Top-charging coke oven coal charging device based on multi-parameter fusion and dynamic metering method

Abstract

The invention relates to the technical field of coke oven coking, in particular to a top-charging coke oven coal charging device based on multi-parameter fusion and a dynamic metering method. The device comprises a scanning imaging radar, a moisture online measuring instrument, a control processing module, a vibrator and four sets of storage bins and screw conveyors which are connected in parallel. The method comprises the following steps: initializing coal moisture W0 and bulk density rho0; the system is started, the vibrator flattens the coal according to specific parameters, and the scanning imaging radar dynamically monitors the volume; the real-time coal loading amount is calculated according to the formula M = rho * V; and when the moisture fluctuation is monitored to be greater than or equal to 2%, re-detecting the bulk density and updating the calculation. Through multi-parameter fusion and dynamic correction of volume, moisture and bulk density, independent, real-time and accurate metering and control of the four coal charging holes are realized, and the problem of poor coal charging uniformity and accuracy caused by incapability of hole-dividing regulation and control due to post-metering in the prior art is fundamentally solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of coke oven coking, in particular to a top-charged coke oven coal charging device based on multi-parameter fusion and a dynamic metering method. BACKGROUND

[0002] The top-charged coke oven is one of the mainstream furnace types in the modern coking industry, and the accuracy and uniformity of its coal charging operation are directly related to the coke quality, furnace body life and production efficiency. At present, the coal charging quantity metering and control method commonly used in the industry has the following significant drawbacks: (1) Post-measurement, unable to real-time regulation and control: The existing technology mainly relies on the coal tower scale to weigh the coal charging car before and after coal charging, and calculates the total coal charging quantity of the single-hole carbonization chamber through the weight difference. This method is a typical post-measurement. Only after the completion of the entire coal charging operation can it be known whether the coal charging quantity meets the standard. Once it is found that the coal charging quantity is insufficient or overloaded, it is already impossible to remedy the current carbonization chamber, and only historical data can be used to adjust the coal charging plan of the next furnace, resulting in serious lag in production adjustment, and unable to realize online real-time monitoring and feedback control of the coal charging process.

[0003] (2) Coarse measurement granularity, unable to meet the requirements of carbonization chamber structure: The carbonization chamber of the top-charged coke oven is a conical cylindrical structure, and the four coal charging holes at the top are not uniformly and symmetrically distributed. This structure determines that, in order to form uniform coal pile density and reasonable coal distribution form in the carbonization chamber, the coal quantity charged through the four coal charging holes should be different in theory. However, the existing post-measurement method based on whole vehicle weighing can only give the total coal charging quantity of the carbonization chamber, and cannot know or control the distribution ratio of the coal among the four coal charging holes. This leads to uneven distribution of coal in the carbonization chamber, large local pile density difference, and thus problems such as uneven coke maturity, local coke formation or overfiring, uneven stress on the carbonization chamber wall, etc. in the coking process, which seriously affect the coke quality and furnace body life.

[0004] (3) Poor coal charging accuracy and uniformity: The above two fundamental defects, namely the lag of measurement and the non-targeted control, together lead to the problem of poor coal charging accuracy and uniformity commonly existing in the existing top-charged coke oven. Large fluctuations in coal charging quantity and uneven distribution of coal in the carbonization chamber have become a bottleneck restricting the further improvement of the production technical index of the top-charged coke oven. SUMMARY

[0005] In order to overcome the shortcomings of the prior art, the present application provides a top-charged coke oven coal charging device based on multi-parameter fusion and a dynamic metering method, to realize independent, real-time and accurate coal charging quantity metering and control of each coal charging hole, thereby fundamentally improving the coal charging quality of the top-charged coke oven.

