Control method for blast furnace atmospheric humidity automatic calculation and multi-furnace data linkage sharing
By installing temperature and humidity meters and regression calculation modules in the blast furnace, and combining them with industrial Ethernet to achieve automated calculation of atmospheric humidity and data sharing among multiple furnaces, the problems of low efficiency and poor accuracy in acquiring atmospheric humidity data in blast furnace production have been solved, thereby improving the real-time response and production efficiency of the blast furnace control system.
Patent Information
- Application Number
- CN202511602918.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-04
- Publication Date
- 2026-02-27
AI Technical Summary
In existing technologies, the acquisition of atmospheric humidity data in blast furnace production is inefficient and inaccurate, and automated calculation and data sharing cannot be achieved, which affects the blast furnace control effect and production efficiency.
Using a temperature and humidity meter, a regression calculation module, and a data transmission module, atmospheric humidity is automatically calculated through a regression equation, and data sharing among multiple furnaces is achieved through industrial Ethernet, replacing manual table lookup and interpolation operations.
It improved the accuracy and efficiency of atmospheric humidity data acquisition, enhanced the real-time response capability of the blast furnace control system, reduced production costs and energy consumption, and ensured the stability and efficiency of blast furnace production.
Smart Images
Figure SMS_1
Abstract
Description
Technical Field
[0001] This invention belongs to the field of blast furnace control technology in the metallurgical industry, and particularly relates to a control method for automated calculation of atmospheric humidity in blast furnaces and data linkage and sharing among multiple furnaces. Background Technology
[0002] In the blast furnace production process of the metallurgical industry, atmospheric humidity is one of the key factors affecting the operating efficiency and product quality of the blast furnace. Accurately grasping atmospheric humidity data and applying it reasonably to blast furnace control is crucial for optimizing the combustion process, reducing energy consumption, and improving output and quality.
[0003] Currently, the traditional method for obtaining atmospheric humidity data mostly involves manually consulting a table corresponding to saturated humidity and atmospheric temperature, calculating the saturated humidity through interpolation, multiplying it by the relative humidity, and then manually inputting it into the blast furnace control system. This method has many drawbacks: firstly, it is inefficient, the interpolation calculation and manual input process is cumbersome, and it cannot respond promptly to the real-time demand for atmospheric humidity data during blast furnace production; secondly, manual interpolation is prone to errors, and manual input carries the risk of operational mistakes, resulting in poor accuracy of atmospheric humidity data, affecting the combustion control effect of the blast furnace, and reducing production efficiency and product quality.
[0004] Currently, centralized control management is widely implemented in the ironmaking industry, and the secondary systems of blast furnaces have been interconnected, creating the necessary hardware and network conditions for cross-furnace sharing and centralized processing of atmospheric humidity data. Although some existing technologies utilize sensors to detect environmental parameters, atmospheric humidity in blast furnace production still cannot be accurately calculated and effectively applied, and the processes from data acquisition and automated calculation to data sharing and automatic updates cannot be completed. Summary of the Invention
[0005] The purpose of this invention is to provide a control method for automated calculation of atmospheric humidity in blast furnaces and data linkage and sharing among multiple furnaces, which solves the problem that atmospheric humidity in existing blast furnace production cannot be accurately calculated and effectively applied, and cannot complete the process from data acquisition and automated calculation to data sharing and automatic updating.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: The control method for automated calculation of atmospheric humidity in blast furnaces and data linkage and sharing among multiple furnaces includes the following specific steps: S1: Hardware Installation S1.1. Temperature and humidity meter Temperature and humidity meters are installed in the blast furnace production area near the blast furnace blower, in an outdoor location that is not easily affected by the external environment. The temperature and humidity meters collect atmospheric temperature and relative humidity signals, preventing rain from interfering with the humidity meter and avoiding interference from high-temperature objects such as fish tankers, to ensure accurate detection of atmospheric temperature and relative humidity. The temperature and humidity meters have a stable data output interface to transmit the detected signals to the control system. S1.2. Signal Access Using reliable transmission media such as shielded cables, the signals from the temperature and humidity meter are connected to the analog input module of a blast furnace primary PLC control system. At the same time, signal converters and other equipment are provided to ensure the stability and accuracy of signal transmission. S2: Constructing a control system S2.1. Define the data foundation and calculation methods (1) Data source A regression analysis model was established based on a table of saturated humidity and atmospheric temperature. (2) Constructing the regression equation Regression analysis of the above data yielded the regression equation for saturated humidity and atmospheric temperature as y = 0.0027x³ + 0.1066x² + 2.9899x + 48.935, where x is atmospheric temperature and y is saturated humidity. The goodness of fit of this regression equation is R² = 