Zinc ash and zinc slag reflux control method and related equipment

Abstract

The invention discloses a zinc ash and zinc slag backflow control method and related equipment, and relates to the technical field of strip steel hot galvanizing, the method is applied to a hot galvanizing production line comprising a zinc pot, a furnace nose and an overflow groove, the overflow groove is formed in one side of the end of the furnace nose, and a slag discharging opening is formed in an outlet of the overflow groove. Comprising the following steps: controlling a slag discharge port to be adjusted to a preset height, so that zinc ash and zinc slag extracted from an overflow groove float upwards to the liquid level of zinc liquid of a zinc pot along a slag discharge port channel; generating a liquid level scum density signal according to the zinc ash and zinc slag accumulation state of the liquid level of the zinc liquid; and according to the incidence relation between the liquid level scum density signal and a preset time interval, triggering a scum salvaging operation so as to remove zinc ash and zinc slag on the liquid level of the zinc liquid. According to the method, through optimization of slag discharging opening height control and intelligent slag salvaging linkage based on the scum density signal, effective separation and dynamic removal of the zinc slag are achieved, and therefore the coating quality and the production stability can be remarkably improved.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of hot-dip galvanizing of steel strips, and more particularly to a zinc dross and zinc slag backflow control method and related equipment. BACKGROUND

[0002] With the continuous development of metal material surface treatment technology, the hot-dip galvanizing process is widely used in the fields of building structures, automobile manufacturing, home appliances, energy equipment, etc. due to its excellent corrosion resistance and economy. Among them, the zinc pot as the core operation unit, the cleanliness of the zinc liquid inside directly affects the adhesion quality and surface appearance of the coating. In the continuous hot-dip galvanizing production process, the furnace nose area is the key position where zinc dross and zinc slag easily accumulate due to its proximity to the running channel of the steel strip, and the zinc dross backflow phenomenon is one of the important reasons for the frequent occurrence of defects on the lower surface of the steel strip.

[0003] In the related art, the zinc dross and zinc slag in the furnace nose are usually discharged by means of setting a zinc dross pump, an overflow system, etc. However, in actual operation, due to unstable flow of the slag-liquid interface, untimely slag removal or unreasonable structure of the slag discharge port, the zinc dross and zinc slag often cannot be effectively separated after being discharged, and even backflow into the furnace nose, increasing the risk of zinc slag adhesion on the lower surface of the steel strip. In addition, the existing slag removal operation mostly relies on manual timing, which makes it difficult to match the slag removal frequency with the actual floating slag accumulation state, and easily causes problems such as excessive slag removal frequency disturbing the zinc liquid or delayed slag removal causing floating slag accumulation. That is, the existing hot-dip galvanizing production line generally has technical problems such as unreasonable design of the slag discharge path, low efficiency of slag-liquid floating, lack of intelligence in slag removal control, etc. in the control of zinc dross and zinc slag backflow. SUMMARY

[0004] A series of simplified concepts are introduced in the summary part of the present application, which will be further described in detail in the specific embodiment part. The summary part of the present application does not mean to try to limit the key features and necessary technical features of the claimed technical solution, and even less to try to determine the protection scope of the claimed technical solution.

[0005] The zinc dross and zinc slag backflow control method and related equipment provided by the present application can realize effective separation and dynamic removal of zinc slag by optimizing the height control of the slag discharge port and the intelligent slag removal linkage based on the floating slag density signal, thereby significantly improving the coating quality and production stability.

[0006] In a first aspect, the application provides a zinc dust and zinc slag backflow control method applied to a hot-dip galvanizing production line including a zinc pot, a furnace snout, and an overflow tank, the overflow tank being arranged on one side of the end of the furnace snout, and a slag discharge port being arranged at the outlet of the overflow tank. The zinc dust and zinc slag backflow control method comprises: controlling the slag discharge port to be adjusted to a preset height, so that the zinc dust and zinc slag extracted from the overflow tank float upwards along the slag discharge port channel to the zinc liquid surface of the zinc pot; generating a liquid surface floating slag density signal according to the accumulation state of the zinc dust and zinc slag on the zinc liquid surface; and triggering a slag removal operation according to the correlation between the liquid surface floating slag density signal and a preset time interval, to remove the zinc dust and zinc slag on the zinc liquid surface.

[0007] In some embodiments, the control of the slag discharge port to be adjusted to a preset height comprises: real-time monitoring of the fluctuation amplitude of the zinc liquid surface, and dynamic adjustment of the preset height according to the fluctuation amplitude; and driving the height adjustment of the slag discharge port to the preset height by a hydraulic lifting device, wherein the range of the preset height is 30-60 cm, and the height of the slag discharge port is the vertical height difference of the slag discharge port relative to the zinc liquid surface.

[0008] In some embodiments, the zinc dust and zinc slag backflow control method further comprises: adjusting the rotational speed of the zinc dust pump to a target rotational speed based on the mapping relationship between the strip production speed and the pumping efficiency of the zinc dust pump, wherein the range of the target rotational speed is 120-280 r / min.

[0009] In some embodiments, the zinc dust and zinc slag backflow control method further comprises: monitoring the concentration distribution of aluminum elements in the zinc liquid in the zinc pot by a spectral analyzer to generate an aluminum content deviation signal; triggering an aluminum ingot feeding device to supplement aluminum elements when the aluminum content deviation signal indicates that the aluminum content of the zinc liquid is lower than a first percentage; and reducing the aluminum ingot feeding rate and activating a zinc liquid circulating stirring device when the aluminum content deviation signal indicates that the aluminum content of the zinc liquid is higher than a second percentage, wherein the first percentage is less than the second percentage.

[0010] In some embodiments, the zinc dust and zinc slag backflow control method further comprises: acquiring temperature gradient distribution data of the zinc liquid in the zinc pot by a distributed temperature sensor arranged at the bottom of the zinc pot; and adjusting the power output of the zinc pot heating element in different zones according to the difference between the temperature gradient distribution data and a first preset temperature range, wherein the first preset temperature range is 455-460℃.