[0006] In order to achieve the above-mentioned purpose, the present application adopts the following technical solutions: A top-charging coke oven charging device based on multi-parameter fusion, comprising: a coal bunker volume measurement module for real-time scanning of the three-dimensional form of coal in the coal bunker and calculating the volume; a coal moisture detection module provided on the wall of the charging car storage bunker for real-time detection of the moisture of the coal; a control processing module connected in signal with the coal bunker volume measurement module and the coal moisture detection module, configured to: receive coal bulk density data, coal volume data measured by the coal bunker volume measurement module, and coal moisture data measured by the coal moisture detection module; calculate the real-time coal charging amount based on the bulk density data and the coal volume data; when a change in the coal moisture data is monitored to exceed a preset threshold, trigger a bulk density re-detection instruction.

[0007] Further, the coal bunker volume measurement module is a scanning imaging radar, and the coal moisture detection module is an online moisture measurement instrument.

[0008] Further, the device further comprises an air induction fan, and the outlet pipeline of the air induction fan is aligned with the scanning lens area of the scanning imaging radar for providing continuous or intermittent air cleaning.

[0009] Further, the bottom of the coal charging car storage bunker is provided with a vibrator and a spring set for supporting the coal bunker; and the coal charging car storage bunker is connected with the screw conveyor through an expansion joint. Further, the device comprises four sets of the combination of the coal charging car storage bunker and the screw conveyor in parallel, for corresponding four coal charging holes of the coke oven and parallel operation.

[0010] A top-charging coke oven charging dynamic measurement method based on multi-parameter fusion, using the above-mentioned charging device, specifically comprising the following steps: S1 parameter initialization: detecting the initial moisture value W0 and the initial bulk density ρ0 of the coal; wherein the initial moisture value W0 is the percentage of the moisture mass to the total mass of the coal; the initial bulk density ρ0 is the mass of the coal in the natural state of accumulation to the volume it occupies, with the unit of kg / m 3 .

[0011] S2 system cooperative start: starting the vibrator, the air induction fan, the online moisture measurement instrument, the scanning imaging radar and the screw conveyor; wherein the vibrator is controlled to operate at a frequency of 15-30 Hz and an amplitude of 1-3 mm for 5-15 s; the scanning imaging radar is controlled to dynamically monitor the volume of the coal bunker at a scanning frequency of not less than 1 time / min.

[0012] S3 real-time coal charging amount calculation: The coal volume V measured by the scanning imaging radar and the current effective bulk density ρ are used to calculate the real-time coal loading amount M according to the formula M = ρ × V; wherein, the unit of M is kg, the unit of ρ is kg / m 3 , and the unit of V is m 3 ; S4 Dynamic monitoring and correction: The moisture of the coal is continuously monitored by the moisture on-line measuring instrument (4), and when the absolute difference |W1-W0| between the current moisture value W1 and the initial moisture value W0 is greater than or equal to 2%, it is determined that the moisture fluctuation is out of standard, then the bulk density of the coal is re-detected, and the bulk density value obtained by the re-detection is used to update the ρ in step S3, and then steps S2 to S4 are repeated.

[0013] Further, in step S2, the starting speed of the screw conveyor is associated with the initial volume V0 of the coal bunker measured by the scanning imaging radar for the first time, and when V0 is greater than 15 m³, the screw conveyor is started at a speed not less than 30 rpm.

[0014] Further, in step S2, the induced draft fan is operated in an intermittent mode during the coal loading operation, and after each continuous operation of 2 minutes, it is intermittently operated for 30 seconds.

[0015] Further, in step S4, if the moisture fluctuation continues to exist and reaches the threshold value of 2% again in the first monitoring period, the system automatically enters a high-frequency monitoring mode, the scanning frequency of the scanning imaging radar is increased to 1 time / 30 seconds, and the sampling frequency of the moisture on-line measuring instrument is also increased synchronously.

[0016] Compared with the prior art, the present application has the following advantages: (1) Real-time, on-line and accurate measurement of the coal loading amount is realized, which fundamentally changes the backward mode of post-measurement.