0.9996, indicating that the equation fits the data very well and accurately describes the relationship between saturated humidity and atmospheric temperature, completely replacing traditional lookup tables. (3) Calculation of atmospheric humidity The method for calculating atmospheric humidity is to multiply the saturated humidity by the relative humidity, that is: Atmospheric humidity = saturated humidity × relative humidity; S2.2. Constructing the Control System Architecture The control system architecture includes a regression calculation module, an atmospheric humidity calculation module, and a data transmission module. (1) Regression Calculation Module The regression calculation module is based on the above regression equation. Based on the high reliability of PLC, the temperature and humidity meter synchronously transmits the temperature signal to the regression calculation module. The temperature signal is read through the analog input module to realize the programmed calculation of the regression equation y=0.0027x³+0.1066x²+2.9899x+48.935, obtain the calculation result of saturated humidity and store it in the data register of the blast furnace PLC. (2) Atmospheric humidity calculation module The atmospheric humidity calculation module reads saturated humidity data from the PLC data register and reads the relative humidity signal transmitted by the temperature and humidity meter. It performs real-time calculations according to the atmospheric humidity calculation formula and stores the results in the signal point of the first-level PLC control system. (3) Data transmission module The data transmission module establishes a communication connection between the communication module of the blast furnace primary PLC and the secondary system server through industrial Ethernet, serial communication and other methods. By writing an S7 communication program, data is uploaded, and saturated humidity and atmospheric humidity data are transmitted from the blast furnace primary PLC control system to the secondary system in real time, ensuring the real-time performance, reliability and security of data transmission. S3: Data Sharing and Control S3.1. Level 2 System Reception and Processing The secondary system receives saturated humidity and atmospheric humidity data from the primary PLC control system of the blast furnace, stores them in the database, and performs data processing and analysis, such as calculating the average value and trend of the data. S3.2. Data Distribution By utilizing the interconnected secondary system among multiple blast furnaces, the processed blast furnace data is sent to the primary PLC control system of other blast furnaces according to their control requirements, thereby realizing data sharing among multiple blast furnaces. The sent data includes current atmospheric temperature, saturation humidity, and atmospheric humidity.
[0007] Preferably, in step S1.1, the temperature and humidity meter uses an industrial-grade high-precision temperature and humidity sensor with a control accuracy of ±0.1℃ for temperature and ±2% for relative humidity.
[0008] Preferably, the control system architecture in step S2.2 further includes (4) the control program of the primary PLC control system, the specific contents of which are as follows: A matching control program is set up in the primary PLC control system of each blast furnace, and a "model calculation value" selection button is set up. When the operator selects this option, the system automatically calls up the atmospheric humidity data issued to update the control parameters, completely replacing the manual operation of looking up tables, interpolating calculations and inputting data.
[0009] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: (1) The traditional lookup table interpolation calculation is replaced by the regression equation with goodness of fit (R²=0.9996), eliminating manual interpolation error; at the same time, PLC programming is used to realize automated calculation and data transmission, avoiding manual input errors, reducing the error rate of atmospheric humidity data, and significantly improving data accuracy. (2) The automatic collection, calculation, transmission and updating of atmospheric humidity data is realized through temperature and humidity meter, regression calculation module, atmospheric humidity calculation module and data transmission module, which completely eliminates the manual steps of looking up tables, interpolation and input. The data update response time is shortened from minutes to seconds, which greatly improves the data acquisition efficiency. The blast furnace control system can adjust the blast furnace air supply parameters in a timely manner based on real-time data. The blast furnace parameter control is accurate and timely, which improves production efficiency. (3) The generated accurate atmospheric humidity data can be used as basic parameters to directly provide data support for key control links such as furnace humidity calibration, theoretical combustion temperature calculation, furnace dry air flow correction, fuel ratio optimization and furnace temperature dynamic control, thereby improving the overall control accuracy of the blast furnace; at the same time, it is conducive to stabilizing the furnace condition, reducing energy waste and lowering production costs. (4) Stable and accurate atmospheric humidity data ensures the accuracy of blast furnace heat control, reduces problems such as abnormal furnace temperature caused by data deviation, and is conducive to accurate control of furnace temperature and achieving stable silicon and reduced silicon content. (5) Based on PLC industrial-grade programming and control, combined with the data transmission architecture of interconnected secondary systems, the system has strong anti-interference ability and data transmission success rate of over 99.9%; with comprehensive maintenance and protection measures, the system failure caused by data problems is greatly reduced, ensuring the continuity of blast furnace production. Detailed Implementation
[0010] The technical solution of the present invention will be described in detail below with reference to the embodiments.
