Device and method for measuring liquid level distance of smelting top-blown furnace based on backpressure principle

Abstract

The invention relates to the technical field of non-ferrous metal smelting process detection and control, in particular to a device and method for measuring the liquid level distance of a smelting top-blown furnace based on the backpressure principle, and the device comprises a pressure measuring probe, a constant flow gas supply unit, a backpressure measuring unit, a purging gas circuit and a control and processing module; the pressure measuring exploring tube is arranged above the smelting top-blown furnace, and the bottom end of the pressure measuring exploring tube can extend into a solution in the smelting top-blown furnace in the axial direction of a spray gun of the smelting top-blown furnace; the constant-flow gas supply unit is communicated with the top end of the pressure measuring probe tube through a purging gas path and is used for providing gas with constant flow into the pressure measuring probe tube; the back pressure measuring unit is arranged at the bottom end of the pressure measuring probe and is used for collecting a gas back pressure value in the pressure measuring probe; the control and processing module is used for obtaining position information of the pressure measuring probe, a gas back pressure value and position information of the spray gun so as to calculate the distance between the bottom end of the spray gun and the liquid level of a solution in the smelting top-blown furnace. Therefore, the distance between the spray gun and the molten pool liquid level can be continuously and stably measured.

Description

Technical Field

[0001] This invention relates to the field of detection and control technology for non-ferrous metal smelting processes, specifically to a device and method for measuring the liquid level distance in a top-blown furnace based on the back pressure principle. Background Technology

[0002] In pyrometallurgical processes such as copper smelting, the top-blown furnace, or the blowing process in a top-blown furnace, is a crucial step determining smelting efficiency and product quality. The distance between the bottom of the lance and the molten pool (i.e., the furnace surface) directly affects oxygen utilization, molten pool stirring intensity, reaction kinetics, and the service life of the lance and furnace lining. Improper control of this distance can easily lead to decreased oxygen utilization efficiency, increased molten splashing, lance burnout, and even furnace instability.

[0003] In current production practices, this distance often relies on manual experience or indirect judgment. To achieve automated control, existing technologies have attempted to detect the solution level in the molten pool using laser ranging, ultrasonic level detection, or mechanical probes. However, under the conditions of high temperature, high dust, highly corrosive atmosphere, and frequent molten splashing in top-blown furnaces, these detection methods generally suffer from problems such as sensor damage, severe signal attenuation, poor measurement stability, and high maintenance costs, making them unsuitable for continuous industrial production applications. Therefore, improving the automation and accuracy of the distance between the spray gun and the molten solution surface during the operation of a top-blown furnace has become an urgent problem to be solved. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a liquid level distance measuring device and method for a top-blown smelting furnace based on the back pressure principle, so as to overcome the problems of low automation and low accuracy in measuring the distance between the spray gun and the liquid level of the furnace solution during the current use of top-blown smelting furnaces.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] In the first aspect, this application provides a liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle, including a pressure measuring probe, a constant flow gas supply unit, a back pressure measuring unit, a purging gas path, and a control and processing module. The pressure probe is positioned above the top-blown smelting furnace and is configured such that its bottom end can extend along the axial direction of the lance in the top-blown smelting furnace into the solution within the furnace. The constant flow gas supply unit is connected to the top of the pressure measuring probe through the purge gas path, and is used to provide a constant flow of gas into the pressure measuring probe; The back pressure measuring unit is connected to the bottom end of the pressure measuring probe and is used to collect the gas back pressure value inside the pressure measuring probe. The control and processing module is communicatively connected to the control systems of the pressure probe, the back pressure measuring unit, and the spray gun, respectively, and is used to obtain the position information of the pressure probe, the gas back pressure value, and the spray gun position information, so as to calculate the distance between the bottom of the spray gun and the liquid surface of the solution in the top blown furnace of smelting.

[0007] Furthermore, in some embodiments of this application, the constant flow gas supply unit includes a flow controller.

[0008] Furthermore, in some embodiments of this application, the back pressure measuring unit includes a pressure transmitter.

[0009] Furthermore, in some embodiments of this application, the pressure transmitter is connected to the bottom end of the pressure measuring probe via a pressure tapping pipe, and a cooling device is provided on the pressure tapping pipe.

[0010] Furthermore, in some embodiments of this application, the pressure probe is provided with a cooling device.

[0011] Furthermore, in some embodiments of this application, the control and processing module includes a data processing module, a memory, and an output interface; The data processing module is used to calculate the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace of smelting, based on the position information of the pressure probe, the gas back pressure value and the position information of the spray gun. The output interface is communicatively connected to the spray gun's control system and is used to output the distance calculation results to the spray gun's control system.

