Intelligent smelting method of high-carbon ferrochrome based on ore smelting furnace

Abstract

This invention belongs to the field of ferroalloy smelting technology and industrial process control technology. Specifically, it discloses an intelligent smelting method for high-carbon ferrochrome alloys based on a submerged arc furnace. The method includes: generating a comprehensive material surface state map by collecting material surface state and temperature data; analyzing the overall spatial distribution pattern of grid cells based on the state map to diagnose the overall furnace condition; triggering corresponding global control commands if abnormalities are found; and comparing the material surface sinking height, raw material sinking speed, current temperature, and temperature change rate of each grid cell with preset evaluation criteria to diagnose local furnace conditions if the overall furnace condition is healthy. For healthy cells, precise quantitative material replenishment is calculated when the sinking height meets the standard, and the replenishment azimuth angle is determined through polar coordinate transformation. For abnormal cells, differentiated local control commands are triggered based on their abnormal characteristics. This invention achieves closed-loop intelligent control of the submerged arc furnace smelting process from global perception to precise local control, effectively improving smelting efficiency.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of ferroalloy smelting process and industrial process control, and relates to an intelligent smelting method of high-carbon chromium iron alloy based on an ore smelting furnace. BACKGROUND

[0002] High-carbon chromium iron alloy is an important raw material indispensable in the modern steel industry, and its production mainly relies on the ore smelting furnace, a large high-temperature smelting device. In the smelting process of the ore smelting furnace, the physical state and thermal state of the charge surface in the furnace directly determine the efficiency of chemical reaction, energy consumption, and the quality and yield of the final product. Therefore, realizing accurate and real-time perception and intelligent regulation and control of the furnace condition is the core key to ensuring efficient, stable and safe operation of the smelting process. However, the interior of the ore smelting furnace is a closed black box environment with strong coupling of multiple physical fields and complex and variable working conditions, which brings great challenges to accurately grasp its running state.

[0003] For example, the Chinese invention patent with publication number CN103667700B discloses a production method for smelting high-carbon chromium iron with carbonaceous combined reducing agent, which provides a solution for improving the furnace condition by optimizing the raw material ratio and pretreatment. This technology focuses on optimization from the raw material end, and maintains the permeability of the charge through manual operation, thereby improving the smelting efficiency to a certain extent and reducing the power consumption.

[0004] The above existing technologies have the following deficiencies: 1. The existing technology improves the permeability by piercing the charge surface, which cannot obtain accurate data of the three-dimensional morphology and temperature field of the charge surface in real time and continuously, and thus cannot quantitatively analyze key dynamic parameters such as raw material sinking and temperature change, resulting in serious lag in discovering and handling evolving furnace condition problems such as abnormal diffusion and thermal imbalance.

[0005] 2. The regulation and control of the existing technology is based on overall or local experience judgment, and cannot realize accurate spatial positioning and quantitative calculation based on grid units. It cannot perform accurate feeding according to the height difference to calculate the amount of feeding for the healthy area where the sinking reaches the benchmark, and cannot trigger differentiated local regulation and control instructions such as electrode power adjustment or local feeding adjustment for specific abnormal areas, resulting in suboptimal resource allocation and low regulation and control efficiency. SUMMARY

[0006] In view of this, an intelligent smelting method of high-carbon chromium iron alloy based on an ore smelting furnace is proposed to solve the problems raised in the background art.

[0007] The objective of this invention can be achieved through the following technical solution: This invention provides an intelligent smelting method for high-carbon ferrochrome alloy based on an electric arc furnace, comprising: S1, spatially registering and fusing the material surface state and temperature to generate a comprehensive material surface state map, and dividing it into grids, wherein the material surface state refers to the height distribution of the material surface within the electric arc furnace.

[0008] S2. Based on the comprehensive material surface status map at each collection time point, analyze the overall spatial distribution pattern of the grid cells, and diagnose the overall furnace condition of the electric arc furnace accordingly. If the overall furnace condition is abnormal, trigger the global control command corresponding to the overall abnormality type.

[0009] S3. If the overall furnace condition is healthy, based on the comprehensive material surface status diagram, analyze the material surface sinking height, raw material sinking speed, current temperature and temperature change rate of each grid unit, and compare them with the preset evaluation criteria to diagnose the local furnace condition of the electric arc furnace.

[0010] S4. For grid cells with healthy furnace conditions, determine whether their sinking height reaches the material sinking height benchmark. If it does, calculate the material replenishment amount of the grid cell based on the sinking height difference and the area of ​​the grid cell, and calculate the target material replenishment azimuth angle of the replenishment equipment based on its spatial position through polar coordinate transformation, and execute the replenishment operation.