[0011] In some embodiments, the zinc dust and zinc dregs backflow control method further comprises: detecting the surface temperature of the strip steel before entering the zinc pot by an infrared thermal imager to generate a strip steel temperature distribution thermal map; and adjusting the opening and closing frequency of the radiant tubes at the end section of the annealing furnace according to the matching degree of the strip steel temperature distribution thermal map and a second preset temperature range, wherein the second preset temperature range is 450-470 DEG C.

[0012] In some embodiments, the triggering of the dregs salvaging operation to remove the zinc dust and zinc dregs on the surface of the zinc liquid according to the correlation between the liquid surface dregs density signal and the preset time interval comprises: shortening the preset time interval when the liquid surface dregs density signal exceeds a preset density threshold, and the preset time interval ranges from 1 hour to 2 hours; and performing the dregs salvaging operation based on the preset time interval.

[0013] In the second aspect, the present application further provides a zinc dust and zinc dregs backflow control device, comprising: a height adjustment unit configured to control the dregs discharge port to be adjusted to a preset height so that the zinc dust and zinc dregs drawn out from the overflow tank float upwards along the dregs discharge port channel to the surface of the zinc liquid in the zinc pot; a dregs density detection unit configured to generate a liquid surface dregs density signal according to the accumulation state of the zinc dust and zinc dregs on the surface of the zinc liquid; and a dregs salvaging operation unit configured to trigger a dregs salvaging operation to remove the zinc dust and zinc dregs on the surface of the zinc liquid according to the correlation between the liquid surface dregs density signal and a preset time interval.

[0014] In the third aspect, the present application further provides an electronic device, comprising: a memory and a processor, wherein the processor is configured to execute the steps of the zinc dust and zinc dregs backflow control method of the first aspect when executing a computer program stored in the memory.

[0015] In the fourth aspect, the present application further provides a computer readable storage medium storing a computer program, wherein the computer program is configured to execute the steps of the zinc dust and zinc dregs backflow control method of the first aspect when executed by a processor.

[0016] In the fifth aspect, the present application further provides a computer program product comprising a computer program or computer executable instructions, wherein the computer program or computer executable instructions are configured to execute the steps of the zinc dust and zinc dregs backflow control method provided in the embodiments of the present application when executed by a processor.

[0017] In summary, the zinc dust zinc slag backflow control method provided by the application can ensure that the zinc dust zinc slag has sufficient buoyancy and path time after being extracted, so that the zinc dust zinc slag smoothly floats to the zinc liquid surface instead of flowing back to the inside of the furnace nose. The height control optimizes the slag-liquid separation effect, effectively reduces the phenomenon of zinc slag adhering to the surface of the strip steel, and improves the uniformity of the coating and the surface quality of the strip steel. By monitoring the density state of the floating slag on the zinc liquid surface, a corresponding density signal is generated, which is linked with the preset time control logic to automatically determine whether to trigger the slag removal operation. Compared with the traditional manual timing slag removal method, the zinc dust zinc slag backflow control method can dynamically respond to the actual accumulation of the floating slag, improve the timeliness and accuracy of slag removal, and avoid the accumulation or excessive disturbance of the slag layer caused by early or late slag removal. In summary, the zinc dust zinc slag backflow control method provided by the application realizes effective separation and dynamic removal of the zinc slag by optimizing the height control of the slag outlet and the intelligent slag removal linkage based on the floating slag density signal, thereby significantly improving the coating quality and production stability. BRIEF DESCRIPTION OF DRAWINGS

[0018] Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are for purposes of illustration only and are not to be construed as limiting the specification. Moreover, in the drawings, like reference numerals designate similar parts throughout the several views, and in which:

[0019] Figure 1 A flowchart of a zinc dust zinc slag backflow control method provided by an embodiment of the application;

[0020] Figure 2 A composition structure schematic diagram of a zinc dust zinc slag backflow control device provided by an embodiment of the application;

[0021] Figure 3 A composition structure schematic diagram of an electronic device provided by an embodiment of the application. DETAILED DESCRIPTION

[0022] The terms in the specification, claims and drawings of the application, such as "first", "second", "third", "fourth" and the like (if any), are used to distinguish similar objects, not to describe a specific order or sequence. Therefore, it is understood that these terms can be used interchangeably under appropriate circumstances, so that the described embodiments can be implemented in different orders, unless the drawings or description specifically require otherwise. In addition, the terms "is" and "has" and any variants thereof in the application are intended to cover non-exclusive inclusion of all possible constituent elements. For example, a process, method, system, product or device including several steps or units does not necessarily limit to only the steps or units explicitly listed, but can also include other steps or units not explicitly listed or inherent to the process, method, product or device.

[0023] In the present application, a "module" or "unit" refers to a computer program or a part of a computer program with a specific function, and works in cooperation with other related parts to achieve a predetermined target. These modules or units can be implemented by software, hardware (such as processing circuitry or memory), or a combination of both. One or more processors or memories can implement one or more modules or units. Meanwhile, each module or unit can also be part of a larger module or unit.

[0024] The technical solutions in the present application will be described in detail below in conjunction with the accompanying drawings in the embodiments. It should be noted that the described embodiments are only a part of the present application, not all embodiments. In the following description, "some embodiments" mentioned is only a subset of all possible embodiments, which can be the same or different subset, and different embodiments can be combined with each other without conflict.

