Electric furnace bottom blowing system of bottom blowing gun shared by multiple media
By designing an electric furnace bottom blowing system with a multi-media shared bottom blowing gun, the problems of discontinuous gas switching, complex control, and difficult precise control in the existing technology are solved, and seamless gas switching, precise flow control and real-time monitoring of breathable bricks are realized. It improves the flexibility and efficiency of smelting, and ensures the stability and efficiency of the smelting process.
Patent Information
- Application Number
- CN202411733958.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-29
- Publication Date
- 2025-02-18
AI Technical Summary
The existing electric furnace bottom blowing system cannot achieve seamless gas switching during multi-media switching, the control is complex and the response is slow, and it is difficult to achieve accurate flow control. The lack of a complete breathable brick monitoring system increases the risk of equipment accidents.
A multi-media shared bottom blowing gun electric furnace bottom blowing system is designed, including gas pretreatment and seamless switching module, flow control module, flow retention and energy saving module, breathable brick monitoring and early warning module and automatic switching module, adopting quality Flow controller, built-in chip-level PID adaptive adjustment technology, PLC system connection, sensors and intelligent algorithms and other technical means to achieve seamless gas switching, precise flow control and real-time monitoring of breathable bricks.
Achieve seamless switching of multi-media bottom blowing gas, improves the flexibility and efficiency of smelting, extends the service life of breathable bricks, reduces maintenance costs, significantly improves the reliability of erosion monitoring of breathable bricks, and ensures the smelting process. Stability and efficiency.
Smart Images
Figure CN119464616A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of bottom blowing refining, and in particular to an electric furnace bottom blowing system with a multi-medium common bottom blowing gun. Background Art
[0002] The bottom blowing system of electric furnace is a fully automatic process equipment used in the process of electric furnace steelmaking. Its technical principle is to blow nitrogen and argon into the molten pool through the breathable bricks or spray guns installed at the bottom of the electric furnace. In the process of gas rising from the bottom, it will stir the molten pool, thereby accelerating the metallurgical reaction, improving the quality and temperature uniformity of the molten steel, and thus achieving the purpose of improving the quality of molten steel.
[0003] Since the raw materials for electric furnace steelmaking are mainly scrap steel, the production rhythm is greatly affected by the plan, and the type of steel to be smelted often needs to be changed. The general bottom blowing system has the following defects and shortcomings: 1. Discontinuous gas switching: During the multi-media switching process, the system cannot achieve seamless gas switching, resulting in vacuum gap time during the bottom blowing process, thus affecting the continuity of the bottom blowing, which may have an adverse effect on the smelting process and reduce production efficiency; 2. Complex control and slow response: The traditional bottom blowing system uses a combination of a membrane control valve and a flow meter, and its structure is relatively complex. This control method relies on external calculations for adjustment and lacks internal adaptive PID adjustment control. Therefore, the response speed is not timely enough and it cannot quickly adapt to changes in the smelting process; 3. Difficulty in precise control: Due to the controller, it is difficult for the traditional bottom blowing system to achieve precise control of extremely small flow rates, which limits the application of the system under specific smelting conditions and may affect the smelting effect and product quality; 4. Insufficient monitoring of air bricks: The traditional bottom blowing system lacks a complete air brick monitoring system, or the monitoring system is not sensitive enough to monitor the erosion of the air bricks in time. This may lead to the failure to detect the corrosion of the air bricks in time, increasing the risk of major equipment accidents and posing a threat to production safety and equipment maintenance.
[0004] Therefore, it is necessary to design an electric furnace bottom blowing system with a multi-media shared bottom blowing gun to solve the above problems. Summary of the invention
[0005] The purpose of the present invention is to solve the shortcomings of the prior art and to propose an electric furnace bottom blowing system with a multi-media common bottom blowing gun.