[0011] S5. For grid cells with abnormal furnace conditions, local control commands are triggered based on their abnormal characteristics.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The present invention uses a non-contact ranging sensor fixed under the furnace cover and an infrared thermal imager on the furnace top to synchronously collect material surface data and perform spatial registration and fusion to generate a comprehensive material surface state map, thereby realizing real-time and synchronous perception of the three-dimensional shape and temperature field of the material surface, overcoming the lag of manual observation, and providing a data basis for subsequent accurate diagnosis.

[0013] (2) This invention divides the comprehensive material surface state diagram into grids and analyzes the material surface sinking height, raw material sinking speed, temperature change rate and current temperature of each grid unit based on continuously collected data, thereby realizing refined monitoring of the furnace condition from macroscopic overall to microscopic local and accurately locating abnormal areas.

[0014] (3) By analyzing the spatial distribution pattern of all grid cell state parameters, this invention can promptly identify global risks such as material surface tilt, abnormal diffusion, and thermal imbalance, and make precise material replenishment decisions for healthy local areas and trigger targeted regulation for abnormal local areas, thus realizing early identification and intervention of local anomalies.

[0015] (4) The present invention calculates the amount of material to be added based on the height difference and the area of ​​the unit when the sinking height reaches the reference for the grid unit with healthy furnace condition, and calculates the target material addition azimuth angle through polar coordinate transformation to perform material addition, thereby realizing on-demand and precise spatial fixed-point material addition, avoiding furnace condition disturbances caused by uniform material addition, and thus improving the utilization efficiency of raw materials and furnace condition stability. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram showing the connections between the steps of the method of the present invention.

[0018] Figure 2 This is a schematic diagram showing the connection steps of generating the comprehensive material surface state diagram of the present invention.

[0019] Figure 3 This is a schematic diagram showing the overall furnace condition diagnosis steps of the electric arc furnace of the present invention. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Please see Figure 1 As shown, the present invention provides an intelligent smelting method for high-carbon ferrochrome alloy based on an electric arc furnace. The method includes: S1, spatial registration and fusion of material surface state and temperature data to generate a comprehensive material surface state map, and then dividing the map into grids. The material surface state refers to the height distribution of the material surface within the electric arc furnace.

[0022] Please see Figure 2 As shown, exemplarily, the generation of the comprehensive material surface status map includes: simultaneously measuring the distance from each measurement point to the material surface using multiple non-contact ranging sensors fixed at different radial and circumferential positions below the furnace cover. Preferably, the non-contact ranging sensors are laser rangefinders with strong resistance to high-temperature interference and high accuracy. The non-contact ranging sensors are evenly distributed along the radial and circumferential directions of the furnace cover, with a number of 8 to 16, to ensure complete coverage of the material surface.

[0023] Considering the physical characteristics of smelting in an electric arc furnace, the reaction and feeding process within the furnace are not uniform in the radial and circumferential directions, resulting in temperature and material surface height differences around the electrodes. By rationally distributing measuring points in the radial and circumferential directions, a spatially representative monitoring network covering the entire material surface can be constructed. This provides a data foundation for subsequently reconstructing a height distribution map reflecting the overall three-dimensional morphology of the material surface, avoiding calculation distortions caused by insufficient or improperly distributed measuring points.

[0024] Based on the fixed installation positions of each sensor on the furnace body, the distance data is converted into the material surface height at each measurement point.

[0025] It should be noted that when installing the sensors, a reference value for the installation height of each sensor is determined. The sensor collects the vertical distance from the material surface directly below it, and the difference between the reference value for the installation height and the vertical distance is taken as the height of the material surface.

[0026] Based on the material surface height at each measurement point, a height distribution map representing the three-dimensional morphology of the material surface is generated using a three-dimensional reconstruction algorithm.

[0027] Specifically, the height distribution map is generated as follows: First, an XY plane coordinate system is established on the horizontal plane with the vertical projection point of the center line of the submerged arc furnace as the origin, and a three-dimensional spatial coordinate system is established with the vertical upward direction as the positive Z-axis.

[0028] Secondly, based on the fixed installation positions of each sensor on the furnace body, the horizontal coordinates of each measurement point in the XY coordinate system are determined, and the current material surface height of each measurement point is used as its Z coordinate, thus representing each measurement point as a three-dimensional spatial point. All measurement points together constitute a spatial scatter dataset describing the current material surface morphology.

[0029] Furthermore, since the measurement points are discrete, a three-dimensional reconstruction of the aforementioned spatial scattered point dataset is required to obtain the continuous height distribution of the entire material surface. This reconstruction process is implemented using a spatial interpolation algorithm. The spatial interpolation algorithm includes, but is not limited to, Kriging interpolation, inverse distance weighted interpolation, or triangulation linear interpolation.

[0030] Finally, using the aforementioned three-dimensional reconstruction algorithm, the entire furnace material surface coverage area is traversed and interpolated to generate a regular gridded height distribution map. The horizontal position of each grid cell and its material surface height together characterize the three-dimensional shape of the material surface.

[0031] An infrared thermal imager mounted on the furnace top is used to perform a two-dimensional scan of the material surface to obtain temperature distribution data.

