Sintering machine sintering end point temperature control system and method

Abstract

The invention provides a sintering machine sintering end point temperature control system and a control method thereof. The system comprises a material processing unit, a combustion control unit, a process monitoring unit, an intelligent regulation and control unit and a transportation execution unit, data such as temperature, pressure and smoke flow are obtained and analyzed in real time through an integrated edge intelligent control system, and combustion parameters are dynamically optimized. The system accurately adjusts the sintering process through multi-source temperature detection, material layer thickness monitoring and air permeability calculation, ensures accurate control of the sintering end point temperature, and avoids waste of energy and raw materials. The intelligent feed-forward control adjusts control signals according to real-time production parameters, improves production efficiency and optimizes energy consumption. And by intelligently adjusting the machine speed of the sintering machine and dynamically matching the feeding rate, collaborative operation of all procedures is ensured, and the controllability and adaptability of the sintering process are improved. The method can stably operate under different production environments or equipment fluctuations, and has high self-adaptive capacity.

Description

Technical Field

[0001] The present invention relates to the technical field of iron and steel metallurgy, and in particular to a sintering end-point temperature control system and method for a sintering machine. Background Art

[0002] Sintering machines are core equipment in steel production. Their operating efficiency and control accuracy directly impact sinter quality and energy consumption. The sintering endpoint temperature is one of the most critical process parameters in the sintering process, directly impacting the physical and metallurgical properties of the sintered ore. However, steel companies currently face numerous challenges in controlling this temperature.

[0003] In the sintering workshops of steel companies, the sintering endpoint temperature must be monitored in real time during sintering machine operation to ensure the stable quality of the sintered ore. Existing temperature control methods rely primarily on manual judgment and traditional PID control. These traditional PID control methods are difficult to adapt to the complex process changes during the sintering process. In particular, the 40 minutes it takes from the sintering head to the sintering machine endpoint temperature is significant, resulting in large fluctuations in the sintering endpoint temperature and affecting the quality stability of the sintered ore. Furthermore, inaccurate temperature control can easily lead to over- or under-burning of the sintered ore, which not only increases the amount of ore returned, causing a decrease in sintering output, but also increases energy consumption and wastes resources.

[0004] Traditional control methods are mostly manual control, which takes up most of the workload of central control personnel; some use traditional PID control methods, which require a lot of manual intervention, increasing the labor intensity of operators, and may also cause control errors due to human factors. Summary of the Invention

[0005] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a sintering end point temperature control system and method for a sintering machine.

[0006] To achieve the above-mentioned purpose, the present invention adopts the following technical solutions: a sintering terminal temperature control system for a sintering machine, the control system including a material handling unit, a combustion control unit, a process monitoring unit, an intelligent control unit and a transport execution unit; the material handling unit includes a mixing bin, a round roller feeder and a material level detector that are linked in sequence; the combustion control unit is provided with an ignition furnace, a bellows, a main exhaust fan and a large flue; the process monitoring unit includes a terminal temperature position, a temperature detector, a first pressure detector, a second pressure detector and a flue gas flow detector arranged along the running direction of the trolley; the intelligent control unit integrates the data of various sensors by the edge intelligent control system to realize dynamic optimization of combustion parameters; the transport execution unit adopts a chain conveyor system controlled by a drive speed regulation device to carry the mixed material to complete the continuous sintering operation.

[0007] Preferably, the material processing unit is further provided with grate bars; the grate bars form a uniform air-permeable layer; the round roller feeder is equipped with a variable frequency speed regulating mechanism to achieve dynamic matching of the feeding rate and the subsequent combustion process.

[0008] Preferably, a temperature detector is provided at the front, rear, left and right of each of the bellows to form a multi-source temperature measurement network, thereby obtaining the temperature change slope of the bellows.

[0009] Preferably, the second pressure detector and the flue gas flow detector are arranged on the front end of the main exhaust fan; the first pressure detector is arranged at the front end of the bellows; and the permeability of the material layer is calculated by the flue gas volume and pressure changes detected by the flue gas flow detector, the first pressure detector and the second pressure detector.

[0010] Preferably, the air permeability calculation formula is: Material layer permeability = gas flow / pressure drop × effective sintering area.

[0011] Preferably, a plurality of material level detectors are arranged below the roller feeder, and dynamically monitor the thickness change of the material layer and take the average value of the real-time thickness of the material layer at each of S consecutive material level detection points.