[0017] The coal bunker volume is scanned at high frequency by the scanning imaging radar, and the coal loading amount is calculated in real time by using the formula M = ρ × V in combination with the bulk density of the coal, so that the operator can monitor the coal loading condition of each coal loading hole throughout the process. This completely abandons the post-measurement mode which relies on the weight difference before / after the coal loading truck, realizes on-line real-time monitoring of the coal loading process, and provides instant data support for fine management of the production process.

[0018] (2) The problem of uniformity of coal charging caused by the special structure of the carbonization chamber is solved, and independent and accurate control for each coal charging hole is realized. The present application adopts four sets of parallel coal charging devices, which correspond to the four coal charging holes of the carbonization chamber. The control system can obtain and compare the real-time coal charging amount data of the four coal charging holes, and independently adjust the rotating speed of the corresponding screw conveyor. This mechanism enables the operator to adjust the coal charging amount of each coal charging hole to adapt to the process requirements of the conical column structure and non-uniformly distributed coal charging holes of the carbonization chamber, so as to ensure more uniform distribution of coal in the carbonization chamber and improve the uniformity of coke quality from the source.

[0019] (3) A dynamic self-correction mechanism is established, which significantly improves the reliability and environmental adaptability of the metering system. By introducing a moisture on-line measuring instrument and setting a command to trigger the re-detection of bulk density when the moisture fluctuation is greater than or equal to 2%, the present application establishes a closed-loop, dynamic self-correction system. This mechanism can automatically compensate for the interference of changes in the physical properties (moisture, bulkiness) of coal caused by factors such as coal source and weather on the volume-weight conversion relationship, overcoming the metering errors caused by fixed or inaccurate bulk density values in traditional methods, making the metering results more reliable and more adaptable to complex actual production conditions.

[0020] (4) The reliable operation of precision instruments in a high-dust environment is effectively solved, and the overall stability of the system is improved.

[0021] By configuring a draft fan for the scanning imaging radar and providing continuous or intermittent air cleaning, the accumulation and blockage of coal dust in the radar lens are effectively prevented. This targeted design ensures the long-term, stable and accurate operation of the core measurement element in the harsh conditions of the top-charged coke oven, reduces the risk of measurement errors or equipment failure caused by lens contamination, and thus ensures the availability and durability of the entire system.

[0022] (5) Through coordinated control, the metering is effectively assisted and the operation efficiency is improved. The vibrator and spring set installed at the bottom of the coal bunker can effectively level the coal interface and reduce the hanging and stacking of coal through vibration with specific parameters (such as 15-30 Hz frequency and 1-3 mm amplitude) before coal charging. This not only provides a more regular and more realistic three-dimensional shape of the coal pile for the scanning imaging radar, improving the accuracy of volume measurement, but also ensures smooth delivery of coal, improving the overall efficiency of coal charging operation.

[0023] In summary, the present application solves the long-standing problems of top-charged coke oven in coal charging metering and control through the core idea of multi-parameter fusion and dynamic correction, combined with a series of software and hardware innovations, and realizes the technical leap from "after, rough, whole vehicle" metering to "real-time, accurate, hole-by-hole" control, which has great significance for improving coke quality, stabilizing production process and realizing intelligent coking. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 Structure diagram of the present application.

[0025] In the figure: 1, scanning imaging radar; 2, induced draft fan; 3, coal car storage bin; 4, on-line moisture meter; 5, spring group; 6, vibrator; 7, expansion joint; 8, screw conveyor. DETAILED DESCRIPTION

[0026] In the following, the embodiments of the present application will be described in detail to make the purposes, technical solutions, and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely in combination with the drawings of 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 of the present application. The following description of at least one exemplary embodiment is actually only illustrative, but not as any limitation on the present application and its application or use. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work belong to the scope of protection of the present application.