[0006] In order to achieve the above object, the present invention adopts the following technical solutions: An electric furnace bottom blowing system with a multi-media common bottom blowing gun includes the following modules: Gas pretreatment and seamless switching module: This module is responsible for the pretreatment and seamless switching of different medium gases. Through the gas pretreatment system, different mediums are pre-regulated to ensure that the gas pressure difference is within 5 bar. The solenoid valve, internal buffer tank, and three-way valve work together to pre-calculate the exhaust time and maintain the buffer tank pressure at the system working pressure. Flow control module: This module adopts mass flow controller, built-in chip-level PID adaptive adjustment technology, connected to PLC system through RS485 or hard wiring scheme, to achieve extremely fast response speed and precise flow control; Flow maintenance and energy saving module: During the waiting period of electric furnace smelting, this module uses the mass flow controller and PLC logic algorithm to achieve precise control of 5 NLPM flow, maintain the activity of bottom-blown air bricks, and reduce the temperature drop of retained steel and the consumption of energy media; Air brick monitoring and early warning module: Through the main control solenoid valve, pressure regulating device, flow switch and pressure switch, the performance of each air brick is monitored in real time. When the air brick corrosion information is detected, an alarm signal is issued to prevent production equipment accidents; Automatic switching module: input and modify the recipe data through the human-machine interface, select the bottom blowing process recipes for different steel grades and different media. At the same time, the module can receive the communication data interface signal of the main PLC of the electric furnace system, identify different smelting stages, and realize the automatic switching of the process in the real-time smelting stage of multi-media bottom blowing.
[0007] As a preferred technical solution of the present invention, in the gas pretreatment and seamless switching module, the gas pretreatment system is used to perform precise pre-pressure regulation on different media. A switching mechanism is designed inside the module, which includes a solenoid valve, an internal buffer tank and a three-way valve, thereby ensuring the smoothness and continuity of the gas switching process. Before switching, the system precalculates the exhaust time. This step is based on the understanding of the characteristics of different gases and the precise control of the system working pressure. Through precise calculation, the system maintains the pressure in the buffer tank stable at the system working pressure level during the switching process, thereby avoiding the bottom blowing vacuum gap time caused by pressure fluctuations and ensuring the continuity of the bottom blowing process.
[0008] As a preferred technical solution of the present invention, in the flow control module, a mass flow controller is used as a core component, which can automatically adjust the control strategy according to the deviation between the actual gas flow and the set value to achieve rapid response and precise control of the flow. The precise flow control module is closely connected to the PLC system through RS485 or hard wiring. The PLC system receives the feedback signal of the mass flow controller to understand the current gas flow situation in real time, and calculates the required gas flow set value according to the smelting process requirements, and then sends this set value to the mass flow controller, which performs specific flow regulation tasks.
[0009] As a preferred technical solution of the present invention, in the flow-keeping and energy-saving module, the flow-keeping and energy-saving module sets a pre-pressure control valve in front of each branch pipe through a mass flow controller to ensure the stability of the gas supply pressure, and can accurately calculate the required minimum ventilation volume through the PLC logic algorithm according to the furnace capacity and smelting requirements. The module also has the function of intelligent energy saving. Through the real-time monitoring and calculation of the PLC system, the ventilation volume is automatically adjusted according to the changes in the smelting process to ensure that the best energy consumption ratio can be maintained at different stages of smelting.
[0010] As a preferred technical solution of the present invention, in the air brick monitoring and early warning module, temperature and pressure sensors are installed on each air brick to collect temperature and pressure data around the air brick in real time, and send these data to the central control system through the signal transmission line. The data analysis algorithm in the central control system will process and analyze the received data to evaluate whether the working status of the air brick is normal. Through the preset threshold, the system can determine whether the air brick has potential problems such as overheating, blockage or wear. Once an abnormal situation is detected, the system immediately activates the early warning mechanism and sends a warning signal to the operator through sound and light alarms, SMS notifications or email reminders. At the same time, the system will also record the time, location and specific parameters of the abnormal event, providing an important basis for subsequent troubleshooting and maintenance.
[0011] As a preferred technical solution of the present invention, the automatic switching module includes multiple independent solenoid valves, each of which corresponds to a medium supply pipeline. Through the instructions of the PLC control system, the solenoid valve group quickly and accurately opens or closes the corresponding medium supply pipeline to achieve automatic switching of the medium. At the same time, the solenoid valve group is equipped with a pressure sensor and a flow sensor to monitor the pressure and flow changes in the pipeline in real time to prevent the pressure fluctuations or flow mutations caused by switching from adversely affecting the smelting process.