[0012] A method for controlling the sintering endpoint temperature of a sintering machine is described as follows: S1: Obtain production parameters and generate intelligent feedforward signals through adjustments; The production parameters include the main exhaust fan inlet flue gas flow rate, the main exhaust fan inlet pressure value, and the bellows pressure value; The adjustment includes correcting the temperature change slope of each bellows, correcting the thickness change slope of the material layer, changing the trolley and changing the grate bars; The acquired parameters are adjusted through intelligent methods to finally generate intelligent feedforward signals; S2: Adjust the main and sub-controllers to make the sintering endpoint temperature reach the actual position; The sintering endpoint temperature position is preset in the system. The main controller adjusts the set value of the sintering machine speed according to the intelligent feedforward signal generated in step S, and controls the speed regulation drive device through the sub-controller to make the sintering machine speed meet the actual position of the sintering endpoint temperature. If it is not met, the set value of the sintering machine speed is readjusted.

[0013] Compared with the existing technology, the beneficial effects of the present invention are as follows: the present invention acquires and analyzes data from various sensors in real time, including temperature, pressure, flue gas flow, etc., through the integration of an edge intelligent control system, and can dynamically optimize combustion parameters. Intelligent feedforward control not only improves the efficiency of the sintering process, but also can adjust the control signal according to real-time production parameters to ensure accurate control of the end temperature of the sintering machine. Secondly, in the combustion control unit and process monitoring unit, the reasonable layout of temperature detectors, pressure detectors and flue gas flow detectors can comprehensively monitor all aspects of the sintering process. Through a multi-source temperature network and dynamic monitoring of the material layer thickness, the permeability of the material layer and its matching with the combustion process can be more accurately detected and adjusted, thereby improving the controllability of the sintering process. This system calculates the permeability of the material layer by comprehensively utilizing data on flue gas flow, pressure drop and effective sintering area, thereby providing more accurate combustion conditions and avoiding sintering quality problems caused by insufficient or excessive permeability of the material layer. This system adopts a dynamically matched feed rate and combustion process, so that each link in the sintering process works together and optimizes energy consumption. At the same time, intelligently adjusting the sintering machine speed ensures precise control of the sintering endpoint temperature, avoiding excessive consumption of energy and raw materials and improving overall production efficiency. The system automatically adjusts sintering parameters, such as bed thickness and bellows temperature, based on real-time data changes. Its strong adaptability allows it to maintain efficient and stable operation despite changes in the production environment or fluctuations in equipment status. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is the end point temperature control system diagram of the sintering machine; Figure 2 This is the principle diagram of sintering endpoint temperature control; Figure 3 This is a schematic diagram of bellows temperature measurement; In the figure: 1. Mixing bin; 2. Roller feeder; 3. Material level detector; 4. Ignition furnace; 5. Trolley; 6. Mixing material; 7. Grate; 8. Bellows; 9. End temperature position; 10. Temperature detector; 11. First pressure detector; 12. Drive speed control device; 13. Large flue; 14. Second pressure detector; 15. Flue gas flow detector; 16. Main exhaust fan; 17. Edge intelligent control system. DETAILED DESCRIPTION

[0015] In order to provide a further understanding of the purpose, structure, features, and functions of the present invention, the present invention is described in detail below with reference to the embodiments.

[0016] Please refer to Figure 1 Figure 2 as well as Figure 3The present invention provides a sintering terminal temperature control system for a sintering machine, the control system comprising a material handling unit, a combustion control unit, a process monitoring unit, an intelligent control unit and a transport execution unit; the material handling unit comprises a mixing bin 1, a round roller feeder 2 and a material level detector 3 which are linked in sequence; the combustion control unit is provided with an ignition furnace 4, a bellows 8, a main exhaust fan 16 and a large flue 13; the process monitoring unit comprises an end temperature position 9, a temperature detector 10, a first pressure detector 11, a second pressure detector 14 and a flue gas flow detector 15 arranged along the running direction of the trolley 5; the intelligent control unit integrates the data of various sensors by an edge intelligent control system 17 to realize dynamic optimization of combustion parameters; the transport execution unit adopts a chain conveyor system controlled by a drive speed regulating device 12 to carry the mixed material 6 to complete the continuous sintering operation.

[0017] Through the close collaboration of the material handling unit, combustion control unit, process monitoring unit, intelligent control unit, and transport execution unit, the system achieves precise control of the sintering process. The intelligent control unit utilizes an edge intelligence system to collect and analyze sensor data in real time, dynamically optimizing combustion parameters. It automatically adjusts parameters such as temperature, pressure, and flue gas flow during production, ensuring the sintering process remains optimal, resulting in efficient and stable sintering operations.

