High-temperature liquid non-contact flow measuring device and method

Abstract

The invention discloses a high-temperature liquid slag non-contact flow measuring device and method, and belongs to the technical field of high-temperature slag flow monitoring in the metallurgical industry. The device comprises a slag ladle, a distance measuring sensor, a temperature sensor and a computer, the distance measuring sensor and the temperature sensor monitor the molten slag liquid level height and temperature in a non-contact mode, and the computer obtains molten slag flow data accurately in real time through a filtering processing module, a liquid level calculation module, a volume flow calculation module and a mass flow calculation module. The method comprises the steps of calibrating a reference distance, collecting the liquid level distance and the temperature in real time, filtering and reducing noise, calculating the liquid level height and the flow, and dynamically displaying data through a graphical interface. According to the invention, a non-contact measurement mode is adopted, high-temperature corrosion of the sensor is avoided, multi-module cooperative calculation is combined, the measurement precision and the response speed are remarkably improved, automatic and high-reliability monitoring of the high-temperature slag flow is realized, and the method is suitable for scenes such as slag waste heat recovery in the ferrous metallurgy industry and has important industrial application value.

Description

Technical Field

[0001] This invention belongs to the field of high-temperature molten slag flow monitoring technology in the metallurgical industry, and specifically relates to a non-contact flow measurement device and method for high-temperature liquids. Background Technology

[0002] Steel production generates high-temperature molten slag, a byproduct with discharge temperatures reaching 1500℃ and containing a significant amount of waste heat. According to relevant research data, the waste heat carried by each ton of high-temperature molten slag is considerable. Effective recovery and utilization of this heat could bring about a significant transformation in energy conservation, emission reduction, and energy efficiency within the steel industry. However, it remains the only high-temperature waste heat resource in the steel industry that is not fully recovered, resulting in substantial energy waste and thermal pollution.

[0003] Among numerous waste heat recovery technologies, centrifugal granulation waste heat recovery technology has significant advantages. It utilizes the centrifugal force of a high-speed rotating centrifugal disc to break molten slag into fine particles. This technology has a compact structure, taking up little space; low energy consumption, reducing energy costs; and high granulation efficiency. Optimized parameters can further reduce particle diameter and improve waste heat recovery efficiency.

[0004] However, this technology has stringent requirements for the stability of molten slag flow. In actual production, the molten slag flow is often unstable due to factors such as the complexity of the steelmaking process. If the flow is too high, the centrifugal disc cannot break the slag in time, and the molten slag will agglomerate and block subsequent equipment; if the flow is too low, too much slag wool will be generated, polluting the environment and reducing the recovery efficiency; flow fluctuations will also make the granulation process unstable, further reducing the recovery efficiency.

[0005] Currently, image recognition technology and weighing methods are common methods for measuring the flow rate of high-temperature molten slag, but both have drawbacks. Image recognition technology is susceptible to interference from high-temperature steam, dust, etc., resulting in poor image quality, slow measurement response, and insufficient accuracy. In the weighing method, the corrosiveness of high-temperature molten slag can damage the sensor, and it can only measure the total amount, failing to reflect the dynamic changes in flow rate in real time, making it difficult to meet the precise measurement needs of industrial sites.

[0006] Therefore, developing a high-temperature slag flow measurement method that can adapt to harsh high-temperature environments, has a fast response speed, and high measurement accuracy is key to solving the technical challenges of waste heat recovery from centrifugal granulation and promoting energy conservation, emission reduction, and sustainable development in the steel industry. Summary of the Invention

[0007] The purpose of this invention is to overcome the problem that existing waste heat flow measurement methods cannot reflect dynamic changes in flow in real time, and to provide a non-contact flow measurement device and method for high-temperature liquids.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a non-contact flow measurement device for high-temperature liquids, comprising a slag bag with a slag outlet at the bottom, a distance sensor positioned directly facing the molten slag surface inside the slag bag, and a temperature sensor positioned at the slag outlet. The distance sensor and the temperature sensor are connected to a computer via a data transmission line. The computer integrates a data filtering module, a liquid level calculation module, a volumetric flow rate calculation module, a mass flow rate calculation module, and a data graphic display module, wherein: The data filtering module is used to filter the distance signal collected by the ranging sensor to eliminate high-frequency noise; The liquid level calculation module is used to calculate the real-time molten slag liquid level height based on the filtered distance data; The volumetric flow rate calculation module is used to calculate the instantaneous volumetric flow rate based on the molten slag level height; The mass flow calculation module is used to calculate the instantaneous mass flow rate by combining the density and volumetric flow rate corresponding to the temperature of the molten slag. The data and graphics display module is used to display the molten slag level height, volumetric flow rate, mass flow rate, and their historical change curves in real time.