[0012] The present invention has the following beneficial effects: The electric furnace bottom blowing system of the multi-media shared bottom blowing gun of the present invention integrates a number of advanced technologies and brings significant benefits. The system realizes seamless switching of multi-media bottom blowing gases, ensures that the type of medium can be flexibly adjusted according to actual needs during the smelting process, and improves the flexibility and efficiency of smelting. At the same time, the system has a small flow rate keep-alive function during the smelting waiting period, which effectively avoids the cooling and clogging problems of the air bricks caused by long-term lack of gas flushing, prolongs the service life of the air bricks, and reduces maintenance costs. In addition, the system significantly improves the reliability of air brick erosion monitoring. Through high-precision sensors and intelligent algorithms, it can monitor in real time It measures the working status of the air-permeable bricks and issues early warnings in time when abnormal conditions such as erosion occur, providing operators with valuable response time, thereby effectively avoiding smelting interruptions caused by air-permeable brick failures. Most importantly, the system realizes automatic process switching in the real-time smelting stage of multi-media bottom blowing, and can automatically adjust the medium type and flow rate according to the real-time data of the smelting process and the preset process requirements, thereby ensuring the stability and efficiency of the smelting process and further improving the smelting quality and production efficiency. In summary, the electric furnace bottom blowing system of the multi-media shared bottom blowing gun of the present invention has brought significant technological progress and economic benefits to the smelting industry. BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Figure 1 This is a system design diagram of an electric furnace bottom blowing system with a multi-media common bottom blowing gun proposed by the present invention; Figure 2 A network connection diagram of an electric furnace bottom blowing system with a multi-media shared bottom blowing gun proposed by the present invention; Figure 3 This is a schematic diagram of the module structure of an electric furnace bottom blowing system with a multi-media shared bottom blowing gun proposed by the present invention. DETAILED DESCRIPTION
[0014] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.
[0015] Reference Figure 1-3 , an electric furnace bottom blowing system with a multi-media shared bottom blowing gun, including the following modules: Gas pretreatment and seamless switching module: This module is responsible for the pretreatment and seamless switching of different medium gases. Through the gas pretreatment system, different mediums are pre-pressure regulated to ensure that the gas pressure difference is within 5 bar. The electromagnetic valve, internal buffer tank and three-way valve work together to pre-calculate the exhaust time and maintain the buffer tank pressure at the system working pressure. In the gas pretreatment and seamless switching module, different mediums are accurately pre-pressure regulated through the gas pretreatment system. The module is internally designed with a switching mechanism, which includes a solenoid valve, an internal buffer tank and a three-way valve, to ensure the smoothness and continuity of the gas switching process. Before switching, the system pre-calculates the exhaust time. This step is based on the understanding of the characteristics of different gases and the precise control of the system working pressure. Through precise calculation, the system maintains the pressure in the buffer tank stable at the system working pressure level during the switching process, thereby avoiding the bottom blowing vacuum gap time caused by pressure fluctuations and ensuring the continuity of the bottom blowing process. Flow control module: This module adopts mass flow controller and built-in chip-level PID adaptive adjustment technology. It is connected to the PLC system through RS485 or hard wiring scheme to achieve extremely fast response speed and precise flow control. In the flow control module, the mass flow controller is used as the core component. It can automatically adjust the control strategy according to the deviation between the actual gas flow and the set value to achieve fast response and precise control of the flow. The precise flow control module is closely connected with the PLC system through RS485 or hard wiring scheme. The PLC system receives the feedback signal of the mass flow controller to understand the current gas flow situation in real time, and calculates the required gas flow set value according to the smelting process requirements, and then sends this set value to the mass flow controller, which performs specific flow regulation tasks; Flow-keeping and energy-saving module: During the waiting period of electric furnace smelting, this module uses a mass flow controller in conjunction with a PLC logic algorithm to achieve precise control of the 5 NLPM flow rate, maintain the activity of the bottom-blown air-permeable bricks, and reduce the temperature drop of the retained steel and the consumption of energy media. In the flow-keeping and energy-saving module, the flow-keeping and energy-saving module uses a mass flow controller to set a pre-pressure control valve in front of each branch pipe to ensure the stability of the gas supply pressure. It can accurately calculate the required minimum ventilation volume through the PLC logic algorithm according to the furnace capacity and smelting requirements. The