[0032] The temperature distribution data and the height distribution map are spatially registered to generate a comprehensive material surface state map.

[0033] S2. Based on the comprehensive material surface status map at each acquisition time point, analyze the overall spatial distribution pattern of the grid cells and diagnose the overall furnace condition of the electric arc furnace accordingly. If the overall furnace condition is abnormal, trigger the global control command corresponding to the overall abnormality type. When the overall furnace condition is abnormal, pause the local diagnosis and only execute the global control.

[0034] Please see Figure 3 As shown, exemplarily, the diagnosis of the overall furnace condition of the submerged arc furnace includes: based on the current material level height, calculating the best-fit plane using the least squares method, and taking the angle between the best-fit plane and the horizontal plane as the overall tilt angle of the material level. When the overall tilt angle of the material level is greater than the reference tilt angle threshold, it is determined to be a material level tilt mode.

[0035] It should be added that the reference tilt angle threshold is a critical angle value used to determine whether the overall tilt of the material surface has exceeded the allowable range of the process. The specific steps for obtaining the reference tilt angle threshold are as follows: During multiple cycles of healthy smelting in the electric arc furnace, material surface height data is continuously collected, and the overall tilt angle of the material surface at each collection time point is calculated, thereby forming a historical angle dataset representing normal tilt fluctuations.

[0036] Statistical analysis of the aforementioned historical angle dataset is performed. Considering that normal fluctuations may contain extreme values, a relatively high quantile, such as the 95th percentile, is typically selected as the baseline tilt angle threshold. In a preferred embodiment, the baseline tilt angle threshold can be set to 5° to 10°.

[0037] Grid cells that are spatially adjacent and have abnormal furnace conditions are identified as abnormal clustering regions. The area of ​​the abnormal clustering region at the current acquisition time point is calculated and compared with the area at the previous N acquisition time points to calculate its area expansion rate. Here, N is used as the reference time window size for calculating the area expansion rate, which is usually 3-5 time points to ensure the stability of the rate calculation.

[0038] When at least one abnormal clustering area is identified, and its area continues to expand within M consecutive collection time points, and the area expansion rate exceeds the baseline area expansion rate threshold, it is determined to be an abnormal diffusion pattern. Here, M is used to determine the minimum number of consecutive time points for continuous expansion, which is usually 2-3 time points to avoid random fluctuations.

[0039] It should be added that the aforementioned benchmark area expansion rate threshold is a critical rate value used to determine whether the diffusion of an abnormal area has entered a dangerous state. This threshold is not a fixed value, but is determined based on statistical analysis of historical operating data of the submerged arc furnace.

[0040] The steps for obtaining the threshold are as follows: Based on historical data of the submerged arc furnace under healthy operating conditions, extract all cases of localized abnormal diffusion events that have occurred but did not lead to serious accidents, and obtain the expansion rate data of the abnormal area during the development of these events. Perform statistical analysis on the expansion rate data of all the above historical diffusion events, for example, calculate the 95th percentile of its distribution as the baseline area expansion rate threshold. The baseline area expansion rate threshold can be set according to the furnace size; for example, for a large submerged arc furnace, it can be 0.1 m² / min.

[0041] Traverse all adjacent grid cell pairs and calculate the temperature difference between each adjacent cell pair. The temperature difference represents the degree of spatial variation of the temperature field inside the furnace. Statistically analyze the distribution of all temperature differences, such as calculating their maximum value, average value, or 95th percentile value, and use this as a quantitative indicator of the overall temperature gradient.

[0042] When the quantitative index of the overall temperature gradient exceeds the threshold of the quantitative index of the baseline temperature gradient, it is determined to be a thermal imbalance mode. When at least one mode exists, the overall furnace condition is determined to be abnormal; otherwise, the overall furnace condition is determined to be healthy.

[0043] It should be added that the threshold value for the quantification index of the reference temperature gradient is a critical gradient value used to determine whether the temperature field distribution inside the furnace has become severely uneven and entered a state of thermal imbalance. This threshold value is obtained based on statistical analysis of historical temperature field data of the submerged arc furnace under healthy operating conditions.

[0044] The threshold is obtained by continuously collecting comprehensive material surface status maps during multiple smelting cycles when the submerged arc furnace is in a healthy operating state, and calculating the overall temperature gradient quantification index, such as the 95th percentile of the temperature difference, at each collection time point, thus forming a historical temperature gradient quantification index dataset characterizing normal heat distribution fluctuations. Statistical analysis is then performed on the aforementioned historical temperature gradient quantification index dataset. To effectively distinguish between normal fluctuations and abnormal imbalances, a relatively high quantile, such as 97%, is typically selected as the baseline gradient threshold, thereby ensuring that the temperature gradient under most healthy operating conditions is below this threshold.