[0009] The ranging sensor is a laser ranging sensor or an ultrasonic ranging sensor, and its measuring axis is perpendicular to the molten slag surface.

[0010] The temperature sensor is an infrared thermometer or a thermocouple array.

[0011] Secondly, the present invention provides a non-contact flow measurement method for high-temperature liquids, comprising the following steps: With the slag bag empty, the reference distance to the bottom of the slag bag is measured using a distance sensor. ; After the high-temperature molten slag is injected into the slag bag, the distance d between the molten slag surface and the molten slag temperature T are measured in real time by the distance sensor and the real-time data is collected by the temperature sensor (4) and transmitted to the computer. Filter the distance data d to calculate the current liquid level height. ; The instantaneous volumetric flow rate is calculated based on the cross-sectional area A of the slag bag corresponding to the liquid level height h, combined with the liquid level change rate. Calculate the instantaneous mass flow rate based on the slag temperature T and the instantaneous volumetric flow rate; The calculated liquid level height, instantaneous volumetric flow rate, instantaneous mass flow rate, and historical change curves are displayed in real time.

[0012] The step of calculating the instantaneous volumetric flow rate based on the cross-sectional area A of the slag bag corresponding to the liquid level height h, combined with the liquid level change rate, is performed as follows:

[0013] in, Indicates the rate of change of liquid level. This represents the instantaneous volumetric flow rate of the molten slag.

[0014] The relationship between the cross-sectional area A of the slag bag and the liquid level height h is determined in the following way: If the slag bag is a standard cylindrical shape, the cross-sectional area is a fixed value. ,in R Where is the radius of the cylinder; If the slag bag is a frustum, its cross-sectional area is... ,in Let be the radius of the lower base of the frustum. Let be the radius of the top of the frustum. The rate of change of radius, , H The height is the frustum.

[0015] The specific method for calculating the instantaneous mass flow rate based on the slag temperature T and the instantaneous volumetric flow rate is as follows: Based on the slag temperature T, a density-temperature relationship is constructed, and the density of the slag is calculated. Instantaneous mass flow rate is calculated based on instantaneous volumetric flow rate and slag density.

[0016] The density-temperature relationship is constructed as follows:

[0017] in, Indicates reference temperature The density of the molten slag below This is the temperature coefficient.

[0018] The formula for calculating instantaneous mass flow rate based on instantaneous volumetric flow rate and slag density is as follows:

[0019] in, This refers to the instantaneous mass flow rate.

[0020] The filtering process employs an average filtering algorithm.

[0021] Compared with the prior art, the present invention has the following beneficial effects: This invention provides a non-contact flow measurement device and method for high-temperature liquids, including a slag pot with a slag outlet at the bottom. A distance sensor is positioned directly above the molten slag surface inside the slag pot, and a temperature sensor is located at the slag outlet. The distance sensor and temperature sensor are connected to a computer via a data transmission line. The computer integrates a data filtering module, a liquid level calculation module, a volumetric flow rate calculation module, a mass flow rate calculation module, and a data graphical display module to acquire molten slag flow data accurately in real time. The method includes calibrating a reference distance, real-time acquisition of liquid surface distance and temperature, filtering and noise reduction, calculating liquid level height and flow rate, and dynamically displaying the data through a graphical interface. This application enables non-contact real-time monitoring of high-temperature molten slag flow, effectively eliminating the impact of environmental interference on measurement accuracy. It simultaneously acquires volumetric and mass flow data through multi-parameter collaborative calculation, avoiding high-temperature corrosion of the sensor. Combined with multi-module collaborative calculation, it significantly improves measurement accuracy and response speed, achieving automated and highly reliable monitoring of high-temperature molten slag flow. The device possesses rapid response characteristics, accurately capturing instantaneous fluctuations in molten slag flow, providing precise flow control for centrifugal granulation processes, thereby preventing molten slag agglomeration or slag wool formation, ensuring the stable operation of the waste heat recovery system. It is suitable for scenarios such as molten slag waste heat recovery in the iron and steel metallurgical industry and has significant industrial application value. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the device structure of the present invention; The following are the labels in the attached diagram: 1. Slag bag; 2. Slag outlet; 3. Distance sensor; 4. Temperature sensor; 5. Computer; 6. Molten slag surface; 7. Data transmission line. Detailed Implementation