[0018] The introduction of multiple monitoring methods into the system makes the entire sintering process more transparent and controllable. Process monitoring units, including temperature detectors, pressure detectors, and flue gas flow detectors, provide real-time monitoring of every step in the sintering process and provide accurate feedback to the intelligent control unit. This multi-dimensional, real-time monitoring helps promptly identify and address potential production issues, reducing manual intervention and improving production efficiency and accuracy.

[0019] The design utilizes a roller feeder, a material level detector, and a drive speed control device on the transport actuator to precisely control the feed rate and match it to the combustion process. Dynamically adjusting the material bed thickness to match combustion parameters avoids sintering quality issues caused by variations in material bed permeability or mismatched combustion conditions. In particular, the system's precise calculation of material bed thickness and permeability ensures a stable sintering process.

[0020] In the combustion control unit, the wind box, main exhaust fan, and large flue work together to more efficiently control airflow and temperature distribution, thereby reducing energy waste. Furthermore, the intelligent control system makes feedforward adjustments based on real-time data, helping to reduce unnecessary energy consumption while ensuring sintering quality, ultimately achieving energy conservation.

[0021] The system utilizes a highly automated design, reducing reliance on manual operation. In particular, with the support of an intelligent control unit, the system adjusts various control points based on real-time data, automatically optimizing production parameters and ensuring the continuity and stability of the sintering process. The intelligent control system not only handles complex production environments but also responds quickly to emergencies, reducing manual intervention and improving overall production efficiency.

[0022] The system integrates multiple feedback mechanisms, including dynamic adjustment of material layer thickness and correction of combustion parameters, and has strong adaptive capabilities. The system can adjust operations in real time based on production conditions and environmental changes, ensuring that the sintering process remains efficient and stable under various changing conditions.

[0023] By real-time monitoring and dynamic adjustment of key parameters during the sintering process, the system ensures precise control of the sintering temperature, thereby improving the consistency and quality of the sintered products. Accurate temperature control prevents over- or under-sintering during the sintering process, ensuring consistent product quality.

[0024] Preferably, the material processing unit is further provided with grate bars 7; the grate bars 7 form a uniform air-permeable layer; the round roller feeder 2 is equipped with a variable frequency speed regulating mechanism to achieve dynamic matching of the feeding rate and the subsequent combustion process.

[0025] The grate design creates a uniform air permeability layer, helping to ensure even airflow distribution during material processing. This improves the efficiency of processes like drying and combustion, preventing localized overheating or incomplete moisture removal, and ultimately enhancing overall process effectiveness. The roller feeder is equipped with a variable frequency speed control mechanism, which adjusts the feed rate according to the needs of the subsequent combustion process. This dynamic matching mechanism ensures an optimal ratio between material supply and combustion, preventing over- or under-supply and optimizing the stability and efficiency of the combustion process.

[0026] Preferably, two temperature detectors 10 are respectively provided at the front, rear, left and right sides of each bellows 8 to form a multi-source temperature measurement network, thereby obtaining the bellows temperature change slope.

[0027] Two temperature detectors are installed in front, behind, and on the left and right sides of each sintering machine wind box, forming a multi-source temperature measurement network to comprehensively monitor the wind box flue gas temperature. To prevent control interference caused by abnormal temperature detector measurements or failures, the system uses abnormal data shielding technology to exclude abnormal temperature data from the control system, ensuring accurate and comprehensive temperature measurement.

[0028] By placing multiple temperature detectors at different locations within the windbox (front, back, left, and right), temperature changes in all areas of the windbox can be more comprehensively monitored. This allows for timely detection of temperature uniformity and abnormal fluctuations within the windbox, ensuring the stability of the entire system. Multi-point temperature monitoring helps obtain more accurate temperature data, allowing analysis of data from each monitoring point to determine the temperature distribution within the windbox. If a temperature anomaly is detected in a specific location, timely adjustments can be made to avoid reduced system efficiency or equipment damage caused by temperature imbalances.

[0029] By acquiring temperature data from multiple temperature measurement points, the slope of the internal temperature change of the windbox can be calculated. This helps evaluate the windbox's thermal dynamic response and understand the rate of temperature increase or decrease. This allows for optimizing the windbox's heating or cooling control strategy, improving energy efficiency and avoiding equipment damage caused by excessively rapid temperature changes.

[0030] Preferably, the second pressure detector 14 and the flue gas flow detector 15 are arranged on the front end of the main exhaust fan 16; the first pressure detector 11 is arranged at the front end of the bellows 8; the permeability of the material layer is calculated by the flue gas volume and pressure changes detected by the flue gas flow detector 15, the first pressure detector 11 and the second pressure detector 14.