[0011] For blast furnaces #3, #5, and #6, whose secondary systems have been interconnected, to address the issue of inaccurate calculation and effective application of atmospheric humidity during production at these three blast furnaces, and the inability to complete data acquisition, automated calculation, data sharing, and automatic updates, this invention employs a control method for automated calculation of blast furnace atmospheric humidity and multi-furnace data linkage and sharing. The specific steps are as follows: S1: Hardware Installation Temperature and humidity meters are installed in the blast furnace production area near the blast furnace blower, in an outdoor location that is not easily affected by the external environment. The temperature and humidity meters use industrial-grade high-precision temperature and humidity sensors with control accuracy of ±0.1℃ for temperature and ±2% for relative humidity. Reliable transmission media such as shielded cables are used to connect the signal output interface of the temperature and humidity meters to the analog input module of the No. 5 blast furnace primary PLC control system. A signal converter is also provided to ensure the stability and accuracy of signal transmission. S2: Constructing a control system S2.1. Define the data foundation and calculation methods (1) Data source A regression analysis model was established based on a table of saturated humidity and atmospheric temperature. Saturation Humidity and Atmospheric Temperature Lookup Table
[0012] (2) Constructing the regression equation Regression analysis of the above data yielded the regression equation for saturated humidity and atmospheric temperature as y = 0.0027x³ + 0.1066x² + 2.9899x + 48.935, where x is atmospheric temperature and y is saturated humidity. The goodness of fit of this regression equation is R² = 0.9996, indicating that the equation fits the data very well and accurately describes the relationship between saturated humidity and atmospheric temperature, completely replacing traditional lookup tables. (3) Calculation of atmospheric humidity The method for calculating atmospheric humidity is to multiply the saturated humidity by the relative humidity, that is: Atmospheric humidity = saturated humidity × relative humidity; S2.2. Constructing the Control System Architecture The control system architecture includes a regression calculation module, an atmospheric humidity calculation module, and a data transmission module. (1) Regression Calculation Module The regression calculation module is based on the Siemens PLC environment. Taking the above regression equation as the core, it reads the temperature signal through the analog input module, and after scaling transformation, it is substituted into the regression equation y=0.0027x³+0.1066x²+2.9899x+48.935 to calculate the saturated humidity. The calculation result is stored in the PLC data register. (2) Atmospheric humidity calculation module The atmospheric humidity calculation module reads saturated humidity data from the PLC data register and reads the relative humidity signal transmitted by the temperature and humidity meter. It performs real-time calculations according to the atmospheric humidity calculation formula and stores the results in the signal point of the first-level PLC control system. (3) Data transmission module The data transmission module uses the industrial Ethernet protocol to establish a communication connection between the communication module of the No. 5 blast furnace primary PLC control system and the secondary system server. Data upload is achieved by writing an S7 communication program, which transmits saturated humidity and atmospheric humidity data from the No. 5 blast furnace primary PLC control system to the secondary system in real time. (4) Control program of the primary PLC control system A matching control program was set up in the primary PLC control system of blast furnaces No. 3, No. 5, and No. 6. A graphical user interface was designed using WinCC, and a "model calculation value" selection button was set up. When the operator selects this option, the system automatically calls up the atmospheric humidity data and updates the control parameters, completely replacing the manual operation of looking up tables, interpolating calculations, and inputting data. S3: Data Sharing and Control The secondary system receives saturated humidity and atmospheric humidity data transmitted from the primary PLC control system of blast furnace #5 and stores it in the database. The secondary systems of blast furnaces #3, #5, and #6 are interconnected. According to the control requirements of blast furnaces #3 and #6, the secondary system sends the processed data of blast furnace #5 to the primary PLC control system of the corresponding blast furnace via industrial Ethernet. The control programs of the primary PLC control systems of blast furnaces #3 and #6 monitor the data update flag in real time. When new data is received, the parameters are immediately updated to realize the dynamic adjustment of the blast furnace combustion process.
