stress erosion resistance. The specifications and performance parameters are shown in Table 1.

[0025] Table 1 Specifications and performance parameters of thermocouple array 1

[0026] Specifications Graduation No. Number of measuring points Packaging Sheath material Casing outer diameter Accuracy level Parameter Description K-grade armored Pt10 Single point or multi-point Dual-core three-wire system Inconel600 Outer diameter not more than 5.0mm Level I

[0027] Furthermore, the main junction box 2 is installed on the outside of the furnace shell 9 of the submerged arc furnace, a pad is arranged between the main junction box 2 and the furnace shell 9 of the submerged arc furnace, a protective shell is installed on the outside of the main junction box 2, a compensation wire entrance is opened on the protective shell, a digital-to-analog converter 21 and a wireless communication module 22 are arranged in the main junction box 2, the digital-to-analog converter 21 is connected to each thermocouple in the thermocouple array 1 through a compensation wire, the wireless communication module 22 is connected to the digital-to-analog converter 21 through a data line, and the wireless communication module 22 sends the converted data to the data acquisition device 3 through a wireless network.

[0028] Furthermore, a memory is provided in the data acquisition device 3, and the data collected by the data acquisition device 3 is stored in the memory and preliminarily preprocessed.

[0029] Furthermore, the data processing device 4 is connected to the data acquisition device 3 via a wireless network, and includes a data processing module 41 and a display device 42. The data processing module 41 analyzes and processes the preprocessed data, and the processing results are displayed through the display device 42 to achieve real-time display of data.

[0030] Furthermore, the display device 42 also includes a buzzer 43, which is connected to the display device 42 via a data line. The buzzer 43 is used to make a sound to warn the staff when the residual lining thickness of the furnace bottom 6 or the furnace wall 7 reaches a threshold thickness.

[0031] This embodiment also provides a method for online real-time monitoring of a submerged arc furnace, which measures the temperature of the furnace bottom and furnace wall of the submerged arc furnace by thermocouples, combines heat transfer principles and numerical calculation methods, and inversely solves the temperature field distribution of the furnace bottom and furnace wall, thereby predicting the erosion state of the furnace bottom and furnace wall. Figure 5 As shown, the method comprises the following steps: Temperature data collection S1: Arrange thermocouple arrays at key positions of the furnace bottom and furnace wall of the submerged arc furnace to obtain real-time temperature data of the furnace bottom and furnace wall; Data preprocessing S2: preprocess the collected temperature data. On the one hand, filter the data to reduce noise interference, and on the other hand, reasonably process or complete abnormal data or missing data. Establish model S3: Based on Fourier's law and the law of conservation of energy: Where: ρ is the density of the control unit body; Cp is the isobaric heat capacity of the control unit body; T is the temperature of the unit body; t is the time; k is the thermal conductivity of the control unit body; s is the source term in the control unit body; Based on the principle that heat flux density is proportional to temperature gradient and the direction of heat transfer is opposite to the direction of temperature rise, a temperature field mathematical model is established according to the geometry, material properties and boundary conditions of the lining inside the submerged arc furnace. The model includes key information such as the thermal conductivity characteristics of the lining, heat source distribution, and boundary conditions. Calculate and predict the temperature field distribution and erosion state of the furnace bottom and furnace wall, as well as the electrode height and the molten pool morphology S4: Use the finite difference method to divide the furnace lining into a finite number of small units. By setting the initial conditions and boundary conditions, use the S3 model to calculate the temperature gradient of each unit, and then obtain the heat flux density; through iterative calculation, continuously adjust the temperature field distribution in the model; by analyzing the thermal conductivity characteristics of the furnace lining material and determining the position of specific isotherms, the hot spot position, erosion state, electrode height and molten pool morphology of the furnace bottom and furnace wall can be obtained; Visualization interface and alarm mechanism S5: Real-time display of the isotherm distribution diagram of the furnace bottom and furnace wall, the lining erosion state diagram of the furnace bottom and furnace wall, the electrode height information, the molten pool morphology and other information calculated through the above steps. At the same time, an alarm mechanism is set up. When an abnormal situation is monitored, an alarm is automatically triggered to remind the operator to take timely measures.