[0031] Changes in air permeability directly affect the combustion rate and sintering endpoint temperature: As air permeability increases, the combustion rate accelerates and the sintering endpoint temperature is reached earlier; as air permeability decreases, the combustion rate slows and the sintering endpoint temperature is reached later. The system adjusts the machine speed in advance based on the slope of the air permeability change to stabilize the combustion rate and reduce fluctuations in the sintering endpoint temperature. Furthermore, the system blocks abnormal bellows pressure data to prevent unreasonable machine speed adjustments.

[0032] Preferably, the air permeability calculation formula is: Material layer permeability = gas flow / pressure drop × effective sintering area.

[0033] in: Gas flow rate is the flue gas flow rate under large flue conditions, m 3 / h; Pressure drop is the main exhaust fan inlet pressure, KPa; The effective sintering area is the effective area of the sintering machine, m².

[0034] The first pressure detector is arranged at the front end of the bellows, which can monitor the pressure changes in the bellows and provide the airflow status at the front end of the material layer.

[0035] The second pressure detector and flue gas flow detector are set in front of the main exhaust fan, which helps to monitor the changes in gas flow and pressure, especially at the end of the exhaust system, ensuring that complete airflow data of the entire system can be obtained.

[0036] By monitoring the pressure and flue gas flow at different locations, we can more comprehensively grasp the dynamic changes of the airflow in the system, thereby more accurately controlling the airflow and permeability of the material layer.

[0037] Through comprehensive analysis of flue gas flow and pressure data, the air permeability of the material bed can be calculated in real time. Air permeability is a key indicator for evaluating the ventilation performance of the material bed, affecting airflow distribution and heat transfer efficiency during material handling. This calculation can promptly identify insufficient or abnormal air permeability, allowing appropriate adjustments and process optimization.

[0038] Accurately calculating the permeability of a material bed helps optimize airflow control and ensure uniform airflow distribution. This is particularly true in processes such as drying and combustion, where air permeability directly impacts energy consumption, thermal efficiency, and material handling quality. Real-time monitoring and calculation of permeability allows for timely adjustment of operating parameters, avoiding excessive or insufficient airflow, thereby ensuring process stability and efficiency.

[0039] Preferably, a plurality of the material level detectors 3 are arranged below the roller feeder 2, and dynamically monitor the thickness change of the material layer and take the average value of the real-time thickness of the material layer at each material level detection point for 30 consecutive seconds.

[0040] By dynamically monitoring changes in material layer thickness, the system analyzes in real time the impact of abnormal material layer thickness on the windbox temperature. Abnormal material layer thickness causes the windbox temperature to change as the sintering machine carriage moves from front to back. The system uses an algorithm to block abnormal temperature data, preventing unreasonable machine speed adjustments caused by abnormal material layer thickness, thereby improving the stability and rationality of machine speed adjustments.

[0041] The calculation formula of sintering machine speed output value is as follows: N = N1 + N2 + N3 + N4 + N5 + N6 Where: N is the output value of sintering machine speed, m / min; N1——Current reference value of sintering machine, m / min; N2——the corresponding adjustment value of the temperature change slope of each wind box, m / min; N3——the corresponding adjustment value of the slope of the average thickness change of the material layer, m / min; N4——the adjustment value corresponding to the slope of the change in the permeability of the material layer, m / min; N5——Corresponding adjustment value for changing grate bars, m / min; N6——Corresponding adjustment value for changing trolleys, m / min; The slope of change refers to the rate of change of the calculated factor over time or space.

[0042] A method for controlling the sintering endpoint temperature of a sintering machine is described as follows: S1: Obtain production parameters and generate intelligent feedforward signals through adjustments; The production parameters include the main exhaust fan inlet flue gas flow rate, the main exhaust fan inlet pressure value, and the bellows pressure value; The adjustment includes correcting the temperature change slope of each bellows, correcting the thickness change slope of the material layer, changing the trolley and changing the grate bars; The acquired parameters are adjusted through intelligent methods to finally generate intelligent feedforward signals; S2: Adjust the main and sub-controllers to make the sintering endpoint temperature reach the actual position; The sintering endpoint temperature position is preset in the system. The main controller adjusts the set value of the sintering machine speed according to the intelligent feedforward signal generated in step S1, and controls the speed regulating drive device through the sub-controller to make the sintering machine speed meet the actual position of the sintering endpoint temperature. If it does not meet the requirements, the set value of the sintering machine speed is readjusted.