[0025] Figure 1 is a flowchart of a zinc ash and zinc slag backflow control method provided by an embodiment of the present application. For example, referring to Figure 1 The zinc ash and zinc slag backflow control method provided by the embodiments of the present application is applied to a hot galvanizing production line including a zinc pot, a furnace nose and an overflow tank. The overflow tank is arranged at one side of the end of the furnace nose, and the slag discharge port is arranged at the outlet of the overflow tank. The zinc ash and zinc slag backflow control method includes the following steps 101 to 103:

[0026] Step 101, control the slag discharge port to be adjusted to a preset height, so that the zinc ash and zinc slag drawn out from the overflow tank float up along the slag discharge port channel to the zinc liquid surface of the zinc pot;

[0027] In some examples, the hot-dip galvanizing production line refers to an industrial production line for continuous hot-dip galvanizing treatment of the surface of steel, which mainly functions to form a dense zinc coating on the surface of the steel strip to improve its corrosion resistance, and the entire production line includes units such as an annealing section, a zinc pot, an air knife device, a cooling zone, and a leveling section. The zinc pot is the core equipment in the hot-dip galvanizing production line, which is used to hold and heat molten zinc liquid, and the steel strip passes through the zinc pot via submerged rollers to realize galvanizing; the furnace nose is an extension structure installed at both ends of the zinc pot and covering the submerged rollers, which is a passage for the steel strip to enter the zinc pot and is also a position where zinc ash and zinc slag are easily deposited; the overflow tank is a metal tank installed on one side of the end of the furnace nose, which is used to guide the zinc ash and zinc slag floating inside the furnace nose into the slag discharge path to assist in the slag discharge process; as an intermediate passage, the overflow tank is arranged at the outlet end of the furnace nose, and the slag discharge port is located at the outlet end of the tank body and connected to the subsequent slag discharge channel for further separation of the extracted zinc slag. The preset height refers to the value of the vertical height difference of the position of the outlet of the slag discharge port relative to the surface of the zinc liquid, which can be measured and adjusted in real time by means of a laser ranging sensor, a height encoder of a hydraulic lifting device, etc. The zinc ash and zinc slag refers to impurity particles suspended or deposited on the surface of the zinc liquid during hot-dip galvanizing due to alloy reaction, impurity oxidation, etc., which usually has a lower density and can float on the liquid. The zinc liquid surface is the liquid level of the molten zinc in the zinc pot, which usually needs to be controlled stably and is related to the thickness of the steel strip coating and the slag control path. By controlling the position of the slag discharge port in the vertical direction, the zinc slag is separated after floating to the surface of the zinc liquid along the preset height path after entering the overflow tank, and it is prevented from flowing back to the inside of the furnace nose, and the path should ensure sufficient buoyancy difference and avoid excessive liquid flow disturbance.

[0028] For example, the slag discharge port can be accurately adjusted to a position about 40 cm higher than the surface of the zinc liquid by a hydraulic lifting device; at the same time, the zinc ash and zinc slag are introduced from the furnace nose into the overflow tank by a zinc ash pump at the end of the furnace nose; in this process, the zinc ash and zinc slag will naturally float upwards along the slag discharge port channel due to their lower density than the zinc liquid, enter the surface of the zinc pot, and thus achieve separation.

[0029] By implementing step 101, the slag discharge port is arranged within the preset height range above the surface of the zinc liquid, which provides sufficient floating path and time for the zinc ash and zinc slag, promotes it to float to the surface of the zinc liquid in time after flowing out of the overflow tank without depositing or flowing back to the inside of the furnace nose, and this height control strengthens the slag-liquid separation effect, which can avoid the zinc slag from flowing back to pollute the running area of the steel strip again, thereby reducing the defect rate and improving the surface quality of the product.

[0030] Step 102, generating a liquid surface floating slag density signal according to the accumulation state of the zinc ash and zinc slag on the surface of the zinc liquid;

[0031] In some examples, the zinc dross accumulation state refers to the distribution, coverage, accumulation thickness, and dynamic change trend of the dross (i.e., zinc dross) on the zinc liquid surface, which reflects the accumulation degree and can be used to determine whether the zinc dross is excessive, whether it affects the running of the strip steel, or whether the dross removal treatment needs to be started. The zinc dross accumulation state can be monitored in real time by an industrial vision camera or a laser scanning device installed above the zinc pot to recognize the dross coverage area on the zinc liquid surface. An infrared thermal imager can also be used to distinguish the temperature difference between the zinc liquid and the dross to analyze the dross distribution and thickness. An ultrasonic or laser displacement sensor can also be used to measure the local height difference of the dross to infer the dross accumulation condition. The liquid surface dross density signal is a parameter such as coverage, thickness, or mass of the dross on the liquid surface, which is converted into an identifiable and quantifiable electrical or digital signal through data acquisition and processing for subsequent judgment of whether to start the dross removal operation. It can be a continuous variable (such as dross thickness in mm) or a level indicator (such as light, medium, or heavy pollution).

[0032] For example, an industrial camera installed above the zinc pot can be used to capture real-time images of the zinc liquid surface, and an image processing algorithm can be used to identify the area distribution and color characteristics of the dross to determine the accumulation degree of the zinc dross. At the same time, an infrared thermal imager can be used to capture the temperature image of the zinc liquid surface, and an image analysis system can be used to compare the temperature difference between the dross and the zinc liquid to generate a corresponding liquid surface dross density signal. After receiving the density signal, the dross coverage state can be displayed in real time on the background panel, and the signal can be used as a decision basis and linked to the subsequent dross removal time logic (such as step 103) to build an intelligent dross control mechanism.

[0033] Through the implementation of step 102, the accumulation of the dross on the zinc liquid surface can be monitored in real time, such as through image recognition, dross detector, or dross weight change, to generate a dross density signal, which can make quantitative judgments and predictions on the dross accumulation trend to realize data-based perception of the cleanliness of the zinc liquid and provide objective and real-time basis for subsequent dross removal decisions.

[0034] Step 103: Trigger the dross removal operation according to the correlation between the liquid surface dross density signal and the preset time interval to remove the zinc dross on the zinc liquid surface.