[0027] In the description of the present application, it should be understood that the orientation or positional relationship indicated by the terms “center”, “longitudinal”, “transverse”, “length”, “width”, “thickness”, “upper”, “lower”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inner”, “outer”, “axial”, “radial”, “circumferential” and the like are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0028] In the description of the present application, it should be noted that, unless otherwise explicitly specified and limited, the terms “mounting”, “connection”, “connecting” should be understood broadly, for example, it can be fixed connection, or detachable connection, or integrally connected; it can be directly connected, or indirectly connected through an intermediate medium; it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0029] In the description of the present application, it should be noted that the terms used herein are only for the purpose of describing specific embodiments, and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is intended to include the plural form, and in addition, it should be understood that when the terms “comprise” and / or “include” are used in the specification, it means that there is a feature, step, operation, device, component and / or combination thereof.

[0030] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0031] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0032] Example 1: refer to Figure 1 This embodiment provides a basic configuration of a top-loading coke oven coal charging device based on multi-parameter fusion. The device includes a scanning imaging radar 1, an induced draft fan 2, a coal charging car storage bin 3, an online moisture meter 4, a spring assembly 5, a vibrator 6, an expansion joint 7, a screw conveyor 8, and a control processing module (not shown in the figure, but can be integrated into the coal charging car control system).

[0033] The scanning imaging radar 1 is installed at the top center of the coal loading car storage bin 3, with its scanning lens facing the surface of the coal inside the bin. It is used to scan the three-dimensional shape of the coal in real time and calculate its volume V (unit: m). 3 The online moisture meter 4 uses the near-infrared principle and is embedded in the lower half of the side wall of the coal loading silo 3. Its probe is in direct contact with the coal to detect the moisture content W (unit: %) of the coal in real time. The induced draft fan 2 is fixed outside the silo, and its outlet pipe is precisely aligned with the scanning lens area of ​​the scanning imaging radar 1 to provide continuous or intermittent air purging and prevent coal dust accumulation. The vibrator 6 and spring assembly 5 are installed at the bottom of the coal loading silo 3 to assist the coal in falling and leveling the material surface. The coal loading silo 3 is flexibly connected to the screw conveyor 8 through a metal corrugated expansion joint 7 to compensate for displacement and vibration between the equipment. The screw conveyor 8 is responsible for transporting the coal to the carbonization chamber.

[0034] The control processing module is connected to the signals of all the aforementioned devices. Its dynamic metering method is as follows: First, parameter initialization: The initial bulk density ρ0=0.75t / m³ of the coal is obtained from the previous system (such as the coal silo batching system) 3 (750kg / m³ 3 ) and the initial moisture value W0=10%.

[0035] Next, the system is started cooperatively: The vibrator 6 is controlled to operate at a frequency of 20Hz and an amplitude of 2mm for 10s to level the coal interface; at the same time, the induced draft fan 2 (operating in intermittent mode), the moisture on-line measuring instrument 4, the scanning imaging radar 1 (the scanning frequency is set to 1 time / min) and the screw conveyor 8 are started.

[0036] Then, the real-time coal charging amount calculation and dynamic monitoring cycle is entered: the control processing module calculates the real-time coal charging amount according to the formula M=ρ×V. During the coal charging process, the moisture on-line measuring instrument 4 monitors that the current moisture value W1 rises to 12.5%, and the absolute difference between W1 and W0 is |12.5%-10%|=2.5%>2%. The control processing module immediately triggers the bulk density re-detection instruction, and the operator or the automatic system re-samples and measures the current bulk density ρ1=0.78t / m³. The control processing module immediately updates ρ in the calculation formula with ρ1, and continues to execute the coal charging and monitoring process until the target coal charging amount is reached. This embodiment realizes dynamic correction of the measurement error caused by moisture fluctuation, and ensures the accuracy of measurement.

[0037] Example 2: This embodiment further describes the precise control strategy for the four coal charging holes on the basis of example 1.

