Novel converting furnace flux feeding control system and method

Abstract

The invention relates to a novel converting furnace flux feeding control system which comprises a flux preparation subsystem, a flux supply subsystem, a flux control subsystem and a converting slag type control subsystem. The flux preparation subsystem conveys flux to a flux intermediate bin through a bin electric vibrator and a belt conveyor, and the flux intermediate bin is provided with a full material monitoring device to achieve stable material preparation and accurate material level control. The flux feeding subsystem is used for connecting the intermediate bin to a discharge port of the furnace kiln through a belt conveyor; the flux control subsystem is combined with a logic controller based on a flux calculation module, a temperature detection module, a flux opening blockage detection module and a deslagging state detection module to drive a belt conveyor to operate; and the converting slag type subsystem dynamically feeds back and adjusts feeding through a slag type detection and judgment module, a slag temperature detection and judgment module and a blanking correction module. According to the system, full-flow automatic control over flux feeding is achieved, accurate flux feeding is achieved, and the stability of the blowing technology and the operation reliability of equipment are effectively improved.

Description

Technical Field

[0001] The present invention relates to the field of copper pyrometallurgy, and particularly to a novel flux feeding control system and method for a converting furnace. Background Art

[0002] During the process of converting matte into blister copper by copper pyrometallurgy, the flux feeding control of the converting furnace directly affects the stability of the slag type structure and the operation efficiency of the production system. Traditional flux feeding systems mostly adopt the method of segmented mechanical conveying combined with manual experience regulation, which has defects such as low automation degree and lagging control parameters. Although the prior art has improvements in specific links such as the feeding device, level monitoring, and batching of the feeding system, when facing complex working conditions such as multi-gun top-blown process, intermittent discharge characteristics of the melt, and sensitivity of the slag type composition, there are still problems such as insufficient system coordination, the correlation between the flux composition and the slag type and slag temperature, and the lack of a dynamic correction mechanism, making it difficult to meet the high standards of the large-scale continuous converting process in terms of operation automation, process intelligence, management visualization, production safety, etc. Summary of the Invention

[0003] To solve the problems existing in the above-mentioned background technology, the present invention provides a novel flux feeding control system for a blowing furnace, which specifically includes a flux preparation subsystem, a flux feeding subsystem, a flux control subsystem, and a blowing slag type control subsystem; the flux preparation subsystem includes a bin electric vibration unit, a belt conveyor, a flux intermediate bin, and an intermediate bin full material judgment control device. Among them, the first belt conveyor extends from the discharge end of the bin electric vibration unit to the feed inlet of the flux intermediate bin, and the output end of the intermediate bin full material judgment module is communicatively connected to the bin electric vibration unit and the first belt conveyor; the flux feeding subsystem includes a belt conveyor, a flux discharge port, a human-machine isolation device, a weighing device, and a monitoring device. Among them, the input end of the second belt conveyor is connected to the discharge port of the flux intermediate bin, and the output end extends to the flux discharge port; the flux control subsystem includes a flux calculation module, a first temperature detection module, a flux port blockage monitoring module, a slag discharge state detection module, and a first logic controller arranged in parallel. Among them, the input end of the first logic controller is communicatively connected to the output ends of the flux calculation module, the first temperature detection module, the flux port blockage monitoring module, and the slag discharge state detection module respectively, and the output end of the first logic controller is communicatively connected to the second belt conveyor; the blowing slag type control subsystem includes a molten slag detection and analysis module, a flux discharge correction module, and a second logic controller. The input end of the second logic controller is communicatively connected to the output end of the molten slag detection and analysis module, and its output end is communicatively connected to the input end of the flux discharge correction module; the output end of the flux discharge correction module is communicatively connected to the flux calculation module for supplementary calculation of the flux addition amount of the blowing furnace; among them, the molten slag detection and analysis module further includes a molten slag temperature sensing unit and a slag temperature logic controller. The signal output end of the molten slag temperature sensing unit is communicatively connected to the input end of the slag temperature logic controller, and the output end of the slag temperature logic controller is communicatively connected to the second belt conveyor.

[0004] Further, the lower space of the flux intermediate bin is composed of a plurality of compartments arranged in parallel, and the compartments share the top space and are connected to the feed inlet of the flux intermediate bin.