[0032] Furthermore, the thermocouple array 1 is arranged at the furnace bottom 6 in the following manner to meet the requirements of temperature field calculation: The longitudinal distribution method of the furnace bottom is as follows: Figure 1 As shown: the thickness of the furnace bottom carbon brick is 400mm, with three layers of carbon bricks in total. A layer of thermocouples D1F-D4F is arranged at the joints between the furnace bottom electrode paste layer 6-1 and the furnace bottom carbon brick layer 6-2, the joints between every two layers of carbon bricks, and the joints between the furnace bottom carbon brick layer 6-2 and the furnace bottom lining 6-3. The total thickness of the furnace bottom lining is 1600mm, and a layer of thermocouple D5F is arranged at the joints between the two layers of lining bricks at a height of 800mm. A total of five layers of thermocouples are arranged longitudinally in the furnace bottom 6; The circumferential distribution method of the carbon brick layer at the bottom of the furnace, such as Figure 2 As shown: A thermocouple 1# is arranged at the furnace core; The entire circumferential surface corresponds to three electrodes ABC. The 120° fan-shaped areas formed between every two electrodes are defined as AB area, BC area and CA area. The following uses AB area to explain the point distribution method. The point distribution methods of BC area and CA area are the same as those of AB area. On the radius line formed by connecting the furnace center point and the center point of the A electrode circle (called the first radius line): a thermocouple 4# is arranged at the center point of the A electrode circle, a thermocouple 3# and a thermocouple 5# are arranged at the inner and outer points of the A electrode circle, a thermocouple 8# is arranged at a distance of 500mm from the furnace wall lining, and the rest of the thermocouples 2#, 6# and 7# are arranged every 1000mm according to the distance on the radius; Push the 30° radius line clockwise from the center of electrode A (called the second radius line): arrange a thermocouple 10# at the intersection with the polar center circle (the circle where the centers of the three electrodes ABC are located), arrange a thermocouple 13# at a distance of 500mm from the furnace wall lining, and arrange the rest of the thermocouples 11# and 12# at intervals of 1000mm according to the distance on the radius; Thermocouples are arranged in the same regular pattern as the second radius line on the radius line of 60° clockwise from the center of the A electrode (called the third radius line) and the radius line of 90° clockwise from the center of the A electrode (called the fourth radius line), namely, 16#, 17#, 18#, 19#, 21#, 22#, 23#, and 24#; On a circle with the furnace center as the center and 500 mm away from the furnace wall, a 9# thermocouple is arranged at the midpoint between the intersection of the first radius line and the intersection of the second radius line, a 14# thermocouple is arranged at the midpoint between the intersection of the second radius line and the intersection of the third radius line, and a 20# thermocouple is arranged at the midpoint between the intersection of the third radius line and the intersection of the fourth radius line; Arrange a thermocouple 15# at the midpoint of the line segment connecting the center point of the A electrode and the center point of the B electrode; The BC and CA areas are arranged in the same way as the AB area, 25# to 47# in the BC area and 48# to 70# in the CA area; Arrange a thermocouple 71# to 76# at each of the left and right intersections of the polar center circle and the three electrode circles ABC; The circumferential distribution method of furnace bottom and furnace lining, such as Figure 3 As shown: A thermocouple 77# is arranged at the furnace core point; Eight thermocouples 78#-85# are evenly arranged on a circle with the furnace center as the center and 500mm away from the furnace wall lining.

[0033] Furthermore, the thermocouple array is arranged on the furnace wall in the following manner to obtain temperature data at two different depths of each layer: The longitudinal distribution method of the furnace wall, such as Figure 1 As shown: a thermocouple Q1F is arranged at the joint between the first and second brick linings at the upper edge of the tap hole 8, and a thermocouple is arranged every three brick linings upward until the top of the furnace wall Q2F-Q9F; a thermocouple Q0F is arranged at the joint between the two brick linings at the center line of the tap hole; a thermocouple Q10F is arranged at the joint between the first and second brick linings at the lower edge of the tap hole, and a thermocouple is arranged every three brick linings downward until the bottom of the furnace wall Q11F-Q13F; a thermocouple is arranged at each layer at 300mm and 400mm away from the furnace shell; The method of arranging points on the furnace wall circumference is as follows: Figure 4As shown: In the circumferential direction of each layer, starting from the center line of the iron mouth, thermocouples are evenly arranged every 10° on two circles 300mm and 400mm away from the furnace shell, with a total of 72 thermocouples in each layer.