[0035] In some examples, the preset time interval refers to a predefined time parameter for triggering the slag removal operation judgment logic, usually in units of minutes or hours, representing a waiting period or delay period after continuously detecting the accumulation of dross (i.e., the dross density signal reaches a certain threshold) for observing the trend of dross change to prevent false triggering of the dross removal mechanism and ensure accurate and stable operation; the preset time interval can be set by technical personnel in combination with production experience, such as evaluating the dross density change every 30 minutes, or according to the optimal dross removal period predicted by the historical dross accumulation rule or AI learning model; for example, it can be set that "the dross density exceeds 60% and lasts for more than 10 minutes", that is, the dross removal operation is triggered. The association between the liquid surface dross density signal and the preset time interval refers to a relationship judgment model between the numerical change of the dross density signal and the continuous trend within the set time interval, that is, the dross density signal is continuously monitored within a period of time, and if the signal continuously exceeds the preset threshold or appears a rapid accumulation trend, it is considered that the dross removal operation needs to be started immediately. The dross removal operation refers to the process of removing the zinc ash and dross accumulated on the surface of the zinc liquid by mechanical or manual means to keep the zinc liquid clean and ensure the uniformity and quality of the strip steel coating. The dross removal operation can use devices such as mechanical arms, scrapers, chain type slag removal devices, etc., to perform automatic operation according to the control signal, or the operator can intervene manually to remove the slag after receiving the alarm prompt; for example, after receiving the high-density signal, the control system drives the hydraulic slag removal device to start and pushes the dross to the slag removal channel according to the preset path.

[0036] For example, when it is detected that the dross density signal exceeds the set threshold (such as the coverage reaching 70%), and the signal does not fall within the next 10 minutes, it is determined to be a serious accumulation state; then, an execution instruction is automatically issued to the dross removal device, such as starting the electric scraper to slide along the liquid surface to concentrate and clean the dross to the slag collection area; if the continuous three times of triggering record shows that the dross is again accumulated within a short period, the dross removal duration can also be automatically extended or the dross cleaning frequency can be increased.

[0037] Through the implementation of step 103, in combination with the density signal of step 102 and the preset time logic model, such as the dross density exceeding the threshold and reaching the minimum dross removal interval, it is automatically judged whether the dross removal operation needs to be performed; compared with the traditional fixed period dross removal mode, this mode is more adaptive, can respond in time when the dross is too much, and can avoid invalid operation when the slag is less, avoid the accumulation of slag layer or disturbance of the zinc liquid surface, and realize the accurate control of the dross removal opportunity and the maximization of the operation efficiency.

[0038] In summary, the embodiment of the present application can ensure that the zinc ash and zinc slag have sufficient buoyancy and path time after being extracted, so that they float smoothly to the surface of the zinc liquid instead of flowing back to the inside of the furnace nose by setting the slag discharge port at the outlet of the overflow tank and adjusting it to a preset height. This height control optimizes the slag-liquid separation effect, effectively reduces the phenomenon of zinc slag adhering to the surface of the strip steel, and thus improves the uniformity of the coating and the surface quality of the strip steel. By monitoring the density state of the floating slag on the surface of the zinc liquid, a corresponding density signal is generated, which is linked with the preset time control logic to automatically determine whether to trigger the slag removal operation. Compared with the traditional manual timing slag removal method, the actual accumulation of the floating slag can be dynamically responded, the timeliness and accuracy of the slag removal are improved, and the slag layer accumulation or excessive disturbance caused by early or late slag removal is avoided. In summary, the zinc ash and zinc slag backflow control method provided by the embodiment of the present application realizes effective separation and dynamic removal of the zinc slag by optimizing the height control of the slag discharge port and the intelligent slag removal linkage based on the floating slag density signal, so as to significantly improve the coating quality and production stability.

[0039] In some embodiments, the aforementioned control of the slag discharge port to adjust to a preset height can include: monitoring the fluctuation amplitude of the surface of the zinc liquid in real time, and dynamically adjusting the preset height according to the fluctuation amplitude; and driving the height adjustment of the slag discharge port to the preset height by a hydraulic lifting device, wherein the range of the preset height is 30 cm to 60 cm, and the height of the slag discharge port is the vertical height difference of the slag discharge port relative to the surface of the zinc liquid.

[0040] In some examples, the fluctuation amplitude of the surface of the zinc liquid refers to the maximum displacement difference of the up and down fluctuation of the molten zinc liquid in the zinc pot during operation due to factors such as thermal convection, disturbance of the steel strip, equipment vibration, or zinc liquid supplement, which is usually measured in centimeters (cm); the fluctuation amplitude reflects the stability of the surface of the zinc liquid and is a reference for the preset height of the slag discharge port. The vertical height difference (preset height) of the slag discharge port relative to the surface can be automatically adjusted according to the fluctuation amplitude of the surface of the zinc liquid to ensure that the zinc slag still has a suitable floating path under different liquid surface heights; for example, if the fluctuation amplitude of the surface of the zinc liquid increases from 6 cm to 8 cm, the height of the slag discharge port is automatically adjusted from 40 cm to 45 cm. The hydraulic lifting device is an actuator that realizes precise displacement control through hydraulic drive and is suitable for device adjustment in high-temperature and high-load scenarios. It has the advantages of large carrying capacity, high adjustment precision, and fast response speed. The hydraulic lifting device can be controlled to adjust the height of the slag discharge port according to the calculation results, so that the height difference of the slag discharge port reaches the preset height that adapts to the current fluctuation condition of the liquid surface, ensuring smooth slag removal path and smooth zinc slag floating.

[0041] For example, the height of the zinc liquid surface can be first collected in real time by using a laser liquid level meter, and the fluctuation amplitude thereof is calculated. If it is found that the fluctuation of the zinc liquid surface is increased from ±3 cm to ±7 cm, the preset height of the slag discharge port is dynamically adjusted, which is increased from 40 cm to 50 cm, so as to ensure that there is a sufficient floating channel for the zinc slag. Subsequently, an adjustment instruction is sent to the hydraulic lifting device, the slag discharge port is smoothly lifted to the newly set height, and the position is confirmed and locked by the sensor after the lifting is completed, so that the efficient separation path of the zinc slag is maintained.

[0042] Through the implementation of the above embodiment, the height of the slag discharge port is dynamically adjusted according to the fluctuation of the liquid surface in real time, so that the reasonable floating channel can be maintained when the liquid surface changes, the deposition or backflow of the zinc ash caused by the change of the liquid level is avoided, the hydraulic lifting device is used to accurately control the height, the adjustment sensitivity and operation reliability are enhanced, the setting of the height range can ensure that the buoyancy condition is optimal, the separation efficiency of the slag and liquid is optimized, and the need for manual intervention is reduced.