[0005] Further, the intermediate bin full material judgment device includes a level sensor arranged on the upper edge of the inner wall of the flux intermediate bin, a camera device fixed above the flux intermediate bin, and a third logic controller. The output end of the third logic controller is communicatively connected to the bin electric vibration unit and the first belt conveyor.

[0006] Further, the first temperature detection module includes a first temperature sensing unit and a second temperature sensing unit. Among them, the first temperature sensing unit is located at the flux discharge port, and the second temperature sensing unit is located at the crude copper discharge port of the blowing furnace kiln.

[0007] Further, the flux calculation module includes a first information storage unit and a flux calculation unit. The information storage unit includes a first computer storage medium with flux component information, the amount of raw materials charged into the furnace, smelting process production parameters, production cumulative time, cumulative value of the amount of raw materials charged into the converter, and the target value of the slag type structure of the converter slag. The output end of the flux calculation unit is connected to the first logic controller.

[0008] Further, the flux feeding correction module includes a second information storage unit and a difference calculation unit. The input end of the difference calculation unit is in data communication with the slag detection and analysis module and the second information storage unit, and the output end is connected to the flux calculation unit. Among them, the second information storage unit includes a computer storage medium with the process control target value of the converter slag.

[0009] The present invention also provides a method for a new type of converter flux feeding control system, including the following steps:

[0010] Step (1): Under the condition that the flux intermediate bin is not full, the first belt conveyor is started to complete the preparation operation of the flux intermediate bin. The flux enters the converter furnace in sequence through the flux intermediate bin, the second belt conveyor, and the flux feeding port.

[0011] Step (2): The flux calculation module obtains the flux component information, the amount of raw materials charged into the furnace, and the target value of the slag type structure of the converter slag, and calculates the amount of flux supplement required by the converter furnace; the first temperature detection module monitors the first melt temperature at the flux feeding port and the second melt temperature at the crude copper discharge port of the converter furnace in real time; the flux port blockage monitoring module obtains the blockage state of the flux feeding port; the slag discharge state detection module obtains the slag discharge situation of the converter furnace.

[0012] Step (3): Based on the information in Step (2), the first logic controller performs the following logical judgments:

[0013] a. When the amount of flux supplement is greater than the actual addition amount, and the melt temperature reaches the process target value, and the flux feeding port is unobstructed and the converter furnace is not in the slag discharge state, start the second belt conveyor to supply flux.

[0014] b. When one of the four conditions that the amount of flux supplement is less than the actual addition amount, or the melt temperature does not reach the process target value, or the flux feeding port is blocked, or the converter furnace is in the slag discharge state is met, stop the second belt conveyor.

[0015] Step (4): The slag detection and analysis module obtains the slag type structure and slag temperature information in real time, compares it with the process control requirements, and the second logic controller performs the following logical judgments:

[0016] 1) If the slag type structure does not meet the process control target, trigger the flux feeding correction module to perform dynamic compensation calculation on the flux supplement amount. Based on the current blowing slag type structure, molten slag amount, actual flux addition amount and calculated amount, calculate the flux correction amount value;

[0017] 2) If the molten slag temperature exceeds the threshold value, cancel the execution action of the slag discharge condition determination. Combine other determination conditions for the start of the second belt conveyor, and on the premise of meeting the start of the second belt conveyor, start the second belt conveyor to supplement flux into the blowing furnace to reduce the temperature of the melt in the blowing furnace;

[0018] 3) If the slag type structure does not meet the process control target and the molten slag temperature does not exceed the threshold value, then maintain the current flux feeding strategy.

[0019] Compared with the prior art, the present invention has the following beneficial effects: The flux feeding control system for the blowing furnace realizes the intelligent control of feeding and blowing slag type by establishing a flux calculation and correction model, logical determination of each process condition, equipment action control, etc., which is beneficial to stabilizing the quality of blowing products, reducing the consumption of flux and the amount of blowing slag, reducing the fuel consumption for smelting, improving the production safety factor, reducing the labor intensity of personnel, and improving the stability of the blowing furnace condition. Description of the Drawings

[0020] Figure 1 It is a schematic diagram of the material carrying structure of the novel flux feeding control system for the blowing furnace of the present invention;

[0021] Figure 2 It is a working flow chart of the novel flux feeding control system for the blowing furnace in Embodiment 1 of the present invention.