[0024] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0025] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0026] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0027] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0028] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0029] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0030] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0031] The accompanying drawings illustrate various structural schematic diagrams according to embodiments disclosed in this invention. These drawings are not to scale, and some details have been enlarged for clarity, and some details may have been omitted. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0032] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0033] Example 1 like Figure 1 As shown, a non-contact measuring device for high-temperature liquids has the following structural components: A non-contact measuring device for high-temperature liquids includes a slag bag 1 with a slag outlet 2 at the bottom for discharging high-temperature molten slag. A distance sensor 3 and a temperature sensor 4 are positioned directly above the slag bag 1 to measure the real-time position and temperature of the molten slag surface, respectively. Both sensors face inwards from the slag bag 1 and are directly opposite the molten slag surface 6. The distance sensor 3 transmits the measured distance data between the molten slag surface and the sensor to a computer 5 via a data transmission line 7. The temperature sensor 4 transmits the measured molten slag temperature to the computer 5 via the data transmission line 7.

[0034] The computer 5 integrates the following functional modules: Distance data filtering module: used to filter the raw distance signal collected by the ranging sensor 3, and eliminate high-frequency noise through averaging filtering or other digital filtering algorithms to achieve signal smoothing; Liquid level calculation module: Based on the filtered liquid surface distance data and the pre-calibrated empty slag bag reference distance, the molten slag liquid level height is calculated in real time; Volumetric flow rate calculation module: Based on the rate of change of molten slag level over time and the cross-sectional area of ​​the slag bag at the corresponding liquid level, the volume change rate of molten slag is calculated, and then the instantaneous volumetric flow rate of molten slag outlet is obtained. Mass flow rate calculation module: Based on the real-time molten slag temperature fed back by the temperature sensor, the current molten slag density is determined through the known temperature-density relationship, and the instantaneous mass flow rate is calculated in combination with the volumetric flow rate; Data and graphics display module: Used to visually display real-time changes and historical trends of liquid level, volumetric flow rate, and mass flow rate in numerical and graphical form on a computer monitor.

[0035] The above modules work together to achieve high-precision, non-contact, real-time measurement of the flow rate of high-temperature liquid slag, effectively improving the reliability and automation level of the system.

[0036] Preferably, the ranging sensor 3 is a laser ranging sensor or an ultrasonic ranging sensor, and its measuring axis is perpendicular to the molten slag surface 6. Vertical alignment with the molten slag surface ensures that the measuring axis coincides with the normal to the molten slag surface, eliminating measurement errors caused by angular deviations. The laser ranging sensor emits short-wavelength infrared laser light that penetrates the steam interference layer, directly acting on the molten slag surface to form a stable reflected signal. Its sampling frequency can reach over 1000Hz, enabling real-time capture of changes in molten slag height. The ultrasonic ranging sensor, under conditions of high dust concentration, utilizes the multipath reflection characteristics of low-frequency sound waves and extracts the effective echo time difference through signal processing algorithms. Both sensors employ a non-contact measurement principle, avoiding direct contact with the high-temperature molten slag and preventing sensor failure due to high-temperature oxidation or chemical corrosion. When the measuring axis is set vertically, the intensity of the reflected signal received by the sensor reaches its maximum value. For example, the echo energy loss of the laser ranging sensor can be controlled within 3%, and the sound wave attenuation rate of the ultrasonic sensor is reduced to below 10dB / m, thereby ensuring the accuracy of the distance measurement.

[0037] Preferably, the temperature sensor 4 is an infrared thermometer or a thermocouple array, and its measurement area covers the molten slag surface near the slag outlet 2.

[0038] Preferably, the data filtering module employs an average filtering algorithm to average n consecutive sampled values ​​in order to suppress measurement noise.