[0043] In some embodiments, the foregoing zinc ash and zinc slag backflow control method can further include: based on a mapping relationship between the strip production speed and the pumping efficiency of the zinc ash pump, adjusting the rotating speed of the zinc ash pump to a target rotating speed, wherein the target rotating speed ranges from 120 r / min to 280 r / min.

[0044] In some examples, the strip production speed refers to the linear speed of the steel strip continuously running on the hot-dip galvanizing production line, usually expressed in meters per minute (m / min), and directly reflects the speed of the strip passing through each process section (such as annealing, galvanizing, cooling, etc.), which plays a leading role in the rhythm of the entire production line; for example, the current strip production speed can be 160 m / min. The zinc dross pump is a special high-temperature-resistant pump used in the hot-dip galvanizing line to extract zinc dross from the zinc pot or furnace nose area. Its function is to guide the floating dross collected on the surface or locally of the zinc liquid into the overflow tank or the dross removal channel to achieve separation and dross removal. The pumping efficiency of the zinc dross pump refers to the mass or volume of zinc dross that the pump can extract and transfer from the zinc liquid per unit time, usually expressed in kg / min or L / min, reflecting the effective processing capacity of the pump. The mapping relationship between the strip production speed and the pumping efficiency of the zinc dross pump refers to the functional relationship between the running speed of the steel strip and the generation rate of zinc dross, as well as the adjustment model established between the pumping efficiency of the pump. The faster the strip production speed, the higher the frequency of stirring the zinc liquid per unit time, and the more zinc dross is generated, so the pumping speed of the zinc dross pump needs to be increased to match the pumping efficiency to keep the liquid surface clean. The speed of the zinc dross pump refers to the number of revolutions per minute (r / min), and the target speed is the optimal working speed calculated according to the current strip speed and the dross generation condition, which can be set in the range of 120-280 r / min to ensure timely and efficient dross removal without over-pumping; for example, when the strip production speed reaches 200 m / min, the target speed is set to 260 r / min according to the mapping relationship between the strip production speed and the pumping efficiency of the zinc dross pump.

[0045] By implementing the above embodiments, a mapping relationship between the strip production speed and the speed of the zinc dross pump is established, the pump speed is adjusted in real time to ensure that the pumping efficiency matches the strip speed, and over-pumping or under-pumping phenomena are avoided; the target speed range of 120-280 r / min balances the efficiency and system stability, which is beneficial to continuously maintaining the clean state of the zinc liquid and improving the running synchronization and energy saving effect.

[0046] In some embodiments, the aforementioned zinc dross backflow control method can further include: monitoring the concentration distribution of aluminum elements in the zinc liquid in the zinc pot by a spectral analyzer to generate an aluminum content deviation signal; triggering the aluminum ingot feeding device to supplement aluminum elements when the aluminum content deviation signal indicates that the aluminum content of the zinc liquid is lower than a first percentage; and reducing the aluminum ingot feeding rate and activating the zinc liquid circulating stirring device when the aluminum content deviation signal indicates that the aluminum content of the zinc liquid is higher than a second percentage, wherein the first percentage is less than the second percentage.

[0047] In some examples, the optical spectrum analyzer is an instrument that uses the principle of optical spectrum to quantitatively or qualitatively analyze the composition of elements in a substance and its concentration. In the process of hot galvanizing, an optical spectrum analyzer such as an atomic emission spectrometer (OES) or a laser-induced breakdown spectrometer (LIBS) can be used to monitor the content of elements such as aluminum and iron in the zinc liquid online. The zinc liquid refers to a pure zinc or zinc alloy liquid heated to about 450°C or above in a molten state, which is a medium used for coating steel strips in the process of hot galvanizing. The concentration distribution of aluminum elements refers to the content of aluminum in the zinc liquid in different regions. The aluminum content deviation signal is an error signal calculated based on a set target range, indicating the deviation between the current detection value and the target value, and is used to control the subsequent replenishment or adjustment operation. The first percentage and the second percentage are respectively the lower threshold and the upper threshold in the control of the aluminum content of the zinc liquid, which are used to determine whether to supplement or inhibit the addition of aluminum. The first percentage and the second percentage can be set by process standards or test data, for example, the first percentage is 0.22%, and the second percentage is 0.27%. The aluminum ingot feeding rate refers to the speed of feeding aluminum ingots into the zinc pot per unit time, which can be measured in kg / h, and the aluminum ingot feeding rate can be dynamically adjusted according to the actual aluminum consumption, the current aluminum concentration and the target concentration; for example, the normal aluminum ingot feeding rate is 3 kg / h, and when the aluminum content is low, it is automatically increased to 5 kg / h. The zinc liquid circulating stirring device is used to form liquid flow inside the zinc pot, enhance the mixing uniformity of alloy elements (such as aluminum), and prevent local enrichment or deposition. The forms include mechanical paddle stirring or electromagnetic stirring system.

[0048] For example, the optical spectrum analyzer periodically collects zinc liquid sample data and analyzes the aluminum content. If it is detected that the current aluminum concentration is only 0.20%, which is lower than the set first percentage (0.22%), a "low deviation signal" is immediately sent out, the aluminum ingot feeding device is started, and the feeding rate is increased from 3 kg / h to 5 kg / h to supplement the aluminum elements; when the analyzer subsequently detects that the aluminum content rises to 0.29%, which exceeds the second percentage (0.27%), the feeding rate is automatically reduced to 1.5 kg / h, and at the same time the zinc liquid circulating stirring device is activated to run for 10 minutes to promote the uniform distribution of aluminum in the zinc liquid and avoid segregation of the plating layer composition.

[0049] Through the implementation of the above examples, the aluminum content is accurately monitored by using the optical spectrum analyzer, and the feeding rate and the stirring device operation are automatically controlled according to the deviation signal, which can effectively avoid the increase of zinc slag caused by low aluminum content or the abnormal plating layer caused by high aluminum content, and keep the zinc liquid composition in the best process window, stabilize the chemical properties and the plating layer quality.

[0050] In some embodiments, the aforementioned zinc dross reflux control method can further include: acquiring temperature gradient distribution data of the zinc liquid in the zinc pot by a distributed temperature sensor arranged at the bottom of the zinc pot; and adjusting the power output of the zinc pot heating element in different zones according to the difference between the temperature gradient distribution data and a first preset temperature range, wherein the first preset temperature range is 455-460°C.

