Ultrahigh-temperature smelting furnace temperature control system based on modular thermal field

Abstract

The invention relates to the field of ultra-high-temperature smelting furnace temperature control systems, and discloses an ultra-high-temperature smelting furnace temperature control system based on a modular thermal field, which comprises a smelting furnace body used for accommodating raw materials and providing an ultra-high-temperature reaction environment of 1800-2200 DEG C; the modularized thermal field unit is fixed on the inner side of the smelting furnace body and comprises a plurality of standardized and interchangeable thermal field modules, and a lining of each thermal field module is made of a gradient composite ultra-high-temperature ceramic refractory material; the intelligent temperature control system comprises high temperature sensor modules which are arranged in all thermotechnical areas and used for collecting temperature, current and furnace charge data in real time; a data acquisition and preprocessing module, a machine learning control module and an execution module; a fail-safe module; and a man-machine interaction module. Compared with the prior art, the system has the advantages that through combination of modular thermal field design, gradient composite refractory materials, machine learning intelligent control and multi-physical field simulation, accurate, stable, efficient and safe control over the high-temperature smelting process is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of ultra-high temperature melting furnaces, and in particular to an ultra-high temperature melting furnace temperature control system based on a modular thermal field. Background Art

[0002] Ultra-high-temperature melting furnaces are widely used in the preparation of high-purity materials such as industrial silicon and silicon carbide. Their reaction temperatures typically reach 1800-2200°C. Traditional melting furnaces suffer from low temperature control accuracy, high energy consumption, short refractory life, and slow fault response. Especially in high-temperature environments, uneven temperature distribution within the furnace and unstable electrode arc behavior can easily lead to product quality fluctuations and equipment damage.

[0003] While some existing temperature control systems employ PID or fuzzy control, these systems struggle to cope with the ultra-high temperatures, multivariable, and nonlinear nature of the melting process, lacking predictability and adaptability. Furthermore, the performance limitations of refractory materials hinder the long-term stable operation of melting furnaces. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the above technical difficulties and provide a temperature control system for an ultra-high temperature smelting furnace based on a modular thermal field. By combining modular thermal field design, gradient composite refractory materials, machine learning intelligent control and multi-physical field simulation, accurate, stable, efficient and safe control of the high-temperature smelting process can be achieved.

[0005] In order to solve the above technical problems, the present invention provides a technical solution: a temperature control system for an ultra-high temperature melting furnace based on a modular thermal field,

[0006] It includes a melting furnace body, which is used to accommodate raw materials and provide an ultra-high temperature reaction environment of 1800-2200℃;

[0007] The modular thermal field unit is fixed to the inside of the smelting furnace body and includes multiple standardized, interchangeable thermal field modules. The lining of each thermal field module is made of gradient composite ultra-high temperature ceramic refractory material. The material shows a continuous gradient change in composition, microstructure and porosity from the hot side to the cold side. The hot side can withstand a temperature of not less than 2200°C.

[0008] Intelligent temperature control system, including: high temperature sensor modules, deployed in each thermal area, used to collect temperature, current and furnace charge data in real time;

[0009] Data acquisition and preprocessing module, used for data synchronization, cleaning and normalization;

[0010] Machine learning control module, with built-in furnace condition prediction and power optimization model based on LSTM neural network, used to output power regulation instructions;

[0011] An execution module for receiving instructions and adjusting the arc power, feed rate and cooling flow of each thermal zone;

[0012] A failsafe module for monitoring abnormal conditions and triggering emergency operations;

[0013] A human-machine interaction module for displaying system status and receiving user instructions.

[0014] As an improvement, the thermal surface of the gradient composite ultrahigh-temperature ceramic refractory material is a silicon carbide-silicon nitride composite phase, the cold surface is an alumina-mullite composite phase, and the intermediate transition layer is a ternary composite phase, and the proportion of each component linearly transitions along the temperature gradient

[0015] The microstructure of the hot zone module transitions from a dense structure at the hot surface to a porous structure at the cold surface, with a porosity transition from 1% to 3% to 15% to 20%.

[0016] As an improvement, the modular hot zone unit divides the furnace into 3-5 independent thermal zones, each corresponding to a set of arc heating components with a rated power of 500-1000kW.

[0017] As an improvement, the high-temperature sensor module includes platinum-rhodium thermocouples and infrared temperature sensors, and the shell material is consistent with the lining of the hot zone module.

[0018] As an improvement, the machine learning control module integrates a SHAP interpretability module for outputting key influencing factors for prediction and adjustment.