[0034] The beneficial effects of the present invention are as follows: The present invention discloses an online real-time monitoring device and method for an ore-heating furnace. A thermocouple array is buried in the lining of the ore-heating furnace. The temperature information collected by the thermocouple is converted into digital form by a data acquisition device and transmitted to a data processing device after preprocessing. The data processing device establishes a mathematical model, and according to the measured temperature value, combines the heat transfer principle and the numerical calculation method, inversely solves the temperature field distribution of the furnace bottom and furnace wall, and then predicts the erosion state of the furnace bottom and furnace wall, so as to realize the online monitoring of the erosion state of the furnace bottom and furnace wall of the ore-heating furnace. Through online monitoring, the temperature data of the furnace bottom and furnace wall can be obtained in real time, and the erosion state and electrode height and molten pool morphology can be predicted in real time; a specific data processing algorithm is used, combined with temperature field calculation and heat flux intensity analysis, to realize the accurate prediction of the erosion state of the furnace bottom and furnace wall; the erosion risk of the furnace bottom and furnace wall can be discovered and warned in time, and the occurrence of safety accidents can be effectively prevented, and the safety of the production process can be ensured; the frequency of manual inspections can be reduced, maintenance costs can be reduced, and production efficiency can be improved.

[0035] Although the present invention has been described in detail above by general description and specific embodiments, it is obvious to those skilled in the art that some modifications or improvements can be made to the present invention. Therefore, these modifications or improvements made without departing from the spirit of the present invention all belong to the scope of protection claimed by the present invention.

Claims

1. A device for online real-time monitoring of a submerged arc furnace, characterized in that: The device comprises: a thermocouple array, a main junction box, a data acquisition device and a data processing device. The thermocouple array is buried in the bottom and wall of the ore-generating furnace. The thermocouple array is connected to the main junction box via a compensation wire. The main junction box converts the data obtained by the thermocouple array and sends it outward via a wired or wireless network. The data acquisition device receives the data sent by the main junction box via a wired or wireless network. The data processing device is connected to the data acquisition device via a wired or wireless network. The data processing device analyzes and processes the data to display the temperature change and erosion state of the bottom and wall of the ore-generating furnace, as well as the electrode height and the morphology of the molten pool in real time.

2. The device for online real-time monitoring of a submerged arc furnace according to claim 1, characterized in that: The thermocouple array is to arrange thermocouples at key positions of the furnace bottom and furnace wall, the top of each thermocouple contacts the brick lining of the furnace bottom and furnace wall of the ore-fired furnace, and each thermocouple is connected to the main junction box through a compensation wire.

3. The device for online real-time monitoring of a submerged arc furnace according to claim 1, characterized in that: The main junction box is installed on the outside of the furnace shell of the submerged arc furnace, a pad is arranged between the main junction box and the furnace shell of the submerged arc furnace, a protective shell is installed on the outside of the main junction box, a compensation wire entrance is opened on the protective shell, a digital-to-analog converter and a wireless communication module are arranged in the main junction box, the digital-to-analog converter is connected to each thermocouple in the thermocouple array through a compensation wire, the wireless communication module is connected to the digital-to-analog converter through a data line, and the wireless communication module sends the converted data to the data acquisition device through a wired or wireless network.

4. The device for online real-time monitoring of a submerged arc furnace according to claim 1, characterized in that: The data acquisition device is provided with a memory, and the data collected by the data acquisition device is stored in the memory and preliminarily preprocessed.

5. The device for online real-time monitoring of a submerged arc furnace according to claim 1, characterized in that: The data processing device is connected to the data acquisition device via a wired or wireless network, and includes a data processing module and a display device. The data processing module analyzes and processes the pre-processed data, and the processing results are displayed via the display device to achieve real-time display of data.

6. The device for online real-time monitoring of a submerged arc furnace according to claim 1, characterized in that: The display device further includes a buzzer, which is connected to the display device via a data line.

7. A method for online real-time monitoring of a submerged arc furnace, characterized in that: The method comprises the following steps: Temperature data collection S1: Arrange thermocouple arrays at key positions of the furnace bottom and furnace wall of the submerged arc furnace to obtain real-time temperature data of the furnace bottom and furnace wall; Data preprocessing S2: preprocess the collected temperature data. On the one hand, filter the data to reduce noise interference, and on the other hand, reasonably process or complete abnormal data or missing data. Establishing model S3: Based on Fourier's law and the law of conservation of energy, a mathematical model of the temperature field is established according to the geometric shape, material properties and boundary conditions of the lining inside the submerged arc furnace. The model includes key information such as the thermal conductivity characteristics of the lining, the distribution of heat sources, and boundary conditions; Calculate and predict the temperature field distribution and erosion state of the furnace bottom and furnace wall, as well as the electrode height and the molten pool morphology S4: Use the finite difference method to divide the furnace lining into a finite number of small units. By setting initial conditions and boundary conditions, use Fourier's law to calculate the temperature gradient of each unit, and then obtain the heat flux density; through iterative calculation, continuously adjust the temperature field distribution in the model; by analyzing the thermal conductivity characteristics of the furnace lining material and determining the position of specific isotherms, the hot spot position, erosion state, electrode height and molten pool morphology of the furnace bottom and furnace wall can be obtained; Visualization interface and alarm mechanism S5: Real-time display of the isotherm distribution diagram of the furnace bottom and furnace wall, the lining erosion state diagram of the furnace bottom and furnace wall, the electrode height information and the molten pool morphology and other information calculated through the above steps. At the same time, an alarm mechanism is set. When an abnormal situation is monitored, an alarm is automatically triggered to remind the operator to take timely measures.