[0051] In some examples, the distributed temperature sensor arranged at the bottom of the zinc pot refers to a group of temperature sensors installed at multiple different positions on the bottom of the zinc pot, forming a distributed temperature measurement network, which can simultaneously sense the real-time temperature of the zinc liquid in different areas for drawing a temperature field distribution. The temperature gradient distribution data refers to the difference between the temperatures of the zinc liquid at different positions, which can reflect phenomena such as uneven heat conduction, abnormal heating, or local heat deposition. The first preset temperature range (455-460°C) is the ideal temperature range of the zinc liquid during galvanizing, which can ensure stable alloy composition, uniform coating, and appropriate fluidity; if the temperature is lower than 455°C, the viscosity of the zinc liquid increases, which can easily lead to poor coating; and if the temperature is higher than 460°C, oxidation can be accelerated and energy consumption can be increased. The zinc pot heating element refers to a device for heating the zinc pot, which can include a resistance heating tube, a gas heater, or an induction heating coil, and is usually arranged in zones on the bottom and sidewall of the pot. By comparing the regional temperature data collected by the sensor with the ideal temperature range, the local cold or hot areas can be automatically identified, and the heating power of the corresponding area can be adjusted to make the overall temperature balanced and tend to the ideal range; for example, if the temperature of the first zone is 453°C, which is lower than the target value, the heating power of this zone is increased to 90%; and if the temperature of the fourth zone is 461°C, the power of this zone is reduced to 40%.

[0052] For example, nine distributed thermocouple sensors are arranged at the bottom of the zinc pot, and the collected temperature is uploaded to the control system every 5 seconds, and then a real-time temperature distribution map is generated to determine that the temperature of a certain area (e.g., the front side of the pot bottom) is 452°C, which is lower than the set range, and the power of the heating element in this area is immediately increased from 60% to 85%; at the same time, the temperature of the rear part of the pot bottom is 461°C, which is slightly higher than the target interval, and the power of the heating element in this area is reduced to 35%; after 10 minutes of dynamic adjustment, the overall zinc liquid temperature is rebalanced between 456-459°C, effectively maintaining the process performance of the zinc liquid.

[0053] Through the implementation of the above embodiments, the fine temperature distribution is acquired by means of the distributed temperature sensor, the heating of different zones of the zinc pot is adjusted, local overheating or temperature dead angle can be avoided, the temperature uniformity is enhanced, which is conducive to the stable flow of the zinc liquid, the reduction of zinc dross generation, and the improvement of the thermal control precision of the entire line.

[0054] In some embodiments, the aforementioned zinc dust zinc slag reflux control method can further include: detecting the surface temperature of the strip steel before entering the zinc pot by an infrared thermal imager to generate a strip steel temperature distribution thermal map; and adjusting the opening and closing frequency of the radiant tube at the end section of the annealing furnace according to the matching degree of the strip steel temperature distribution thermal map and a second preset temperature range, wherein the second preset temperature range is 450-470°C.

[0055] In some examples, the infrared thermal imager is a non-contact temperature measuring device that forms a thermal imaging map using infrared energy radiated by an object to detect the surface temperature and distribution of the target, and can be installed on a positioning support before the strip steel enters the zinc pot. The surface temperature of the strip steel before entering the zinc pot refers to the real-time state of the surface layer temperature of the steel strip before entering the zinc pot through the end section of the annealing furnace, which directly affects the adhesion of the zinc liquid and the uniformity of the plated layer. The strip steel temperature distribution thermal map is image data output by the infrared thermal imager, which displays the temperature values of different regions of the strip steel in different colors or gray scales, and can be used to intuitively judge the temperature uniformity and deviation points. The matching degree of the strip steel temperature distribution thermal map and the second preset temperature range refers to the proportion of the area in the strip steel temperature distribution thermal map where the temperature falls within the second preset temperature range (such as 450-470°C), which can be used to evaluate the overall heating quality of the steel strip; for example, 85% of the area of the strip steel temperature distribution thermal map is found to be within the second preset temperature range, and the matching degree is 85%. The second preset temperature range (450-470°C) is the optimal surface temperature interval required before the strip steel enters the zinc pot, which can ensure good intermetallic bonding between the zinc liquid and the steel strip; if the temperature of the strip steel is lower than 450°C, it may lead to "leakage plating"; and if it is higher than 470°C, it may generate excessive reaction to form zinc slag. The radiant tube at the end section of the annealing furnace is one of the heating elements in the annealing furnace, and the opening and closing frequency refers to the periodic parameter of the on-off control, which is used to control the heat input, and the higher the frequency, the more intense the heating.

[0056] For example, the infrared thermal imager collects one frame of thermal map data per second, and analyzes the thermal map to find that only 76% of the area is within the target interval of 450-470°C, and the matching degree is lower than the set threshold (such as 85%), so the opening and closing frequency of the radiant tube in the second region at the end section of the annealing furnace is automatically increased from 3Hz to 4.5Hz to strengthen the heat compensation for the temperature low area; after 3 minutes of adjustment, the matching degree of the thermal map is increased to 91%, which ensures the temperature uniformity of the steel strip before entering the zinc pot and improves the consistency of the plated layer quality.

[0057] Through the implementation of the above embodiments, the surface temperature of the strip steel before entering the zinc pot is monitored by the infrared thermal imager to generate a thermal map, which can accurately judge whether the heating of the strip steel meets the standard, and adjust the frequency of the heating unit at the end section of the annealing furnace, which helps to maintain the temperature consistency of the strip steel and prevent the disturbance of the dross or the unevenness of the plated layer caused by the disturbance of the zinc liquid by the cold strip steel.

[0058] In some embodiments, the aforementioned step 103 can comprise: shortening the preset time interval when the liquid surface dross density signal exceeds the preset density threshold value, the preset time interval ranging from 1 hour to 2 hours; and performing the dross salvaging operation based on the preset time interval.