[0022] Description of the reference numerals: 1. Flux preparation subsystem; 101. Bin electric vibration unit; 102. First belt conveyor; 103. Flux intermediate bin; 104. Intermediate bin full material determination control device; 1041. Level sensor; 1042. Camera device; 2. Flux feeding subsystem; 201. Second belt conveyor; 202. Flux feeding port; 3. Flux control subsystem; 301. Flux calculation module; 302. First temperature detection module; 3021. First temperature sensor; 3022. Second temperature sensor; 303. Flux port blockage monitoring module; 304. Slag discharge state detection module; 305. First logic controller; 4. Blowing slag type control subsystem; 401. Molten slag detection and analysis module; 402. Flux feeding correction module; 403. Second logic controller. Detailed Embodiments

[0023] The present invention will be described in detail below in conjunction with the accompanying drawings and specific embodiments. The embodiments shown below do not limit the content of the invention described in the claims in any way. In addition, all the contents of the configurations shown in the following embodiments are not limited to those necessary for the solution of the invention described in the claims.

[0024] Embodiment 1

[0025] A novel flux feeding control system for a blowing furnace is as Figure 1 and Figure 2 shown, and includes a flux preparation subsystem 1, a flux feeding subsystem 2, a flux control subsystem 3, and a blowing slag type control subsystem 4; the flux preparation subsystem 1 is composed of a bin electric vibration unit 101, a first belt conveyor 102, a flux intermediate bin 103, and an intermediate bin full material determination control device 104. The intermediate bin full material determination control device 104 receives signals from a level sensor 1041 provided on the upper edge of the inner wall of the flux intermediate bin 103 and a camera device 1042 fixed above the flux intermediate bin 103 through a third logic controller, and controls the start and stop operations of the first belt conveyor and the bin electric vibration unit by using "AND" and "OR" relationships to achieve the flux preparation function for the blowing furnace.

[0026] The working principle of the flux preparation subsystem 1 is as follows: Under the condition that the flux intermediate bin 103 is not full, start the first belt conveyor 102. After the belt conveyor runs normally, start the bin electric vibration unit 101 to complete the preparation and supply of the flux from the flux ore bin to the flux intermediate bin; when the system is in the process of preparing materials, if the flux intermediate bin 103 is in a full state, first stop the electric vibration device of the bin electric vibration unit 101, and then stop the operation of the first belt conveyor after the electric vibration device is completely closed; a certain adjustment space should be reserved for the flux intermediate bin during the preparation process, and the flux intermediate bin should not be overfilled to avoid equipment damage or increased labor intensity and operation risks of personnel; when the system is in a full state, it is prohibited to start the bin electric vibration unit 101 and the first belt conveyor 102 at its upper end to ensure the stable and safe operation of the equipment during this process; the running device of the belt conveyor is provided with an isolation net and a guardrail to achieve effective physical isolation between people and the running equipment. At the same time, an emergency stop device and an interlock function are provided on site for easy emergency handling; if a running equipment fails, it should be shut down for processing to ensure the safety of personnel operations.

[0027] The flux feeding subsystem 2 is composed of a second belt conveyor 201, a flux discharging port 202, a weighing device, and a human-machine isolation device. The input end of the second belt conveyor 201 is connected to the discharging port of the flux intermediate bin 103, and the output end extends to the flux discharging port 202 of the blowing furnace to ensure the stability of the flux feeding state.