[0013] This method avoids manual input errors and reduces the error rate of atmospheric humidity data, especially in summer when atmospheric temperature and humidity fluctuate greatly, and traditional manual adjustments are not timely, resulting in deviations greater than 2g / m³. 3 This situation is widespread. Taiyuan Iron & Steel Group's blast furnace has an annual output of 9.3 million tons. After adopting this method, the blast furnace fuel cost was reduced by 5.68 yuan / tFe, and the total annual cost savings were 9.3 million * 5.68 * 3% = 1.58 million yuan, which is a significant economic benefit.
Claims
1. A control method for automated calculation of atmospheric humidity in blast furnaces and data linkage and sharing among multiple furnaces, characterized in that, The specific steps are as follows: S1: Hardware Installation S1.
1. Temperature and humidity meter Temperature and humidity meters are installed in the blast furnace production area near the blast furnace blower, in an outdoor location that is not easily affected by the external environment. The temperature and humidity meters collect atmospheric temperature and relative humidity signals to ensure accurate detection of atmospheric temperature and relative humidity. The temperature and humidity meters have a stable data output interface to transmit the detected signals to the control system. S1.
2. Signal Access Using reliable transmission media such as shielded cables, the signals from the temperature and humidity meter are connected to the analog input module of a blast furnace primary PLC control system. At the same time, a signal converter is provided to ensure the stability and accuracy of signal transmission. S2: Constructing a control system S2.
1. Define the data foundation and calculation methods (1) Data source A regression analysis model was established based on a table of saturated humidity and atmospheric temperature. (2) Constructing the regression equation Regression analysis of the above data yielded the regression equation for saturated humidity and atmospheric temperature as y = 0.0027x³ + 0.1066x² + 2.9899x + 48.935, where x is atmospheric temperature and y is saturated humidity. The goodness of fit of this regression equation is R² = 0.9996, indicating that the equation fits the data very well and accurately describes the relationship between saturated humidity and atmospheric temperature, completely replacing traditional lookup tables. (3) Calculation of atmospheric humidity The method for calculating atmospheric humidity is to multiply the saturated humidity by the relative humidity, that is: Atmospheric humidity = saturated humidity × relative humidity; S2.
2. Constructing the Control System Architecture The control system architecture includes a regression calculation module, an atmospheric humidity calculation module, and a data transmission module. (1) Regression Calculation Module The regression calculation module is based on the above regression equation. The temperature and humidity meter transmits the temperature signal synchronously to the regression calculation module. The temperature signal is read through the analog input module to realize the programmed calculation of the regression equation y=0.0027x³+0.1066x²+2.9899x+48.935, obtain the calculation result of saturated humidity and store it in the data register of the blast furnace PLC. (2) Atmospheric humidity calculation module The atmospheric humidity calculation module reads saturated humidity data from the PLC data register and reads the relative humidity signal transmitted by the temperature and humidity meter. It performs real-time calculations according to the atmospheric humidity calculation formula and stores the results in the signal point of the first-level PLC control system. (3) Data transmission module The data transmission module establishes a communication connection between the communication module of the blast furnace primary PLC and the secondary system server via industrial Ethernet or serial communication. Data is uploaded by writing an S7 communication program, and the saturated humidity and atmospheric humidity data are transmitted from the blast furnace primary PLC control system to the secondary system in real time. S3: Data Sharing and Control S3.
1. Level 2 System Reception and Processing The secondary system receives saturated humidity and atmospheric humidity data from the primary PLC control system of the blast furnace, stores them in the database, and enables data processing and analysis. S3.
2. Data Distribution By utilizing the interconnected secondary system among multiple blast furnaces, the processed blast furnace data is sent to the primary PLC control system of other blast furnaces according to their control requirements, thereby realizing data sharing among multiple blast furnaces. The sent data includes the current atmospheric temperature, saturation humidity, and atmospheric humidity.
2. The control method for automated calculation of blast furnace atmospheric humidity and multi-furnace data linkage and sharing according to claim 1, characterized in that, In step S1.1, the temperature and humidity meter uses an industrial-grade high-precision temperature and humidity sensor with control accuracy of ±0.1℃ for temperature and ±2% for relative humidity.
3. The control method for automated calculation of blast furnace atmospheric humidity and multi-furnace data linkage and sharing according to claim 1, characterized in that, The control system architecture in step S2.2 also includes (4) the control program of the primary PLC control system, the specific contents of which are as follows: A matching control program is set up in the primary PLC control system of each blast furnace, and a "model calculation value" selection button is set. When the operator selects this option, the system automatically calls up the issued atmospheric humidity data to update the control parameters, completely replacing the manual operation of looking up tables, interpolating calculations and inputting data.