[0059] In some examples, the preset density threshold value is a standard limit value for triggering the dross salvaging operation, to determine whether the accumulation degree of the liquid surface zinc ash zinc dross reaches a critical point requiring intervention treatment, the preset density threshold value can be a quantitative parameter such as dross thickness (e.g., ≥ 5 mm), coverage rate (e.g., ≥ 60%), dross pixel density (e.g., high gray area ratio in a heat map ≥ 70%), etc. The dross salvaging operation based on the preset time interval is to perform the dross salvaging operation once every set time period (e.g., every 90 minutes), to ensure that even without high density alarm, the zinc ash zinc dross can be cleaned regularly to avoid long-term accumulation causing quality problems; and once the density signal is too high, the time interval can be shortened (e.g., shortened to 60 minutes or lower) to increase the dross salvaging frequency.

[0060] For example, the preset density threshold value is set to be a dross coverage rate ≥ 60%, when the image recognition module detects that the liquid surface dross coverage rate reaches 68%, it is automatically determined to be in a "high density" state, and the original set dross salvaging time interval is shortened from 90 minutes to 60 minutes, and then the dross salvaging mechanical arm is automatically dispatched to perform a surface cleaning operation; at the same time, the operation process automatically records the dross density value and time change in the background system, to provide trend analysis data support for the operation and maintenance personnel.

[0061] Through the implementation of the above embodiments, the dross salvaging interval (1-2 hours) is dynamically adjusted according to the dross density signal, which can realize frequent dross salvaging when there is much dross and slow dross salvaging when there is little dross, to avoid excessive dross salvaging causing disturbance of the zinc liquid, or delayed dross salvaging causing accumulation of zinc ash, to realize intelligent optimization of the dross salvaging operation and reasonable allocation of resources.

[0062] Further, as an implementation of the foregoing method embodiments, the present application also provides a zinc ash zinc dross backflow control device for implementing the foregoing method embodiments. The device embodiment corresponds to the foregoing method embodiment, and for the sake of readability, the details of the foregoing method embodiments will not be described one by one, but it should be clear that the device in the present embodiment can correspondingly implement all the contents of the foregoing method embodiments. For example, Figure 2As shown, the zinc dross zinc slag backflow control device 20 comprises a height adjustment unit 201, a dross density detection unit 202, and a dross operation unit 203. The height adjustment unit 201 is configured to control the slag discharge port to be adjusted to a preset height, so that the zinc dross zinc slag extracted from the overflow tank floats up to the zinc liquid surface of the zinc pot along the slag discharge port channel. The dross density detection unit 202 is configured to generate a liquid surface dross density signal according to the accumulation state of the zinc dross zinc slag on the zinc liquid surface. The dross operation unit 203 is configured to trigger the dross operation according to the correlation between the liquid surface dross density signal and the preset time interval, so as to remove the zinc dross zinc slag on the zinc liquid surface.

[0063] In some embodiments, the height adjustment unit 201 is further configured to monitor the fluctuation amplitude of the zinc liquid surface in real time, and dynamically adjust the preset height according to the fluctuation amplitude. The height of the slag discharge port is adjusted to the preset height by a hydraulic lifting device, wherein the range of the preset height is 30 cm to 60 cm, and the height of the slag discharge port is the vertical height difference of the slag discharge port relative to the zinc liquid surface.

[0064] In some embodiments, the zinc dross zinc slag backflow control device 20 further comprises a rotating speed control unit configured to adjust the rotating speed of the zinc dross pump to a target rotating speed based on the mapping relationship between the strip steel production speed and the pumping efficiency of the zinc dross pump, wherein the range of the target rotating speed is 120 r / min to 280 r / min.

[0065] In some embodiments, the zinc dross zinc slag backflow control device 20 further comprises an aluminum content control unit configured to monitor the concentration distribution of aluminum elements in the zinc liquid in the zinc pot by a spectral analyzer to generate an aluminum content deviation signal. When the aluminum content deviation signal indicates that the aluminum content of the zinc liquid is lower than a first percentage, the aluminum ingot feeding device is triggered to supplement aluminum elements. When the aluminum content deviation signal indicates that the aluminum content of the zinc liquid is higher than a second percentage, the aluminum ingot feeding rate is reduced and the zinc liquid circulating stirring device is activated, wherein the first percentage is less than the second percentage.

[0066] In some embodiments, the zinc dross zinc slag backflow control device 20 further comprises a temperature control unit configured to obtain temperature gradient distribution data of the zinc liquid in the zinc pot by a distributed temperature sensor arranged at the bottom of the zinc pot. The power output of the zinc pot heating element is adjusted in different zones according to the difference between the temperature gradient distribution data and a first preset temperature range, wherein the first preset temperature range is 455℃ to 460℃.

[0067] In some embodiments, the temperature control unit is further configured to detect the surface temperature of the strip steel before entering the zinc pot by an infrared thermal imager to generate a strip steel temperature distribution thermal map. The opening and closing frequency of the radiant tube at the end of the annealing furnace is adjusted according to the matching degree between the strip steel temperature distribution thermal map and a second preset temperature range, wherein the second preset temperature range is 450℃ to 470℃.

[0068] In some embodiments, the slag skimming operation unit 203 is further configured to shorten the preset time interval when the liquid surface slag density signal exceeds the preset density threshold, the preset time interval being in a range of 1 hour to 2 hours; and perform the slag skimming operation based on the preset time interval.

[0069] The application further provides a computer readable storage medium, which stores computer executable instructions or computer programs, and when the computer executable instructions or computer programs are executed by a processor, the processor executes any step of the zinc dust and zinc slag backflow control method provided by the application.

[0070] In some embodiments, the computer readable storage medium can be a random access memory (RAM), a read-only memory (ROM), a flash memory, a magnetic surface memory, an optical disc, or a compact disc read-only memory (CD-ROM), etc. The computer readable storage medium can also be various devices including one or any combination of the above storage mediums.

[0071] In some embodiments, the computer executable instructions can be in the form of programs, software, software modules, scripts or codes, written in any form of programming language (including compiled or interpreted languages, or declarative or procedural languages), and can be deployed in any form, including being deployed as independent programs or as modules, components, subroutines or other units suitable for use in a computing environment.