[0028] The flux control subsystem 3 consists of a flux calculation module 301, a first temperature detection module 302, a flux port blockage monitoring module 303, a slag discharge state detection module 304, and a first logic controller 305. The input ends of the first logic controller 305 are respectively communicatively connected to the flux calculation module 301, the first temperature detection module 302, the flux feeding port blockage monitoring module 303, and the slag discharge state detection module 304. The output end of the first logic controller 305 is communicatively connected to the second belt conveyor 201, and uses the "AND" and "OR" relationships to control the start and stop operations of the second belt conveyor 201, ensuring the stability of the smelting process and the safe operation of the equipment. Among them, the flux calculation module 301 collects raw material composition information, the amount of raw materials entering the furnace, smelting process production parameters, production cumulative time, the cumulative value of the amount of raw materials entering the furnace for blowing, and the target parameters of the slag type structure for blowing, comprehensively calculates the amount of flux required by the blowing furnace, and initially formulates the flux addition method in combination with the actual production situation. The first temperature detection module 302 includes a first temperature sensor 3021 and a second temperature sensor 3022. The first temperature sensor 3021 is located at the flux feeding port and is used to detect the melt temperature in the furnace, that is, the first melt temperature. The second temperature sensor 3022 is located at the crude copper discharge port of the blowing furnace and is used to detect the melt temperature at the discharge port, that is, the second melt temperature. The first logic controller 305 determines the next control action of the second belt conveyor 201 based on the condition information such as the supplementary flux amount, melt temperature, whether to discharge slag, and whether the blowing flux port is unobstructed output by the flux calculation module 301. The specific determination process is as follows:

[0029] (1) The supplementary flux is one of the determination conditions for the start and stop of the second belt conveyor 201. After the supplementary flux condition is met, the second belt conveyor 201 may be started. This condition is the "yes (AND 1)" relationship for the operation of the second belt conveyor 201. If the supplementary flux condition is not met, the second belt conveyor 201 shall not be started. This condition is the "no (OR 1)" relationship for the stop of the second belt conveyor 201. Its determination standard is mainly based on the comparison relationship between the calculated value of the flux calculation model and the actual addition amount. When the calculated value is greater than the actual addition value, the "yes (AND 1)" relationship is used. When the calculated value is less than the actual addition value, the "no (OR 1)" relationship is used. The setting of this condition is highly adaptable to other production processes on the basis of meeting the flux addition in the blowing process, ensuring the safety and stability of the production control of the blowing furnace;

[0030] (2) The melt temperature is one of the start / stop determination conditions for the second belt conveyor 201. When the first melt temperature measured at the flux feeding port and the second melt temperature measured at the crude copper discharge port of the smelting furnace kiln both reach the target values, the second belt conveyor is started. This condition is the "qualified (and 2)" relationship for the operation of the second belt conveyor 201. If either the first melt temperature or the second melt temperature does not reach the target value, the second belt conveyor 201 shall not be started. This condition is the "unqualified (or 2)" relationship for the second belt conveyor 201 to stop running. The setting of this condition is based on the operation status and stability of the smelting process, ensuring that the smelting melt temperature is controlled within the process standard requirements, reducing a series of adverse effects caused by abnormal temperature, and further promoting the stability of the process production and the safety of the equipment operation;

[0031] (3) The unobstructed state of the flux feeding port is one of the start / stop determination conditions for the second belt conveyor 201. Only when the flux feeding port is unobstructed can the second belt conveyor 201 be started. This condition is the "yes (and 3)" relationship for the operation of the second belt conveyor 201. When the flux feeding port is obstructed, the second belt conveyor 201 shall not be started. This condition is the "no (or 3)" relationship for the second belt conveyor 201 to stop running. The front end of the smelting flux port is connected to the feeding system, and the rear end is connected to the smelting furnace kiln, playing a connecting role. Only by keeping the smelting furnace flux port 202 unobstructed can the smooth feeding control of the smelting flux be satisfied;

[0032] (4) The slag discharge state of the smelting furnace is one of the start / stop determination conditions for the second belt conveyor 201. When the smelting furnace has discharged slag or has a slag discharge plan in a short time, and the air quenching pressure, water jacket temperature, and water pump current all increase to the target values of the slag discharge operation parameters, the second belt conveyor 201 shall not be started. This condition is the "yes (or 4)" relationship for the second belt conveyor 201 to stop running. When the air quenching pressure, water jacket temperature, and water pump current do not reach the target values of the slag discharge operation parameters during the slag discharge process, the second belt conveyor 201 is started. This condition is the "no (and 4)" relationship for the operation of the second belt conveyor 201. As an endothermic mineral in the smelting process, the flux affects the smelting melt temperature and the slag properties, and may have an adverse impact on the slag discharge process of the smelting furnace. In order to ensure the smooth progress of the smelting slag discharge process, this control requirement is specifically set.