[0045] For example, the global control command corresponding to the triggering of the overall abnormality type includes: S201, when the material surface tilting mode is identified, the electrode displacement adjustment amount and the power adjustment amount of each phase are calculated based on the tilting angle and direction of the material surface, and the electrode position adjustment and power control command is generated.

[0046] Furthermore, the specific implementation method for calculating the electrode displacement adjustment amount and the power adjustment amount of each phase is described as follows: After the system identifies the material surface tilting mode, the electrode displacement adjustment amount and the power adjustment amount of each phase are calculated based on the tilting angle and direction of the material surface. The principle is: by coordinating the adjustment of the electrode position and the input power, the distribution of the high temperature zone in the furnace is changed, and the fluidity of the molten material is used to smooth the tilted material surface and rebuild the thermal balance. The specific calculation logic is as follows: (1) Calculate the electrode displacement adjustment amount.

[0047] First, the angle and direction of the material surface inclination are obtained through plane fitting.

[0048] Then, based on the spatial relationship between the tilt direction and each electrode, a displacement coefficient is assigned to each phase electrode. The basic principle is: on the side with a lower material level, the corresponding electrode should be lowered; on the side with a higher material level, the corresponding electrode can be raised or slightly lowered. The sign and magnitude of the displacement coefficient are determined by the relative position of the electrode and the tilt area, and can be preset based on historical debugging data.

[0049] The displacement adjustment of each electrode is determined by the formula. The calculation yields the following result: [Equation omitted for brevity] For the first The displacement of the phase electrode is indicated by positive values ​​for downward insertion and negative values ​​for upward insertion. The displacement coefficient of this electrode, determined based on the aforementioned spatial relationships, has a specific value determined based on the furnace structure and historical commissioning data. The angle of inclination of the material surface. Electrode serial number, .

[0050] (2) Calculate the power adjustment for each phase.

[0051] Power adjustment and electrode displacement are coordinated. The principle is: in areas where the material level is low and smelting needs to be intensified, the corresponding electrode should be lowered appropriately while the power is increased accordingly. In areas where the material level is high and smelting needs to be slowed down, the power should be reduced or maintained accordingly.

[0052] Based on the tilt direction, a power adjustment coefficient is assigned to each phase electrode. The allocation logic is coordinated with the displacement coefficient: typically, electrodes requiring downward insertion correspond to a positive power adjustment coefficient, while electrodes requiring upward insertion correspond to a negative power adjustment coefficient.

[0053] The adjustment amount of each phase power is related to the tilt angle and the current reference power of that phase, and can be expressed by the formula. Perform the calculation, where For the first The adjustment amount of phase power, For the first The current reference power of the phase electrode, The power adjustment ratio coefficient determines the direction and magnitude of the power adjustment by its sign and magnitude. At the same time, it is necessary to ensure that the total adjustment of the three-phase power is controlled within the range allowed by the process to avoid impacting the power grid.

[0054] Finally, the calculated electrode displacement adjustment and phase power adjustment are used to generate electrode position adjustment and power control commands.

[0055] S202. When an abnormal diffusion pattern is identified, the adjustment range of the raw material ratio is calculated based on the diffusion speed and range of the abnormal area, a raw material ratio adjustment command is generated, and a system early warning of the corresponding level is triggered.

[0056] For example, the specific implementation of the raw material ratio adjustment instruction is as follows: based on the area ratio and area expansion rate of the abnormal area, the severity level of the diffusion is assessed and classified into mild, moderate and severe levels.

[0057] Preferably, the classification criteria for the levels are as follows: mild diffusion refers to a low level in both area ratio and expansion rate. In this case, a first-level coke ratio adjustment instruction is triggered, with the adjustment range being the first interval.

[0058] Moderate diffusion refers to a situation where the area proportion and expansion rate have reached a level requiring active intervention. At this point, a second-level coke blending ratio adjustment order is triggered, with the adjustment magnitude being greater than that of the first interval.

[0059] Severe diffusion refers to a situation where both the area proportion and the expansion rate have reached a level that seriously affects the stability of the furnace conditions. At this point, a third-level coke ratio adjustment instruction is triggered, with the adjustment range being greater than that of the second interval, and a higher-level system warning is triggered simultaneously.

[0060] The system will eventually encapsulate the determined proportioning parameters into adjustment instructions, send them to the automatic batching system, and trigger warning messages corresponding to the severity level.

[0061] S203. When a thermal imbalance mode is identified, the average temperature of the corresponding regions of the three-phase electrodes is calculated respectively, and the adjustment value of the power of each phase is calculated based on the total average value of the three-phase average temperature, and a power balance control command is generated based on the power adjustment amount.

[0062] For example, the generated power balance control command specifically includes the following steps: Q1, Delineating electrode regions: Delineating the dominant heat-affected zone for each of the three phase electrodes. Preferably, the region can be defined as a circular region with a specific radius centered on each electrode.

[0063] Q2. Calculate the overall reference temperature: Calculate the average current temperature of all grid cells within the region corresponding to each phase electrode. , and The arithmetic mean of the three values ​​is calculated as the overall reference temperature. .