[0072] In some embodiments, the computer executable instructions can but not necessarily correspond to files in a file system, can be stored in a part of a file storing other programs or data, for example, stored in one or more scripts in a HyperText Markup Language (HTML) document, stored in a single file dedicated to the program in question, or stored in multiple cooperating files (for example, files storing one or more modules, subroutines or code portions).

[0073] In some embodiments, the computer executable instructions can be deployed to execute on one electronic device, or on multiple electronic devices located at one site, or on multiple electronic devices distributed at multiple sites and interconnected through a communication network.

[0074] As shown in Figure 3 The application further provides an electronic device 30, which includes a memory 310, a processor 320, and a computer program 311 stored in the memory 310 and executable on the processor, and the processor 320 executes the computer program 311 to implement any step of the zinc dust and zinc slag backflow control method.

[0075] The present application also provides a computer program product, comprising a computer program or computer-executable instructions stored in a computer-readable storage medium. A processor of an electronic device reads the computer program or computer-executable instructions from the computer-readable storage medium and executes the computer program or computer-executable instructions, causing the electronic device to perform any step of the zinc ash and zinc slag backflow control method described above.

[0076] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A method for controlling zinc ash and zinc slag backflow, characterized in that: Applicable to a hot-dip galvanizing production line including a zinc pot, a furnace nose and an overflow trough, wherein the overflow trough is arranged on one side of the end of the furnace nose, and the slag discharge port is arranged at the outlet of the overflow trough. The zinc ash and zinc slag backflow control method includes: Controlling the slag discharge port to be adjusted to a preset height so that the zinc ash and zinc slag extracted from the overflow trough floats along the slag discharge port channel to the zinc liquid level in the zinc pot; generating a liquid surface slag density signal according to the zinc ash and zinc slag accumulation state on the zinc liquid surface; According to the correlation between the liquid surface slag density signal and the preset time interval, a slag removal operation is triggered to remove zinc ash and slag on the surface of the zinc liquid.

2. The zinc ash and zinc slag backflow control method according to claim 1, characterized in that: The controlling the slag discharge port to be adjusted to a preset height includes: monitoring the fluctuation amplitude of the zinc liquid level in real time, and dynamically adjusting the preset height according to the fluctuation amplitude; The height of the slag discharge port is adjusted to the preset height by a hydraulic lifting device, wherein the preset height range is 30 cm to 60 cm, and the height of the slag discharge port is the vertical height difference of the slag discharge port relative to the zinc liquid level.

3. The zinc ash and zinc slag backflow control method according to claim 1, characterized in that: The zinc ash and zinc slag backflow control method further comprises: Based on the mapping relationship between the strip production speed and the suction efficiency of the zinc ash pump, the rotation speed of the zinc ash pump is adjusted to a target rotation speed, wherein the target rotation speed ranges from 120 r / min to 280 r / min.

4. The zinc ash and zinc slag backflow control method according to claim 1, characterized in that: The zinc ash and zinc slag backflow control method further comprises: The concentration distribution of aluminum in the zinc liquid in the zinc pot is monitored by a spectrum analyzer to generate an aluminum content deviation signal; When the aluminum content deviation signal indicates that the aluminum content of the zinc liquid is lower than a first percentage, triggering the aluminum ingot feeding device to replenish aluminum elements; When the aluminum content deviation signal indicates that the aluminum content of the zinc liquid is higher than a second percentage, the aluminum ingot feeding rate is reduced and the zinc liquid circulation stirring device is activated, wherein the first percentage is less than the second percentage.

5. The zinc ash and zinc slag backflow control method according to claim 1, characterized in that: The zinc ash and zinc slag backflow control method further comprises: Obtaining temperature gradient distribution data of the zinc liquid in the zinc pot by means of a distributed temperature sensor provided at the bottom of the zinc pot; According to the difference between the temperature gradient distribution data and the first preset temperature range, the power output of the zinc pot heating element is adjusted in different zones, wherein the first preset temperature range is 455°C to 460°C.

6. The zinc ash and zinc slag backflow control method according to claim 1, characterized in that: The zinc ash and zinc slag backflow control method further comprises: Using an infrared thermal imager to detect the surface temperature of the steel strip before it enters the zinc pot, and generating a thermal map of the temperature distribution of the steel strip; The opening and closing frequency of the radiation tubes in the final section of the annealing furnace is adjusted according to the matching degree between the strip temperature distribution thermogram and the second preset temperature range, wherein the second preset temperature range is 450°C to 470°C.

7. The zinc ash and zinc slag backflow control method according to claim 1, characterized in that: The triggering of the slag removal operation according to the correlation between the liquid surface slag density signal and the preset time interval includes: When the liquid surface scum density signal exceeds a preset density threshold, shortening the preset time interval, wherein the preset time interval ranges from 1 hour to 2 hours; The slag removal operation is performed based on the preset time interval.

8. A zinc ash and zinc slag backflow control device, characterized in that: Applicable to a hot-dip galvanizing production line including a zinc pot, a furnace nose and an overflow trough, wherein the overflow trough is arranged on one side of the end of the furnace nose, and the slag discharge port is arranged at the outlet of the overflow trough, comprising: A height adjustment unit is used to control the slag discharge port to be adjusted to a preset height so that the zinc ash and zinc slag extracted from the overflow trough floats along the slag discharge port channel to the zinc liquid level in the zinc pot; a slag density detection unit, configured to generate a liquid surface slag density signal according to the zinc ash and zinc slag accumulation state on the zinc liquid surface; The slag removal operation unit is used to trigger the slag removal operation according to the correlation between the liquid surface slag density signal and the preset time interval to remove the zinc ash and zinc slag on the surface of the zinc liquid.

9. An electronic device comprising: A memory and a processor, wherein the processor is configured to implement the steps of the zinc ash and zinc slag backflow control method according to any one of claims 1 to 7 when executing the computer program stored in the memory.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the zinc ash and zinc slag backflow control method according to any one of claims 1 to 7 are implemented.

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