[0038] The device contains four sets of completely parallel coal charging units, each set of unit including a coal charging car storage bin 3 and a screw conveyor 8, respectively corresponding to the four coal charging holes of the coke oven coking chamber.

[0039] The control processing module has independent four-channel control function. During the coal charging operation, the module simultaneously obtains the volume data V1, V2, V3, V4 measured by the four scanning imaging radars 1, and calculates the real-time coal charging amounts M1, M2, M3, M4 of the four coal bins based on the unified bulk density ρ.

[0040] Due to the conical column structure of the coking chamber and the asymmetric distribution of the coal charging holes, the preset target coal charging amounts of the four coal charging holes are not the same, for example: M1target=5200kg, M2target=5000kg, M3target=4800kg, M4target=5000kg.

[0041] In the process of coal charging, the control processing module compares the difference between the actual coal charging amount of each hole and the target value in real time. When it is found that the coal charging progress of No. 1 hole is slow, the rotation speed of the corresponding screw conveyor 8 can be independently increased, while the rotation speeds of other holes remain unchanged. Through this independent closed-loop control, the actual coal charging amount of the four coal charging holes ultimately approaches the respective preset target value with extremely high precision (such as a deviation of within ±50 kg), thereby forming a uniform and ideal coal distribution in the carbonization chamber and ensuring uniform coke quality from the source.

[0042] Embodiment 3: This embodiment focuses on the adaptive ability and energy-saving strategy of the system under extreme working conditions based on embodiments 1 and 2.

[0043] In step S2, the control processing module sets the starting rotation speed of the screw conveyor 8 according to the initial volume V0 of the coal bunker measured by the scanning imaging radar 1 for the first time. When V0>15m 3 , it is determined to be a heavy load start, and the screw conveyor 8 starts at a higher rotation speed of 35 rpm to quickly establish the conveying flow; when V0≤15m 3 , it starts at a regular rotation speed of 25 rpm to achieve energy saving and smooth start.

[0044] In step S2, the induced draft fan 2 operates in a preset energy-saving intermittent mode: it operates continuously for 2 minutes and then pauses for 30 seconds. This mode can save about 20% energy compared to the continuous operation mode while ensuring the cleanliness of the lens of the scanning imaging radar 1.

[0045] In the dynamic monitoring of step S4, it is assumed that the new bulk density ρ1 has been updated after the system triggers the bulk density re-detection for the first time. However, within the next monitoring period (1 min), the moisture online measuring instrument 4 again detects that the moisture value fluctuates from 12.5% to 14.8%, i.e., it again exceeds the threshold of 2%. At this time, the control processing module determines that the coal property is extremely unstable and automatically starts the high-frequency monitoring mode: the scanning frequency of the scanning imaging radar 1 is increased from 1 time / min to 1 time / 30s, and the sampling frequency of the moisture online measuring instrument 4 is also increased accordingly. This greatly enhances the response speed and measurement accuracy of the system under harsh working conditions. When the coal property stabilizes, the system can automatically return to the regular monitoring mode.

[0046] The above is only a preferred specific embodiment of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can make equivalent substitutions or changes within the technical scope disclosed by the present application and according to the technical solution and inventive concept of the present application, which should be covered within the protection scope of the present application.

Claims

1. A top-charging coke oven charging device based on multi-parameter fusion, characterized in that, The device comprises: a coal bunker volume measurement module for real-time scanning of the three-dimensional shape of the coal in the coal bunker and calculating the volume; a coal moisture detection module arranged on the wall of the coal loading car storage bunker (3) for real-time detection of the moisture of the coal; a control processing module connected in signal with the coal bunker volume measurement module and the coal moisture detection module, configured to: receive coal bulk density data, coal volume data measured by the coal bunker volume measurement module, and coal moisture data measured by the coal moisture detection module; calculate real-time coal loading amount based on the bulk density data and coal volume data; trigger bulk density re-detection instruction when the change of the coal moisture data exceeds a preset threshold.