[0033] The converter slag type determination control system 4 is composed of a slag detection and analysis module 401, a flux feeding correction module 402, and a second logic controller 403. The input end of the second logic controller 403 is communicatively connected to the output end of the slag detection and analysis module 401, its output end is communicatively connected to the input end of the flux feeding correction module 402, and the output end of the flux feeding correction module 402 is communicatively connected to the flux calculation module 301. The detection and analysis results of the converter slag obtained by the slag detection and analysis module 401 are compared and analyzed with the process control target value of the converter slag type to determine whether the structure of the converter slag type meets the process requirements. If it meets the requirements, the current flux feeding operation of the converter furnace is completed. If it does not meet the requirements, the system will execute the correction of the flux calculation model. The output end of the flux feeding correction module 402 is communicatively connected to the flux calculation module 301. Based on the current converter slag type structure, the slag amount, the actual added amount and the calculated amount of the flux, the corrected amount value of the flux is calculated to further ensure that the structure of the converter slag type meets the requirements of process production.

[0034] The slag detection and analysis module 401 further includes a slag temperature sensor and a slag temperature logic controller. The slag temperature sensor is arranged at the slag discharge port of the converter furnace to collect the slag temperature, and its signal output end is communicatively connected to the input end of the slag temperature logic controller for temperature supplementary determination. The output end of the slag temperature logic controller is connected to the start operation of the second belt conveyor 201. Its determination and control principle is as follows: when the slag temperature exceeds the process control target limit value (i.e., "overlimit"), it has seriously affected the service life of the furnace and the safety of production operation. This method is an emergency disposal measure to cancel the execution of the slag discharge condition "yes (or 4)". At the same time, it is combined with the determination processes of (1), (2), and (3) of the next control action of the second belt conveyor 201. After all the start conditions of the belt conveyor 201 are met, the belt conveyor 201 is started to supplement the lacking flux amount to the feeding port for the cooling operation of the melt inside the converter furnace. When the slag temperature does not exceed the process control target limit value (i.e., "not overlimit"), the execution of the slag discharge condition "yes (or 4)" is carried out, and it is combined with the determination processes of (1), (2), (3), and (4) of the next control action of the second belt conveyor 201, and the stop operation of the second belt conveyor 201 is executed.

[0035] Embodiment 2

[0036] Based on Embodiment 1 of the present invention, the lower space of the flux intermediate bin 103 is composed of a plurality of compartments arranged in parallel. The compartments share the top space and are connected to the feed port of the flux intermediate bin 103. The discharge ports of the compartments are connected to the belt conveyors of a plurality of flux feeding subsystems, ensuring uniform cloth feeding and enabling simultaneous material preparation for multiple production lines.

[0037] The foregoing description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A novel flux feeding control system for a blowing furnace, characterized in that, It includes a flux preparation subsystem, a flux feeding subsystem, a flux control subsystem, and a converter slag type control subsystem; The flux preparation subsystem includes a bin electro-vibrating unit, a belt conveyor, a flux intermediate bin, and an intermediate bin full material determination control device. Among them, the first belt conveyor extends from the discharge end of the bin electro-vibrating unit to the inlet of the flux intermediate bin, and the output end of the intermediate bin full material determination module is communicatively connected to the bin electro-vibrating unit and the first belt conveyor; The flux feeding subsystem includes a belt conveyor, a flux discharging opening, a man-machine isolation device, a weighing device, and a monitoring device. Among them, the input end of the second belt conveyor is connected to the discharge port of the flux intermediate bin, and the output end extends to the flux discharging opening; The flux control subsystem includes a flux calculation module, a first temperature detection module, a flux opening blockage monitoring module, a slag discharging state detection module, and a first logic controller arranged in parallel. Among them, the input end of the first logic controller is communicatively connected to the output ends of the flux calculation module, the first temperature detection module, the flux opening blockage monitoring module, and the slag discharging state detection module respectively, and the output end of the first logic controller is communicatively connected to the second belt conveyor; The converter slag type control subsystem includes a molten slag detection and analysis module, a flux feeding correction module, and a second logic controller. The input end of the second logic controller is communicatively connected to the output end of the molten slag detection and analysis module, and its output end is communicatively connected to the input end of the flux feeding correction module; the output end of the flux feeding correction module is communicatively connected to the flux calculation module, and is used for supplementary calculation of the flux addition amount of the converter; Among them, the molten slag detection and analysis module further includes a molten slag temperature sensing unit and a slag temperature logic controller. The signal output end of the molten slag temperature sensing unit is communicatively connected to the input end of the slag temperature logic controller, and the output end of the slag temperature logic controller is communicatively connected to the second belt conveyor.