[0064] Q3. Calculate the power adjustment amount: Based on the deviation between the average temperature of each phase region and the total reference temperature, calculate the power adjustment value for each phase. The specific calculation formula can be used as follows: In the formula For the first Phase electrode power adjustment If it is positive, it means that power needs to be increased. If it is negative, it means that power needs to be decreased. The power-temperature compensation coefficient is a constant preset based on the thermal efficiency and process characteristics of a specific submerged arc furnace. Its value is determined through regression analysis of historical operating data. For the first The average temperature of the region corresponding to the phase electrode.

[0065] Q4. Generate control commands: Encapsulate the calculated three-phase power adjustment amount into a structured power balance control command, which is used to adjust the input power of each phase electrode.

[0066] S3. If the overall furnace condition is healthy, based on the comprehensive material surface status diagram, analyze the material surface sinking height, raw material sinking speed, current temperature and temperature change rate of each grid unit, and compare them with the preset evaluation criteria to diagnose the local furnace condition of the electric arc furnace.

[0067] For example, the analysis of the material surface sinking height of each grid cell includes: obtaining the material surface height at each measurement point at the first acquisition time point from the comprehensive material surface state diagram at each acquisition time point, and using it as the initial material surface height at each measurement point.

[0068] Obtain the current material level height at each measurement point from the comprehensive material level status map at the current data collection time.

[0069] Calculate the difference between the current material surface height and the initial material surface height at each measurement point, and use it as the material surface sinking height.

[0070] Calculate the average value of the material surface sinking height at all measurement points within each grid cell, and use this value as the material surface sinking height for each grid cell.

[0071] For example, the analysis of the raw material sinking velocity of each grid cell includes: obtaining the material surface height of each measurement point at each collection time point from the comprehensive material surface state diagram at each collection time point, and constructing the material surface height change curve of each measurement point with the collection time point as the abscissa and the material surface height as the ordinate.

[0072] The slope of the curve is obtained as the raw material sinking velocity at each measurement point.

[0073] The raw material sinking velocity of all measurement points within the grid cell is statistically analyzed, and its average value is calculated to obtain the raw material sinking velocity of each grid cell.

[0074] For example, the analysis of the current temperature and temperature change rate of each grid cell includes: obtaining the temperature of each grid cell at the current acquisition time point as the current temperature of each grid cell.

[0075] The temperature of each grid cell at each time point is obtained from the comprehensive material surface state diagram at each collection time point, and the temperature change curve of each grid cell is constructed.

[0076] Preferably, the specific construction process of the temperature change curve of each grid unit is as follows: First, from the comprehensive material surface state map at each acquisition time point, the temperature of the same grid unit at different time points is extracted in chronological order. This forms a set of time-temperature data pairs for that grid unit.

[0077] Secondly, based on the aforementioned time-temperature data set, a temperature change curve is generated by processing the discrete time-temperature data points using a numerical fitting algorithm.

[0078] Extract the temperature change rate of each grid cell from the temperature change curve.

[0079] For example, the diagnosis of local furnace conditions of the submerged arc furnace includes comparing the material level sinking height, raw material sinking speed, current temperature and temperature change rate of each grid cell with their preset evaluation criteria.

[0080] It should be noted that the preset evaluation criteria refer to a series of quantitative standards used to determine the health of the furnace in each grid unit. These criteria are derived from statistical analysis of historical smelting data.

[0081] The evaluation criteria consist of the normal ranges or thresholds of the following four core parameters: the raw material sinking speed criterion refers to the normal range of material level descent speed per unit time under healthy furnace conditions. Excessive speed may indicate crucible zone expansion or material leakage, while excessively slow speed may indicate furnace charge sintering or the formation of a dead material zone.

[0082] The material level sinking height benchmark refers to the ideal sinking height value that triggers a precise material replenishment during a normal smelting cycle. This value is determined by the process design and serves as the basis for calculating the replenishment amount.

[0083] The temperature change rate benchmark refers to the normal range of temperature fluctuation per unit time under thermal equilibrium conditions. An abnormal change rate indicates that thermal equilibrium has been disrupted.

[0084] The current temperature reference refers to the normal operating temperature range of different grid cells at various stages of smelting. Temperatures that are too high or too low are considered abnormal.

[0085] The evaluation criteria are obtained and established through the following steps: during the operation of the electric arc furnace, historical data on the material surface sinking height, raw material sinking speed, temperature change rate, and current temperature of all grid cells are continuously collected and stored.

[0086] Data segments characterizing healthy furnace conditions are selected from the historical data, and statistical analysis such as calculating the mean and standard deviation is used to determine the confidence interval. Then, the typical numerical range or threshold of the above four parameters under healthy conditions is determined to form the final evaluation criteria.

[0087] When all of the above parameters of a grid cell are simultaneously within its reference range, its furnace condition is determined to be healthy.