2. A top-charging coke oven charging device based on multi-parameter fusion according to claim 1, characterized in that, The coal bunker volume measurement module is a scanning imaging radar (1), and the coal moisture detection module is a moisture online measurement instrument (4).

3. A top-charging coke oven charging device based on multi-parameter fusion according to claim 2, characterized in that, The device further comprises an air induction fan (2), and the outlet pipeline of the air induction fan (2) is aligned with the scanning lens area of the scanning imaging radar (1) to provide continuous or intermittent air cleaning.

4. A top-charging coke oven charging device based on multi-parameter fusion according to claim 1, characterized in that, The bottom of the coal loading car storage bunker (3) is provided with a vibrator (6) and a spring set (5) for supporting the coal bunker; the coal loading car storage bunker (3) is soft-connected with the screw conveyor (8) through an expansion joint (7).

5. A top charging coke oven charging device based on multi-parameter fusion according to claim 1 or 4, characterized in that, The device comprises four sets of the combination of the coal loading car storage bunker (3) and the screw conveyor (8) in parallel, which are used for parallel operation corresponding to the four coal loading holes of the coke oven coking chamber.

6. A top-charging coke oven charging dynamic measurement method based on multi-parameter fusion, using the top-charging coke oven charging device based on multi-parameter fusion according to any one of claims 1-5, characterized in that, Specifically comprising the following steps: S1 parameter initialization: detecting the initial moisture value W0 and the initial bulk density ρ0 of the coal; Wherein, the initial moisture value W0 is the percentage of moisture mass in total mass of coal; the initial bulk density p0 is the mass of coal in the natural state of accumulation and its volume, unit kg / m 3 ; S2 system cooperative start: starting the vibrator (6), the air induction fan (2), the moisture online measurement instrument (4), the scanning imaging radar (1) and the screw conveyor (8); wherein the vibrator (6) is controlled to operate at a frequency of 15-30 Hz and an amplitude of 1-3 mm for 5-15 s; the scanning imaging radar (1) is controlled to dynamically monitor the coal bunker volume at a scanning frequency of not less than 1 time / min; S3 real-time coal loading amount calculation: The real-time coal loading amount M is calculated according to the formula M = p x V by measuring the coal volume V by the scanning imaging radar (1) and the current effective bulk density p; wherein the unit of M is kg, the unit of p is kg / m 3 , and the unit of V is m 3 . S4 dynamic monitoring and correction: continuously monitoring the moisture of the coal by the moisture online measurement instrument (4), and when the absolute difference |W1-W0| between the current moisture value W1 and the initial moisture value W0 is greater than or equal to 2%, it is determined that the moisture fluctuation exceeds the standard, then the bulk density of the coal is re-detected, and the bulk density value is updated in step S3, and then steps S2 to S4 are repeated.

7. A top-charging coke oven charging dynamic metering method based on multi-parameter fusion according to claim 6, characterized in that, In step S2, the starting speed of the screw conveyor (8) is associated with the initial volume V0 of the coal bunker measured by the scanning imaging radar (1) for the first time, and when V0 is greater than 15 m³, the screw conveyor (8) is started at a speed of not less than 30 rpm.

8. A top-charging coke oven charging dynamic metering method based on multi-parameter fusion according to claim 6, characterized in that, In step S2, the air induction fan (2) operates in an intermittent mode during the coal loading operation, and after continuously operating for 2 min, it is intermittently operated for 30 s.

9. A top-charging coke oven charging dynamic metering method based on multi-parameter fusion according to claim 6, characterized in that, In step S4, if the moisture fluctuation continues to exist and reaches the threshold of 2% again in the first monitoring period, the system automatically enters a high-frequency monitoring mode, the scanning frequency of the scanning imaging radar (1) is increased to 1 time / 30 s, and the sampling frequency of the moisture online measurement instrument is also increased synchronously.

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