2. The novel converter flux feeding control system according to claim 1, wherein The lower space of the flux intermediate bin is composed of a plurality of compartments arranged in parallel, and the compartments share the top space and are connected to the inlet of the flux intermediate bin.

3. The novel converter flux feeding control system according to claim 1, characterized in that, The intermediate bin full material determination device includes a level sensor arranged on the upper edge of the inner wall of the flux intermediate bin, a camera device fixed above the flux intermediate bin, and a third logic controller. The output end of the third logic controller is communicatively connected to the bin electro-vibrating unit and the first belt conveyor.

4. The novel converter flux feeding control system according to claim 1, wherein The first temperature detection module includes a first temperature sensing unit and a second temperature sensing unit. Among them, the first temperature sensing unit is located at the flux discharging opening, and the second temperature sensing unit is located at the crude copper discharge port of the converter furnace.

5. The novel converter flux feeding control system according to claim 1, characterized in that, The flux calculation module includes a first information storage unit and a flux calculation unit. The information storage unit includes a first computer storage medium with flux component information, furnace charge amount, smelting process production parameters, production cumulative time, cumulative value of the furnace charge amount for converting, and target value of the converter slag type structure. The output end of the flux calculation unit is connected to the first logic controller.

6. The novel converter flux feeding control system according to claim 5, characterized in that The flux feeding correction module includes a second information storage unit and a difference calculation unit. The input end of the difference calculation unit is in data communication with the slag detection and analysis module and the second information storage unit, and the output end is connected to the flux calculation unit. Among them, the second information storage unit includes a computer storage medium with the process control target value of the blowing slag.

7. A method for a new converter flux feeding control system according to any one of claims 1-6, characterized in that, The method includes the following steps: Step (1): Under the condition that the flux intermediate bin is not full, the first belt conveyor starts to complete the feeding operation of the flux intermediate bin. The flux enters the blowing furnace through the flux intermediate bin, the second belt conveyor, and the flux feeding port in sequence. Step (2): The flux calculation module obtains the flux component information, the amount of raw materials entering the furnace, and the target value of the slag type structure of the blowing slag, and calculates the required flux supplement amount for the blowing furnace; the first temperature detection module monitors the first melt temperature at the flux feeding port and the second melt temperature at the crude copper discharge port of the blowing furnace in real time; the flux port blockage monitoring module obtains the blockage state of the flux feeding port; the slag discharge state detection module obtains the slag discharge situation of the blowing furnace. Step (3): Based on the information in Step (2), the first logic controller performs the following logical judgments: a. When the flux supplement amount is greater than the actual addition amount, and the melt temperature reaches the process target value, and the flux feeding port is unobstructed and the blowing furnace is not in the slag discharge state, start the second belt conveyor to supply flux. b. When one of the four conditions that the flux supplement amount is less than the actual addition amount, or the melt temperature does not reach the process target value, or the flux feeding port is blocked, or the blowing furnace is in the slag discharge state is satisfied, stop the second belt conveyor. Step (4): The slag detection and analysis module obtains the slag type structure and slag temperature information in real time, compares it with the process control requirements, and the second logic controller performs the following logical judgments: 1). If the slag type structure does not meet the process control target, trigger the flux feeding correction module to perform dynamic compensation calculation on the flux supplement amount, and calculate the flux correction value based on the current blowing slag type structure, slag amount, actual flux addition amount, and calculated amount. 2). If the slag temperature exceeds the threshold, cancel the execution action of the slag discharge condition judgment, combine the other judgment conditions for starting the second belt conveyor, and start the second belt conveyor to supplement flux into the blowing furnace to reduce the melt temperature in the blowing furnace on the premise of satisfying the start of the second belt conveyor. 3) If the slag type structure does not meet the process control target and the slag temperature does not exceed the threshold, maintain the current flux feeding strategy.

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