[0088] If any parameter deviates from its reference range, it is judged as abnormal, and the local furnace condition of the electric arc furnace is obtained.

[0089] S4. For grid cells with healthy furnace conditions, determine whether their sinking height reaches the material sinking height benchmark. If it does, calculate the material replenishment amount of the grid cell based on the sinking height difference and the area of ​​the grid cell, and calculate the target material replenishment azimuth angle of the replenishment equipment based on its spatial position through polar coordinate transformation, and execute the replenishment operation.

[0090] Specifically, the calculation of the feed amount of the grid cell includes the following steps: Y1, Calculate the required furnace charge volume: Multiply the area of ​​the grid cell by the difference in material surface height to obtain the furnace charge volume that needs to be replenished.

[0091] Y2. Convert volume to feed mass: Calculate the final feed mass based on the bulk density of the furnace charge and the compensation coefficient. The calculation formula is as follows: In the formula, This indicates the final amount of material added to the grid cell. This indicates the bulk density of the furnace charge, which is a known process parameter determined based on the physical properties of the raw materials used. This represents a compensation coefficient. It is used to compensate for the compaction and sintering losses of the furnace charge during its descent, and its value is determined based on historical production data and process experience.

[0092] It should be noted that the bulk density of the furnace charge can be dynamically updated according to the raw material ratio. When the adjustment of the raw material ratio exceeds a preset threshold, the system calculates the weighted average of the bulk densities of each component raw material based on the new ratio to update the density. The value of is determined to ensure the accuracy of the feeding quality. The preset threshold is set based on the sensitivity analysis of the impact of changes in raw material composition on bulk density. In a preferred embodiment, the threshold is set when the ratio change exceeds ±2%.

[0093] As an example, assuming a grid cell area of ​​0.5m², the calculated height difference... m, bulk density of furnace charge kg / m³, material compensation coefficient The required replenishment volume m³.

[0094] Final replenishment quality kg, and then generate an instruction to precisely deliver 105 kg of material to the location corresponding to that grid cell.

[0095] For example, the target feeding azimuth angle of the calculation feeding device includes: establishing a polar coordinate system on a horizontal plane with the vertical projection point of the center of the submerged arc furnace as the origin and the reference direction as the polar axis, wherein the reference direction, in a preferred embodiment, is the due north direction determined when the furnace body is installed, or the direction perpendicular to the center line of the furnace door.

[0096] Calculate the geometric center point of the covered area based on the boundary vertex coordinates of the grid cell to be replenished.

[0097] The spatial position of the geometric center point is transformed into polar coordinates in the polar coordinate system, where the polar radius represents the horizontal distance from the center point to the center of the furnace, and the polar angle represents the orientation of the center point relative to the reference direction.

[0098] The polar angle is used as the target feeding azimuth angle for the furnace top feeding equipment.

[0099] S5. For grid cells with abnormal furnace conditions, local control commands are triggered based on their abnormal characteristics.

[0100] For example, the triggering of the local control command includes: if at least one of the raw material sinking speed, temperature change rate or current temperature is abnormal, then based on the magnitude and direction of its deviation from the reference value, calculating and triggering an adjustment command for the electrode position and input power.

[0101] The specific implementation process is as follows: First, determine the control direction: For abnormal raw material sinking speed: if the real-time value is higher than the upper limit of the raw material sinking speed benchmark, it is determined that the thermal field intensity needs to be weakened, and the electrode is raised accordingly while the input power is reduced. If it is lower than the lower limit of the raw material sinking speed benchmark, it is determined that the thermal field intensity needs to be strengthened, and the electrode is lowered accordingly while the input power is increased.

[0102] For temperature-related anomalies: if the real-time temperature is higher than the current temperature reference upper limit or the temperature change rate is higher than the temperature change rate reference upper limit, then it is determined that the thermal field intensity needs to be reduced. If the real-time temperature is lower than the current temperature reference lower limit or the temperature change rate is lower than the temperature change rate reference lower limit, then it is determined that the thermal field intensity needs to be increased.

[0103] Subsequently, the adjustment magnitude is quantified: the adjustment magnitude is proportional to the degree to which the parameter deviates from the baseline value. Based on the calculated deviation... The specific adjustment amount is calculated using the following formula: , In the formula: For the first The displacement adjustment amount of the phase electrode. For the first The power adjustment amount of the phase electrode. and The first The signs of the electrode displacement-compensation coefficient and power-compensation coefficient in this local control of the phase electrode are determined by the control direction.

[0104] Finally, generate and trigger the instruction: to calculate and It is encapsulated into specific electrode position and input power adjustment instructions.

[0105] The abnormal characteristics of the raw material sinking speed and temperature both reflect the imbalance of the thermodynamic state inside the furnace, and therefore can be corrected by adjusting the electrode position and input power.

[0106] If the material surface sinking height is abnormal, then based on the type of abnormality, a targeted mechanical intervention or energy adjustment command is calculated and triggered, wherein the abnormality type includes sinking stagnation and excessive collapse.