[0043] The mixed material 6 is fed into the mixing bin 1, which then feeds the mixed material into the sintering machine trolley 5 via the roller feeder 2. The sintering trolley moves from front to back under the power of the speed regulating drive device 12. The mixed material in the trolley contains coal powder, and the upper surface of the mixed material is ignited and burned under the ignition combustion of the ignition furnace. The burned mixed material is sucked by the negative pressure of the main exhaust fan 16, and external air enters the mixed material from the top of the trolley as combustion-supporting air to accelerate the combustion of the mixed material. The high-temperature flue gas generated by the combustion enters the wind box 8 through the grate bars 7 at the bottom of the trolley, and then enters the large flue 13, and is finally discharged to the environmental protection system at the rear end through the main exhaust fan for pollutant treatment. The mixed material burns gradually downward from the upper surface and moves from front to back with the trolley. When the trolley moves to the vicinity of the second bellows at the end, the mixed material is completely burned from top to bottom. At this time, the sintering temperature is the highest, that is, the wind box flue gas temperature is the highest. This position is called the sintering end temperature 9 position. Then the sintering temperature drops, and the sintered ore is sent to the rear end of the sintering machine for crushing and cooling.

[0044] The present invention has been described with reference to the above embodiments. However, the above embodiments are merely exemplary embodiments of the present invention. It should be noted that the disclosed embodiments do not limit the scope of the present invention. On the contrary, modifications and improvements that do not depart from the spirit and scope of the present invention are intended to be protected by the present invention.

Claims

1. A sintering machine sintering endpoint temperature control system, characterized by: The control system includes a material handling unit, a combustion control unit, a process monitoring unit, an intelligent control unit and a transport execution unit; the material handling unit includes a mixing bin (1), a roller feeder (2) and a material level detector (3) which are linked in sequence; the combustion control unit is provided with an ignition furnace (4), a bellows (8), a main exhaust fan (16) and a large flue (13); the process monitoring unit includes an end temperature position (9) arranged along the running direction of the trolley (5), a temperature detector (10), a first pressure detector (11), a second pressure detector (14) and a flue gas flow detector (15); the intelligent control unit integrates the data of various sensors by an edge intelligent control system (17) to realize dynamic optimization of combustion parameters; the transport execution unit adopts a chain conveyor system controlled by a drive speed regulating device (12) to carry the mixed material (6) to complete the continuous sintering operation.

2. The sintering endpoint temperature control system of a sintering machine according to claim 1, characterized in that: The material processing unit is further provided with grate bars (7); the grate bars (7) form a uniform air-permeable layer; the round roller feeder (2) is equipped with a variable frequency speed regulating mechanism to achieve dynamic matching of the feeding rate and the subsequent combustion process.

3. The sintering endpoint temperature control system of a sintering machine according to claim 1, characterized in that: Two temperature detectors are respectively provided on the front, back, left and right sides of each bellows (8). (10), a multi-source temperature measurement network is formed to obtain the temperature change slope of the bellows.

4. The sintering endpoint temperature control system of a sintering machine according to claim 3, characterized in that: The second pressure detector (14) and the smoke flow detector (15) are arranged on the front end of the main exhaust fan (16); the first pressure detector (11) is arranged on the front end of the wind box (8); The air permeability of the material layer is calculated based on the flue gas volume and pressure changes detected by the flue gas flow detector (15), the first pressure detector (11), and the second pressure detector (14).

5. The sintering endpoint temperature control system of a sintering machine according to claim 4, characterized in that: The air permeability calculation formula is: Material layer permeability = gas flow rate / (pressure drop × effective sintering area).

6. The sintering endpoint temperature control system of a sintering machine according to claim 4, characterized in that: A plurality of material level detectors (3) are arranged below the roller feeder (2), and dynamically monitor the thickness change of the material layer and take the average value of the material layer thickness of each material level detection point for 30 consecutive seconds.

7. A method for controlling the sintering endpoint temperature of a sintering machine according to claim 1, characterized in that: The method is specifically as follows: S1: Obtain production parameters and generate intelligent feedforward signals through adjustments; The production parameters include the main exhaust fan inlet flue gas flow rate, the main exhaust fan inlet pressure value, and the bellows pressure value; The adjustment includes correcting the temperature change slope of each bellows, correcting the thickness change slope of the material layer, changing the trolley and changing the grate bars; The acquired parameters are adjusted through intelligent methods to finally generate intelligent feedforward signals; S2: Adjust the main and sub-controllers to make the sintering endpoint temperature reach the actual position; The sintering endpoint temperature position is preset in the system. The main controller adjusts the set value of the sintering machine speed according to the intelligent feedforward signal generated in step S1, and controls the speed regulating drive device through the sub-controller to make the sintering machine speed meet the actual position of the sintering endpoint temperature. If it does not meet the requirements, the set value of the sintering machine speed is readjusted.

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