[0019] As an improvement, the execution module includes arc power regulators, feed rate regulators and cooling flow regulators with a response time of ≤0.5s.

[0020] As an improvement, the failsafe module monitors abnormal conditions including overheating, electrode failure and collapsed material, and emergency operations include power reduction, shutdown and emergency cooling.

[0021] As an improvement, it also includes a multi-physical field coupling simulation module for interacting with the machine learning control module to optimize the hot zone layout and temperature control strategy.

[0022] As an improvement, it also includes an energy consumption optimization module to achieve energy saving through zoned temperature control, waste heat recovery and dynamic power adjustment.

[0023] The advantages of the present application compared with the prior art are:

[0024] (1) Through modular hot zone design, the hot zone can be quickly replaced and maintained, improving equipment utilization;

[0025] (2) Gradient composite refractory material improves furnace lining life and thermal insulation performance;

[0026] (3) Machine learning algorithm realizes advanced prediction and adaptive control, improves temperature control accuracy and stability;

[0027] (4) Multi-channel execution and fault safety mechanism guarantee system safe operation;

[0028] (5) Energy consumption optimization module significantly reduces operating cost, meets green manufacturing requirements. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 is a system block diagram of a superhigh-temperature smelting furnace temperature control system based on modular thermal field. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0031] Embodiment one

[0032] A superhigh-temperature smelting furnace temperature control system based on modular thermal field,

[0033] including a smelting furnace body for containing raw materials and providing a superhigh-temperature reaction environment of 1800℃;

[0034] A modular thermal field unit fixed to the inside of the smelting furnace body includes a plurality of standardized and interchangeable thermal field modules. The inner lining of each thermal field module adopts gradient composite superhigh-temperature ceramic refractory material. The material presents continuous gradient changes in composition, microstructure and porosity from the hot face to the cold face. The hot face has a temperature resistance not lower than 2200℃. The hot face of the gradient composite superhigh-temperature ceramic refractory material is a silicon carbide-silicon nitride composite phase, the cold face is an alumina-mullite composite phase, and the intermediate transition layer is a ternary composite phase. The proportion of each component linearly transitions along the temperature gradient. The microstructure of the thermal field module transitions from the dense structure of the hot face to the porous structure of the cold face, and the porosity transitions from 1% to 15%. The modular thermal field unit divides the furnace into three independent thermal regions, each region corresponding to a group of electric arc heating components with a rated power of 500kW.

[0035] An intelligent temperature control system includes a high-temperature sensor module arranged in each thermal region for real-time collection of temperature, current and furnace charge data. The high-temperature sensor module includes a platinum-rhodium thermocouple and an infrared temperature sensor, and the shell material is consistent with the inner lining of the thermal field module.

[0036] A data acquisition and preprocessing module is used for data synchronization, cleaning and normalization processing.

[0037] a machine learning control module, which is built-in with a furnace condition prediction and power optimization model based on LSTM neural network, for outputting power adjustment instructions, and integrates a SHAP interpretability module for outputting key influence factors of prediction and adjustment;

[0038] an execution module for receiving instructions and adjusting the electric arc power, charge feeding and cooling flow of each thermal zone, which includes an electric arc power regulator, a charge feeding regulator and a cooling flow regulator, with a response time ≤0.5s;

[0039] a fail-safe module for monitoring abnormal states and triggering emergency operations, which monitors abnormal states including over-temperature, electrode failure and charge collapse, and the emergency operations include power reduction, shutdown and emergency cooling;

[0040] a human-machine interaction module for displaying system status and receiving user instructions.

[0041] a multi-physical field coupling simulation module for interacting with the machine learning control module to optimize thermal field layout and temperature control strategy.

[0042] an energy consumption optimization module for energy saving through zoned temperature control, waste heat recovery and dynamic power adjustment.

[0043] Embodiment Two

[0044] a temperature control system for ultra-high temperature smelting furnace based on modular thermal field,

[0045] including a smelting furnace body for containing raw materials and providing an ultra-high temperature reaction environment of 2000℃;

[0046] a modular thermal field unit fixed inside the smelting furnace body, which includes multiple standardized and interchangeable thermal field modules, the inner lining of each thermal field module adopts gradient composite ultra-high temperature ceramic refractory material, which has a continuous gradient change in composition, microstructure and porosity from the hot face to the cold face, with a hot face temperature resistance not less than 2200℃, the hot face of the gradient composite ultra-high temperature ceramic refractory material is a silicon carbide-silicon nitride composite phase, the cold face is an alumina-mullite composite phase, and the intermediate transition layer is a ternary composite phase, with the proportion of each component transitioning linearly along the temperature gradient, the microstructure of the thermal field module transitions from a dense structure at the hot face to a porous structure at the cold face, with a porosity transition from 2% to 18%, and the modular thermal field unit divides the furnace into four independent thermal zones, each corresponding to a set of electric arc heating components with a rated power of 800kW.