8. The method for online real-time monitoring of a submerged arc furnace according to claim 7, characterized in that: The thermocouple array is arranged at the furnace bottom in the following manner: Longitudinal point arrangement method of furnace bottom: the first layer of thermocouples is arranged at the joint between the furnace bottom electrode paste layer and the furnace bottom carbon brick layer, and the furnace bottom carbon brick layer is arranged downward in sequence at the joint of two layers of carbon bricks every 400mm, for a total of three layers, i.e. the second to fourth layers of thermocouples, and a layer of thermocouples is laid at the midpoint of the total thickness of the furnace bottom lining, i.e. the fifth layer of thermocouples; Circumferential distribution method of carbon brick layer at the bottom of furnace: A thermocouple is arranged at the core point of the furnace; The entire circumferential surface corresponds to three electrodes ABC. The 120° fan-shaped areas formed between every two electrodes are defined as AB area, BC area and CA area. The following uses AB area to explain the point distribution method. The point distribution methods of BC area and CA area are the same as those of AB area. On the radius line formed by connecting the furnace center point and the center point of the A electrode circle (called the first radius line): a thermocouple is arranged at the center point of the A electrode circle, a thermocouple is arranged at each of the inner and outer points of the A electrode circle, a thermocouple is arranged at a distance of 500mm from the furnace wall, and the rest of the thermocouples are arranged every 1000mm according to the distance on the radius; Push the 30° radius line clockwise from the center of electrode A (called the second radius line): arrange a thermocouple at the intersection with the polar center circle (the circle where the centers of the three electrodes ABC are located), arrange a thermocouple at a distance of 500mm from the furnace wall lining, and arrange the rest of the thermocouples every 1000mm according to the distance on the radius; Thermocouples are arranged on the radius line of 60° clockwise from the center of electrode A (called the third radius line) and the radius line of 90° clockwise from the center of electrode A (called the fourth radius line) in the same regular manner as the second radius line; On a circle with the furnace center as the center and 500 mm away from the furnace wall, a thermocouple is arranged at the midpoint between the intersection of the first radius line and the intersection of the second radius line, at the midpoint between the intersection of the second radius line and the intersection of the third radius line, and at the midpoint between the intersection of the third radius line and the intersection of the fourth radius line; Arrange a thermocouple at the midpoint of the line segment connecting electrode A and electrode B; The distribution method of the BC and CA areas is the same as that of the AB area; A thermocouple is arranged at each of the left and right intersections of the polar center circle and the three electrode circles ABC; Circumferential distribution method of furnace bottom lining: A thermocouple is arranged at the core point of the furnace; Eight thermocouples are evenly arranged on a circle with the furnace center as the center and 500 mm away from the furnace wall lining.

9. The method for online real-time monitoring of a submerged arc furnace according to claim 7, characterized in that: The thermocouple array is arranged on the furnace wall in the following manner: Method for longitudinal point arrangement of furnace wall: start arranging thermocouples at the joint between the first and second layers of brick lining at the upper edge of the taphole, and arrange one thermocouple every three layers of brick lining upwards until the top of the furnace wall; or arrange one thermocouple every three layers of brick lining upwards, after arranging five layers in total, arrange one thermocouple every six layers of brick lining upwards until the top of the furnace wall; arrange one thermocouple at the joint between the two layers of brick lining at the center line of the taphole; start arranging thermocouples at the joint between the first and second layers of brick lining at the lower edge of the taphole, and arrange one thermocouple every three layers of brick lining downwards until the bottom of the furnace wall; arrange one thermocouple at each layer at 300mm and 400mm from the furnace shell; Circumferential distribution method of furnace wall: In the circumferential direction of each layer, with the center line of the iron mouth as the starting point, the thermocouples are evenly arranged at certain angles on the two circles 300mm and 400mm away from the furnace shell. The closer to the iron mouth layer, the smaller the interval angle, and the farther away from the iron mouth layer, the larger the interval angle can be. The interval angle range is 10° to 30°.

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