module also has the function of intelligent energy saving. Through real-time monitoring and calculation of the PLC system, the ventilation volume is automatically adjusted according to changes in the smelting process to ensure that the best energy consumption ratio can be maintained at different stages of smelting; Air brick monitoring and early warning module: through the main control solenoid valve, pressure regulating device, flow switch and pressure switch, the performance of each air brick is monitored in real time. When the air brick corrosion information is detected, an alarm signal is issued to prevent production equipment accidents. In the air brick monitoring and early warning module, temperature and pressure sensors are installed on each air brick to collect temperature and pressure data around the air brick in real time, and these data are sent to the central control system through the signal transmission line. The data analysis algorithm in the central control system will process and analyze the received data to evaluate whether the working status of the air brick is normal. Through the preset threshold, the system can determine whether the air brick has potential problems such as overheating, blockage or wear. Once an abnormal situation is detected, the system immediately activates the early warning mechanism and sends a warning signal to the operator through sound and light alarms, SMS notifications or email reminders. At the same time, the system will also record the time, location and specific parameters of the abnormal event, providing an important basis for subsequent troubleshooting and maintenance; Automatic switching module: input and modify the recipe data through the human-machine interface, select the bottom blowing process recipes for different steel grades and different media. At the same time, the module can receive the communication data interface signal of the main PLC of the electric furnace system, identify different smelting stages, and realize the automatic switching of the process of multi-media bottom blowing in real-time smelting stages. In the automatic switching module, multiple independent solenoid valves are included, each solenoid valve corresponds to a medium supply pipeline. Through the instructions of the PLC control system, the solenoid valve group quickly and accurately opens or closes the corresponding medium supply pipeline to realize automatic switching of the medium. At the same time, the solenoid valve group is equipped with pressure sensors and flow sensors to monitor the pressure and flow changes in the pipeline in real time to prevent the pressure fluctuations or flow mutations caused by switching from adversely affecting the smelting process.
[0016] The specific working principle of the present invention is as follows: The bottom blowing system of the electric furnace with multi-media common bottom blowing gun is a highly integrated and intelligent mechatronic product. Its core control system adopts Siemens S7-1200PLC to ensure the stability and accuracy of the system. The pipe design of the whole system is pre-set as a whole, and the gas path process is clear. All design components and annotations are listed in detail in the attached Figure 1 For easy maintenance and operation; The system mainly consists of three parts: gas pretreatment system, main blowing branch pipe system and efficiency monitoring system. The gas pretreatment system is located on the left side of the system. It supports multi-media input, such as argon, nitrogen or carbon dioxide. These gases are first purified by filters to ensure gas quality. Then, the gas is pre-regulated to the pressure level required by the system and controlled by the corresponding solenoid valve, and finally stored in the buffer tank. On each air intake circuit, the system is equipped with a gas release valve to perform safe release operations when necessary, thereby ensuring the safety of the system. The middle part is the main blowing branch pipe system, which is the core part of the system. Each main blowing branch pipe is equipped with a high-precision mass flow controller to accurately detect and control the main blowing flow rate, ensuring that the gas supply during the smelting process is stable and meets the process requirements. At the same time, a mass flow meter is set up in the bypass to monitor the bypass flow rate so as to further optimize and adjust the system. At the rear end of each main blowing branch pipe, the system is also equipped with a pressure transmitter and a pressure switch. The pressure transmitter is used to monitor the back pressure of the main blowing branch pipe in real time, thereby providing monitoring data on the performance of the air-permeable brick; and the pressure switch is used to send an alarm signal when the air-permeable brick is blocked, so as to promptly remind the operator to handle it; The right part is the performance monitoring system, which is controlled by a pressure regulating valve and distributed to three monitoring branches. Each monitoring branch is directly connected to the bottom-blowing air brick to monitor the working status of the air brick in real time. On the monitoring branch, the system is equipped with a flow switch and a pressure switch. When it detects that gas is passing through a certain path, the system will integrate the flow and pressure data and generate a corresponding alarm signal. If the air brick shows abnormal conditions such as erosion, the system will immediately issue an alarm so that the operator can take timely measures to intervene and repair.
[0017] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can replace or change the technical solution and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.