[0047] The intelligent temperature control system comprises: a high-temperature sensor module arranged in each thermal work area for collecting temperature, current and charge data in real time, the high-temperature sensor module comprising a platinum-rhodium thermocouple and an infrared temperature sensor, and the shell material being consistent with the lining of the thermal field module.

[0048] A data acquisition and preprocessing module for data synchronization, cleaning and normalization processing;

[0049] A machine learning control module with a furnace condition prediction and power optimization model based on an LSTM neural network for outputting power adjustment instructions, the machine learning control module integrating a SHAP interpretability module for outputting key influence factors of prediction and adjustment;

[0050] An execution module for receiving instructions and adjusting the arc power, charge feeding and cooling flow of each thermal work area, the execution module comprising an arc power regulator, a charge feeding regulator and a cooling flow regulator, the response time being less than or equal to 0.5s;

[0051] A fault safety module for monitoring abnormal states and triggering emergency operations, the abnormal states monitored by the fault safety module including over-temperature, electrode failure and charge collapse, and the emergency operations including power reduction, shutdown and emergency cooling;

[0052] A human-computer interaction module for displaying system status and receiving user instructions.

[0053] A multi-physical field coupling simulation module for interacting with the machine learning control module to optimize thermal field layout and temperature control strategy.

[0054] An energy consumption optimization module for realizing energy saving through zoned temperature control, waste heat recovery and dynamic power adjustment.

[0055] Embodiment three

[0056] An ultra-high temperature smelting furnace temperature control system based on a modular thermal field,

[0057] comprising a smelting furnace body for accommodating raw materials and providing an ultra-high temperature reaction environment of 2200℃;

[0058] The modular hot field unit is fixed inside the smelting furnace body and includes multiple standardized and interchangeable hot field modules. The inner lining of each hot field module is made of gradient composite ultrahigh-temperature ceramic refractory material, which continuously changes in composition, microstructure, and porosity from the hot face to the cold face. The hot face has a temperature resistance of not less than 2200℃. The hot face of the gradient composite ultrahigh-temperature ceramic refractory material is a silicon carbide-silicon nitride composite phase, the cold face is an alumina-mullite composite phase, and the intermediate transition layer is a ternary composite phase. The proportion of each component linearly transitions along the temperature gradient. The microstructure of the hot field module transitions from a dense structure at the hot face to a porous structure at the cold face, and the porosity transitions from 3% to 20%. The modular hot field unit divides the furnace into five independent thermal regions, each corresponding to a set of arc heating components with a rated power of 1000kW.

[0059] The intelligent temperature control system includes high-temperature sensor modules arranged in each thermal region for real-time acquisition of temperature, current, and charge data. The high-temperature sensor modules include platinum-rhodium thermocouples and infrared temperature sensors, and the shell material is consistent with the inner lining of the hot field module.

[0060] The data acquisition and preprocessing module is used for data synchronization, cleaning, and normalization processing.

[0061] The machine learning control module has a built-in furnace condition prediction and power optimization model based on an LSTM neural network for outputting power adjustment instructions. The machine learning control module integrates a SHAP interpretability module for outputting key influence factors of prediction and adjustment.

[0062] The execution module is used for receiving instructions and adjusting the arc power, charge feeding, and cooling flow of each thermal region. The execution module includes an arc power regulator, a charge feeding regulator, and a cooling flow regulator with a response time of ≤0.5s.

[0063] The fault safety module is used for monitoring abnormal states and triggering emergency operations. The abnormal states monitored by the fault safety module include over-temperature, electrode failure, and charge collapse. The emergency operations include power reduction, shutdown, and emergency cooling.

[0064] The human-computer interaction module is used for displaying system states and receiving user instructions.

[0065] The multi-physical field coupling simulation module is used for interacting with the machine learning control module to optimize the hot field layout and temperature control strategy.

[0066] The energy consumption optimization module realizes energy saving through partition temperature control, waste heat recovery, and dynamic power adjustment.