[0039] Example 2 A high-temperature non-contact flow measurement method includes the following steps: Activate the ranging sensor 3 to put it into working condition, ready to collect distance data from the molten slag surface 6; with the slag pot empty, record the initial reference distance from the ranging sensor 3 to the bottom of the slag pot. This serves as a reference value for calculating the liquid level height. After the high-temperature molten slag is injected into the slag bag 1, the distance sensor 3 measures the distance between the molten slag surface 6 and the distance sensor 3 in real time. d The measurement data is transmitted to computer 5 in real time. The distance data filtering module inside computer 5 filters the real-time received distance data. d Average filtering is performed to eliminate high-frequency noise and improve data stability and accuracy. The liquid level calculation module calculates the liquid level based on the filtered distance value and the reference distance. H 0. Calculate the current slag level height h:

[0040] The volumetric flow rate calculation module calculates the current liquid level height based on the geometric model of slag bag 1. h corresponding cross-sectional area A : If the slag bag is a standard cylindrical shape, the cross-sectional area is a fixed value. ,in R Where is the radius of the cylinder; If the slag bag is a frustum, its cross-sectional area is... ,in Let be the radius of the lower base of the frustum. Let be the radius of the top of the frustum. The rate of change of radius, , H The height is the frustum.

[0041] Calculate the instantaneous volumetric flow rate of the molten slag based on the rate of change of liquid level over time: ; Temperature sensor 4 collects the molten slag temperature at slag outlet 2. T And based on the preset density-temperature relationship, calculate the density of the current molten slag. ρ :

[0042] in, Indicates reference temperature The density of the molten slag below This is the temperature coefficient. This can be achieved by isothermal weighing of molten slag samples under laboratory conditions, and this parameter serves as the initial baseline value for density calculation. Here, k refers to the linear decay coefficient of molten slag density with temperature change, which can be determined through linear regression analysis of multiple sets of measured molten slag density data at different temperatures. This coefficient is used to quantify the degree of influence of temperature change on material density.

[0043] During the molten slag flow, a temperature sensor continuously collects molten slag temperature data and inputs it into a calculation unit. The unit then calculates the molten slag density corresponding to the current temperature in real time using a preset density-temperature relationship. This relationship transforms temperature changes into density correction values ​​through a linear model, where the reference temperature... The temperature can be set to the normal discharge temperature of the molten slag, such as 1500℃, and the temperature coefficient k is determined based on the thermal expansion characteristics of the specific molten slag composition. As the temperature increases, the density value increases according to... The density parameter decreases gradually, thereby dynamically correcting the density parameter in the mass flow rate calculation and eliminating the density calculation deviation caused by temperature fluctuations.

[0044] The mass flow calculation module calculates the instantaneous mass flow rate based on the instantaneous volumetric flow rate and density. The calculation formula is as follows: ; Instantaneous mass flow rate refers to the mass of molten slag passing through the measuring section per unit time.

[0045] The data graphics display module visualizes the real-time calculated liquid level height, volumetric flow rate, and mass flow rate, and simultaneously plots and outputs corresponding historical change curves for operators to monitor and analyze.

[0046] Preferably, this method can also be used to measure the flow rate of other liquids, including but not limited to molten iron, high-temperature oil, and molten salt.

[0047] Compared to existing technologies, traditional image recognition techniques rely on optical imaging, which is prone to image blurring or delay in high-temperature steam and dust environments, leading to decreased measurement accuracy. This solution employs non-contact ranging technology, directly acquiring the liquid surface distance parameter and avoiding optical interference. Weighing methods require contact-mounted sensors, which are susceptible to corrosion by molten slag over time and cannot reflect real-time dynamic changes in flow rate. This solution derives flow rate through the liquid level change rate and a geometric model, achieving a second-level response speed. Furthermore, the sensor is positioned outside the slag bag 1, avoiding direct contact with the high-temperature molten slag. In addition, existing technologies do not consider the effect of temperature on density, resulting in systematic errors in mass flow rate calculation. This solution introduces a temperature sensor to correct the density parameter in real time, improving the accuracy of mass flow rate calculation.

[0048] Finally, it should be noted that the above embodiments only describe the basic principles, main features, and advantages of the present invention. For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or basic characteristics of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects. The scope of the present invention is defined by the appended claims rather than the foregoing description, and therefore all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0049] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can be appropriately combined to form other embodiments that can be understood by those skilled in the art. The above content is only for illustrating the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made based on the technical concept proposed in this invention shall fall within the scope of protection of the claims of this invention.