Claims
1. An electric furnace bottom blowing system with a multi-media common bottom blowing gun, characterized in that: Includes the following modules: Gas pretreatment and seamless switching module: This module is responsible for the pretreatment and seamless switching of different medium gases. Through the gas pretreatment system, different mediums are pre-regulated to ensure that the gas pressure difference is within 5 bar. The solenoid valve, internal buffer tank, and three-way valve work together to pre-calculate the exhaust time and maintain the buffer tank pressure at the system working pressure. Flow control module: This module adopts mass flow controller, built-in chip-level PID adaptive adjustment technology, connected to PLC system through RS485 or hard wiring scheme, to achieve extremely fast response speed and precise flow control; Flow maintenance and energy saving module: During the waiting period of electric furnace smelting, this module uses the mass flow controller and PLC logic algorithm to achieve precise control of 5 NLPM flow, maintain the activity of bottom-blown air bricks, and reduce the temperature drop of retained steel and the consumption of energy media; Air brick monitoring and early warning module: Through the main control solenoid valve, pressure regulating device, flow switch and pressure switch, the performance of each air brick is monitored in real time. When the air brick corrosion information is detected, an alarm signal is issued to prevent production equipment accidents; Automatic switching module: input and modify the recipe data through the human-machine interface, select the bottom blowing process recipes for different steel grades and different media. At the same time, the module can receive the communication data interface signal of the main PLC of the electric furnace system, identify different smelting stages, and realize the automatic switching of the process in the real-time smelting stage of multi-media bottom blowing.
2. The electric furnace bottom blowing system with a multi-media common bottom blowing gun according to claim 1 is characterized in that: In the gas pretreatment and seamless switching module, the gas pretreatment system is used to perform precise pre-pressure regulation on different media. A switching mechanism is designed inside the module, which includes a solenoid valve, an internal buffer tank and a three-way valve, ensuring the smoothness and continuity of the gas switching process. Before switching, the system precalculates the exhaust time. This step is based on the understanding of the characteristics of different gases and the precise control of the system working pressure. Through precise calculation, the system maintains the pressure in the buffer tank stable at the system working pressure level during the switching process, thereby avoiding the bottom blowing vacuum gap time caused by pressure fluctuations and ensuring the continuity of the bottom blowing process.
3. The electric furnace bottom blowing system with a multi-media common bottom blowing gun according to claim 1 is characterized in that: In the flow control module, a mass flow controller is used as a core component, which can automatically adjust the control strategy according to the deviation between the actual gas flow and the set value to achieve rapid response and precise control of the flow. The precise flow control module is closely connected to the PLC system through RS485 or hard wiring. The PLC system receives the feedback signal from the mass flow controller to understand the current gas flow situation in real time, and calculates the required gas flow set value according to the smelting process requirements, and then sends this set value to the mass flow controller, which performs specific flow regulation tasks.
4. The electric furnace bottom blowing system with a multi-media common bottom blowing gun according to claim 1 is characterized in that: In the flow maintenance and energy saving module, a pre-pressure control valve is set in front of each branch pipe through a mass flow controller to ensure the stability of the gas supply pressure. The minimum ventilation volume required can be accurately calculated through the PLC logic algorithm according to the furnace capacity and smelting requirements. The module also has the function of intelligent energy saving. Through real-time monitoring and calculation of the PLC system, the ventilation volume is automatically adjusted according to changes in the smelting process to ensure that the best energy consumption ratio can be maintained at different stages of smelting.
5. The electric furnace bottom blowing system with a multi-media common bottom blowing gun according to claim 1, characterized in that: In the air brick monitoring and early warning module, temperature and pressure sensors are installed on each air brick to collect temperature and pressure data around the air brick in real time, and send these data to the central control system through the signal transmission line. The data analysis algorithm in the central control system will process and analyze the received data to evaluate whether the working status of the air brick is normal. Through the preset threshold, the system can determine whether the air brick has potential problems such as overheating, blockage or wear. Once an abnormal situation is detected, the system immediately activates the early warning mechanism and sends a warning signal to the operator through sound and light alarms, SMS notifications or email reminders. At the same time, the system will also record the time, location and specific parameters of the abnormal event, providing an important basis for subsequent troubleshooting and maintenance.
6. The electric furnace bottom blowing system with a multi-media common bottom blowing gun according to claim 1, characterized in that: The automatic switching module includes multiple independent solenoid valves, each of which corresponds to a medium supply pipeline. Through the instructions of the PLC control system, the solenoid valve group quickly and accurately opens or closes the corresponding medium supply pipeline to achieve automatic switching of the medium. At the same time, the solenoid valve group is equipped with a pressure sensor and a flow sensor to monitor the pressure and flow changes in the pipeline in real time to prevent the pressure fluctuations or flow mutations caused by switching from adversely affecting the smelting process.