[0067] The standard parts used in the present application can be purchased from the market, and the special-shaped parts can be ordered according to the description and the drawings, the specific connection mode of each part adopts the conventional means such as bolt, rivet and welding in the prior art, the mechanical, parts and equipment adopt the conventional type in the prior art, and the circuit connection adopts the conventional connection mode in the prior art, which will not be described in detail here.

[0068] It should be noted that, in this text, relational terms such as first and second are used only to distinguish one entity or operation from another, and do not necessarily require or imply that there is any such actual relationship or order between these entities or operations. Moreover, the terms "include", "contain" or any other variants thereof are intended to cover non-exclusive inclusion, so that the process, method, article or equipment including a series of elements not only includes those elements, but also includes other elements not explicitly listed or inherent to such process, method, article or equipment.

[0069] Although the embodiments of the present application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

[0070] The above describes the present application and its embodiments, which is not restrictive, and the drawings shown are only one of the embodiments of the present application, and the actual structure is not limited thereto. In general, if a person skilled in the art is inspired by it, without departing from the purpose of the present application, without creating a similar structure and embodiment of the technical solution, which should belong to the protection scope of the present application.

Claims

1. A temperature control system for an ultra-high temperature melting furnace based on a modular thermal field, characterized by: The smelting furnace body is used to accommodate raw materials and provide an ultra-high temperature reaction environment of 1800-2200℃; The modular thermal field unit is fixed to the inside of the smelting furnace body and includes multiple standardized, interchangeable thermal field modules. The lining of each thermal field module is made of gradient composite ultra-high temperature ceramic refractory material. The material shows a continuous gradient change in composition, microstructure and porosity from the hot side to the cold side. The hot side can withstand a temperature of not less than 2200°C. Intelligent temperature control system, including: high temperature sensor modules, deployed in each thermal area, used to collect temperature, current and furnace charge data in real time; Data acquisition and preprocessing module, used for data synchronization, cleaning and normalization; Machine learning control module, with built-in furnace condition prediction and power optimization model based on LSTM neural network, used to output power regulation instructions; The execution module is used to receive instructions and adjust the arc power, charge feed and cooling flow of each thermal zone; Fail-safe modules to monitor abnormal conditions and trigger emergency actions; Human-computer interaction module, used to display system status and receive user instructions.

2. The ultra-high temperature melting furnace temperature control system based on a modular thermal field according to claim 1, characterized in that: The hot surface of the gradient composite ultrahigh temperature ceramic refractory material is a silicon carbide-silicon nitride composite phase, the cold surface is an alumina-mullite composite phase, the middle transition layer is a ternary composite phase, and the proportion of each component transitions linearly along the temperature gradient.

3. The ultra-high temperature melting furnace temperature control system based on a modular thermal field according to claim 1 or 2, characterized in that: The microstructure of the thermal field module transitions from a dense structure on the hot side to a porous structure on the cold side, and the porosity thereof transitions from 1% to 3% to 15% to 20%.

4. The ultra-high temperature melting furnace temperature control system based on a modular thermal field according to claim 1, characterized in that: The modular thermal field unit divides the furnace into 3 to 5 independent thermal zones, each zone corresponding to a set of arc heating components with a rated power of 500-1000kW.

5. The ultra-high temperature melting furnace temperature control system based on a modular thermal field according to claim 1, characterized in that: The high-temperature sensor module includes a platinum-rhodium thermocouple and an infrared temperature sensor, and the shell material is consistent with the lining of the thermal field module.

6. The ultra-high temperature melting furnace temperature control system based on a modular thermal field according to claim 1, characterized in that: The machine learning control module integrates the SHAP interpretability module to output key influencing factors for prediction and adjustment.

7. The ultra-high temperature melting furnace temperature control system based on a modular thermal field according to claim 1, characterized in that: The execution module includes an arc power regulator, a charge feeding regulator and a cooling flow regulator, and the response time is ≤0.5s.

8. The ultra-high temperature melting furnace temperature control system based on a modular thermal field according to claim 1, characterized in that: The abnormal conditions monitored by the fault safety module include over-temperature, electrode failure and material collapse, and the emergency operations include power reduction, shutdown and emergency cooling.

9. The ultra-high temperature melting furnace temperature control system based on a modular thermal field according to claim 1, characterized in that: It also includes a multi-physics field coupling simulation module for interacting with the machine learning control module to optimize the thermal field layout and temperature control strategy.

10. The ultra-high temperature melting furnace temperature control system based on a modular thermal field according to claim 1, characterized in that: It also includes an energy consumption optimization module that achieves energy saving through zoned temperature control, waste heat recovery and dynamic power adjustment.

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