Claims

1. A non-contact flow measurement device for high-temperature liquids, characterized in that, The system includes a slag bag (1), with a slag outlet (2) at the bottom. A distance sensor (3) is positioned directly opposite the molten slag surface (6) inside the slag bag (1). A temperature sensor (4) is positioned at the slag outlet (2). The distance sensor (3) and the temperature sensor (4) are connected to a computer (5) via a data transmission line (7). The computer integrates a data filtering module, a liquid level calculation module, a volumetric flow rate calculation module, a mass flow rate calculation module, and a data graphics display module. The data filtering module is used to filter the distance signal collected by the ranging sensor (3) to eliminate high-frequency noise; The liquid level calculation module is used to calculate the real-time molten slag liquid level height based on the filtered distance data; The volumetric flow rate calculation module is used to calculate the instantaneous volumetric flow rate based on the molten slag level height; The mass flow calculation module is used to calculate the instantaneous mass flow rate by combining the density and volumetric flow rate corresponding to the temperature of the molten slag. The data and graphics display module is used to display the molten slag level height, volumetric flow rate, mass flow rate, and their historical change curves in real time.

2. The high-temperature liquid non-contact flow measurement device according to claim 1, characterized in that, The ranging sensor (3) is a laser ranging sensor or an ultrasonic ranging sensor, and its measuring axis is perpendicular to the molten slag surface (6).

3. The high-temperature liquid non-contact flow measurement device according to claim 1, characterized in that, The temperature sensor (4) is an infrared thermometer or a thermocouple array.

4. A non-contact flow measurement method for high-temperature liquids, characterized in that, Includes the following steps: In the empty slag bag state, the reference distance to the bottom of the slag bag is measured by the distance measuring sensor (3). ; After the high-temperature molten slag is injected into the slag bag, the distance d between the molten slag surface (6) is measured in real time by the distance sensor (3), and the molten slag temperature T is collected in real time by the temperature sensor (4). The collected data is then transmitted to the computer (5). Filter the distance data d to calculate the current liquid level height. ; The instantaneous volumetric flow rate is calculated based on the cross-sectional area A of the slag bag corresponding to the liquid level height h, combined with the liquid level change rate. Calculate the instantaneous mass flow rate based on the slag temperature T and the instantaneous volumetric flow rate; The calculated liquid level height, instantaneous volumetric flow rate, instantaneous mass flow rate, and historical change curves are displayed in real time.

5. The method for non-contact flow measurement of high-temperature liquids according to claim 4, characterized in that, The step of calculating the instantaneous volumetric flow rate based on the cross-sectional area A of the slag bag corresponding to the liquid level height h, combined with the liquid level change rate, is performed as follows: in, Indicates the rate of change of liquid level. This represents the instantaneous volumetric flow rate of the molten slag.

6. The method for non-contact flow measurement of high-temperature liquids according to claim 5, characterized in that, The relationship between the cross-sectional area A of the slag bag and the liquid level height h is determined in the following way: If the slag bag is a standard cylindrical shape, the cross-sectional area is a fixed value. ,in R Where is the radius of the cylinder; If the slag bag is a frustum, its cross-sectional area is... ,in Let be the radius of the lower base of the frustum. Let be the radius of the top of the frustum. The rate of change of radius, , H The height is the frustum.

7. The method for non-contact flow measurement of high-temperature liquids according to claim 4, characterized in that, The specific method for calculating the instantaneous mass flow rate based on the slag temperature T and the instantaneous volumetric flow rate is as follows: Based on the slag temperature T, a density-temperature relationship is constructed, and the density of the slag is calculated. Instantaneous mass flow rate is calculated based on instantaneous volumetric flow rate and slag density.

8. The method for non-contact flow measurement of high-temperature liquids according to claim 7, characterized in that, The density-temperature relationship is constructed as follows: in, Indicates reference temperature The density of the molten slag below This is the temperature coefficient.

9. The method for non-contact flow measurement of high-temperature liquids according to claim 8, characterized in that, The formula for calculating instantaneous mass flow rate based on instantaneous volumetric flow rate and slag density is as follows: in, This refers to the instantaneous mass flow rate.

10. A non-contact flow measurement method for high-temperature liquids according to claim 4, characterized in that, The filtering process employs an average filtering algorithm.

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