[0107] Preferably, the determination and handling of the abnormality type is as follows: The sinking stagnation refers to a situation where, within the continuous data collection period, the material level of the grid cell fails to drop to the replenishment reference height and the raw material sinking speed remains below the lower threshold. This state is typically caused by material bridging. At this time, a mechanical intervention command is triggered, controlling the actuator located above this area to perform a bridging operation to restore the normal replenishment cycle.

[0108] Excessive collapse refers to a situation where the material level drops below the feed reference height for a short period and the sinking velocity instantaneously exceeds the upper limit threshold, indicating that the material layer structure inside the furnace may have become unstable. At this point, an energy adjustment command is triggered, and after the bridging operation is completed and the material sinking velocity returns to normal, a feed command for that area is triggered again. The energy adjustment command is used to significantly reduce or cut off the electrode power corresponding to that area to quickly stabilize the material layer. The cautious feed command is used to perform small-batch, multiple feed operations with a dosage that is a certain percentage less than the normal feed amount.

[0109] If multiple abnormal characteristics exist, a composite control command is generated according to a preset priority rule. This priority rule is set based on the degree and urgency of the impact of different abnormal characteristics on furnace stability: temperature anomalies directly reflect the disruption of thermodynamic equilibrium, having the most fundamental and rapid impact, and therefore have the highest priority. Abnormal raw material sinking velocity is an indirect representation and result of the thermodynamic state, and therefore has the next highest priority. Abnormal material surface sinking height is mostly a morphological result caused by the aforementioned anomalies, and therefore has a relatively lower priority. When generating composite commands, the system integrates each individual adjustment command according to this priority order. When commands of different priorities conflict in the adjustment direction, the adjustment direction of the higher priority command takes precedence, and the adjustment amount of the conflicting lower priority command is ignored or proportionally reduced to ensure that the most critical thermodynamic imbalance is corrected first from the root.

[0110] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, in the form of a computer program product.

[0111] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0112] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0113] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0114] Finally, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A smart smelting method for high-carbon ferrochrome alloys based on a submerged arc furnace, characterized in that: include: S1. By collecting the material surface state and temperature, spatial registration and fusion are performed to generate a comprehensive material surface state map, and the map is then divided into grids. The material surface state refers to the height distribution of the material surface in the electric arc furnace. S2. Based on the comprehensive material surface status map at each collection time point, analyze the overall spatial distribution pattern of the grid cells, and diagnose the overall furnace condition of the electric arc furnace accordingly. If the overall furnace condition is abnormal, trigger the global control command corresponding to the overall abnormality type. The overall furnace condition of the ferroelectric furnace being diagnosed includes: Based on the current material surface height, the best-fitting plane is calculated using the least squares method, and the angle between the plane and the horizontal plane is taken as the overall tilt angle of the material surface. When the overall tilt angle of the material surface is greater than the reference tilt angle threshold, it is determined to be a material surface tilting mode. The grid cells that are spatially adjacent and have abnormal furnace conditions are identified as abnormal clustering regions. The area of ​​the abnormal clustering region at the current acquisition time point is calculated and compared with the area at the previous N acquisition time points to calculate its area expansion rate. When at least one abnormal clustering area is identified, and its area continues to expand within M consecutive collection time points, and the area expansion rate exceeds the baseline area expansion rate threshold, it is determined to be an abnormal diffusion pattern. Traverse all adjacent grid cell pairs, calculate the temperature difference between each adjacent cell pair, statistically analyze the distribution of all temperature differences, and use it as a quantitative indicator of the overall temperature gradient. When the quantitative index of the overall temperature gradient exceeds the threshold of the quantitative index of the baseline temperature gradient, it is determined to be a thermal imbalance mode. When at least one mode exists, the overall furnace condition is determined to be abnormal; otherwise, the overall furnace condition is determined to be healthy. S3. If the overall furnace condition is healthy, based on the comprehensive material surface condition diagram, analyze the material surface sinking height, raw material sinking speed, current temperature and temperature change rate of each grid unit, and diagnose the local furnace condition of the electric arc furnace accordingly. S4. For grid cells with healthy furnace conditions, determine whether their sinking height reaches the material sinking height benchmark. If it does, calculate the material replenishment amount of the grid cell based on the sinking height difference and the area of ​​the grid cell, and calculate the target material replenishment azimuth angle of the replenishment equipment based on its spatial position through polar coordinate transformation, and execute the replenishment operation. S5. For grid cells with abnormal furnace conditions, local control commands are triggered based on their abnormal characteristics.

2. The intelligent smelting method for high-carbon ferrochrome alloy based on a submerged arc furnace according to claim 1, characterized in that: The generated comprehensive material surface state diagram includes: Multiple non-contact distance sensors fixed at different radial and circumferential positions under the furnace cover are used to simultaneously measure the distance from each measurement point to the material surface. Based on the fixed installation positions of each sensor on the furnace body, the distance data is converted into the material surface height at each measurement point; Based on the material surface height at each measurement point, a height distribution map representing the three-dimensional morphology of the material surface is generated using a three-dimensional reconstruction algorithm. An infrared thermal imager mounted on the top of the furnace is used to perform a two-dimensional scan of the material surface to obtain temperature distribution data of the material surface; The temperature distribution data and the height distribution map are spatially registered to generate a comprehensive material surface state map.

3. The intelligent smelting method for high-carbon ferrochrome alloys based on a submerged arc furnace according to claim 1, characterized in that: The global control instructions that trigger the overall anomaly type include: When the material surface tilt mode is identified, the electrode displacement adjustment amount and the power adjustment amount of each phase are calculated based on the tilt angle and direction of the material surface, and the electrode position adjustment and power control command are generated. When an abnormal diffusion pattern is identified, the adjustment range of the raw material ratio is calculated based on the diffusion speed and range of the abnormal area, a raw material ratio adjustment command is generated, and a system early warning of the corresponding level is triggered. When a thermal imbalance mode is identified, the average temperature of the corresponding regions of the three-phase electrodes is calculated respectively. Based on the total average value of the three-phase average temperature, the adjustment value of the power of each phase is calculated, and a power balance control command is generated based on the power adjustment amount.

4. The intelligent smelting method for high-carbon ferrochrome alloy based on a submerged arc furnace according to claim 1, characterized in that: The analysis of the material surface sinking height of each grid cell includes: The material surface height at each measurement point is obtained from the comprehensive material surface status map at each collection time point, and is used as the initial material surface height at each measurement point. Obtain the current material level height at each measurement point from the comprehensive material level status map at the current data collection time. Calculate the difference between the current material surface height and the initial material surface height at each measurement point, and use it as the material surface sinking height; Calculate the average value of the material surface sinking height at all measurement points within each grid cell, and use this value as the material surface sinking height for each grid cell.

5. The intelligent smelting method for high-carbon ferrochrome alloy based on a submerged arc furnace according to claim 1, characterized in that: The analysis of the raw material sinking velocity in each grid cell includes: The material surface height at each measurement point is obtained from the comprehensive material surface status map at each collection time point. The material surface height variation curve at each measurement point is constructed with the collection time point as the horizontal axis and the material surface height as the vertical axis. The slope of the curve is used as the raw material sinking velocity at each measurement point; The raw material sinking velocity of all measurement points within the grid cell is statistically analyzed, and its average value is calculated to obtain the raw material sinking velocity of each grid cell.

6. The intelligent smelting method for high-carbon ferrochrome alloy based on a submerged arc furnace according to claim 1, characterized in that: The analysis of the current temperature and temperature change rate of each grid cell includes: The temperature of each grid cell at the current acquisition time is obtained as the current temperature of each grid cell; The temperature of each grid cell at each time point is obtained from the comprehensive material surface state map at each collection time point, and the temperature change curve of each grid cell is constructed. Extract the temperature change rate of each grid cell from the temperature change curve.

7. The intelligent smelting method for high-carbon ferrochrome alloy based on a submerged arc furnace according to claim 1, characterized in that: The diagnostic features of the submerged arc furnace include: The material sinking height, raw material sinking speed, current temperature and temperature change rate of each grid cell are compared with their preset evaluation criteria. When all of the above parameters of a grid cell are simultaneously within its reference range, its furnace condition is determined to be healthy. If any parameter deviates from its reference range, it is judged as abnormal, and the local furnace condition of the electric arc furnace is obtained.

8. The intelligent smelting method for high-carbon ferrochrome alloy based on a submerged arc furnace according to claim 1, characterized in that: The target feeding azimuth angle of the calculated feeding equipment includes: A polar coordinate system is established on the horizontal plane with the vertical projection point of the center of the submerged arc furnace as the origin and the reference direction as the polar axis. Calculate the geometric center point of the area covered by the boundary vertex coordinates of the grid cell to be replenished; The spatial position of the geometric center point is transformed into polar coordinates in the polar coordinate system, where the polar radius represents the horizontal distance from the center point to the center of the furnace, and the polar angle represents the orientation of the center point relative to the reference direction. The polar angle is used as the target feeding azimuth angle for the furnace top feeding equipment.

9. The intelligent smelting method for high-carbon ferrochrome alloy based on a submerged arc furnace according to claim 1, characterized in that: The triggering local control command includes: If at least one of the raw material sinking speed, temperature change rate, or current temperature is abnormal, an adjustment command for electrode position and input power is calculated and triggered based on the magnitude and direction of its deviation from the reference value. If the material surface sinking height is abnormal, then based on the type of abnormality, a targeted mechanical intervention or energy adjustment command is calculated and triggered. If multiple abnormal characteristics exist, a composite control command will be generated according to the preset priority rules.

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