[0012] Furthermore, in some embodiments of this application, a flow detection module disposed on the purge gas path is also included; The flow detection module is used to trigger an alarm when it detects that the gas flow rate in the purge gas path deviates from the preset range.

[0013] Secondly, this application provides a method for measuring the liquid level distance in a top-blown smelting furnace based on the back pressure principle, applicable to the aforementioned liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle, comprising: The bottom end of the pressure probe is controlled to extend along the axial direction of the spray gun in the top-blown smelting furnace into the solution in the top-blown smelting furnace. The constant flow gas supply unit provides a constant flow rate of gas into the pressure probe. The back pressure value of the gas inside the pressure probe is acquired by the back pressure measuring unit. Based on the position information of the pressure probe, the gas back pressure value, and the position information of the spray gun, the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace of the smelting is calculated.

[0014] Furthermore, in some embodiments of this application, before controlling the bottom end of the pressure probe to extend axially along the lance of the top-blown smelting furnace into the solution within the furnace, the following steps are further included: The pressure probe is controlled to extend along the axial direction of the spray gun in the top-blown smelting furnace to a position above the solution in the top-blown smelting furnace, and the back pressure correction value corresponding to the gas flow rate is collected.

[0015] Furthermore, in some embodiments of this application, the formula for calculating the distance between the bottom of the spray gun and the liquid surface in the top-blown furnace is as follows:

[0016]

[0017] in, This is the gas back pressure value. Atmospheric pressure The density of the solution in the top-blown furnace during smelting. This is the back pressure correction value. Let be the acceleration due to gravity, h be the distance between the bottom of the pressure probe and the surface of the solution in the top-blown furnace, and H be the distance between the bottom of the spray gun and the surface of the solution in the top-blown furnace. To measure the distance from the bottom of the pressure probe to the furnace opening of the top-blown smelting furnace, This is the distance from the bottom of the spray gun to the furnace opening of the top-blown smelting furnace.

[0018] Compared with the prior art, the present invention has at least the following beneficial effects: Based on the back pressure measurement principle, this invention enables online measurement of the distance between the spray gun and the molten pool surface in harsh smelting environments such as high temperature, strong corrosion, and strong dust by introducing a constant flow of gas into the pressure measuring probe. It is suitable for long-term continuous operation in industrial sites such as top-blown furnaces.

[0019] This invention effectively reduces the impact of pipeline resistance and flow fluctuations on measurement results by introducing a pipeline pressure drop acquisition and compensation mechanism, thereby improving measurement accuracy and system stability.

[0020] The measurement results of this invention can be directly output to the control system of the spray gun or top-blown furnace, realizing automatic control of the distance between the spray gun and the molten pool surface, providing key technical support for the refined and intelligent operation of the smelting process. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art 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.

[0022] Figure 1 This is a schematic diagram of the liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle provided in an embodiment of the present invention; Figure 2 This is a flowchart illustrating the liquid level distance measurement method for a top-blown smelting furnace based on the back pressure principle provided in this embodiment of the invention. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0024] Figure 1 This is a schematic diagram of the liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle provided in an embodiment of the present invention. Please refer to [link / reference]. Figure 1 The liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle provided in this embodiment may include: a pressure measuring probe 1, a constant flow gas supply unit 2, a back pressure measuring unit 3, a purging gas path 4, and a control and processing module 5.

[0025] Specifically, such as Figure 1 As shown, the pressure probe 1 is positioned above the top-blown furnace 6, specifically above the furnace top, and is configured such that its bottom end can extend axially along the spray gun 7 of the top-blown furnace 6 into the solution within the furnace. In practical applications, one end of the pressure probe 1 can be positioned as follows: Figure 1 The top of the pressure probe 1 is equipped with a control actuator. The control actuator can be connected to the control and processing module 5, so that under the control of the control and processing module 5, it extends along the axial direction of the spray gun 7 of the top blown furnace 6 into the solution in the top blown furnace 6.

[0026] The constant flow air supply unit 2 purges the air path ( Figure 1 The black line above the constant flow gas supply unit 2 is shown. It is connected to the top of the pressure probe 1 and is used to supply a constant flow of gas (such as inert gas) into the pressure probe 1.

[0027] The back pressure measuring unit 3 is connected to the bottom end of the pressure measuring probe 1 and is used to collect the gas back pressure value inside the pressure measuring probe 1.

[0028] The control and processing module 5 is connected to the control systems of the pressure probe 1, the back pressure measuring unit 3, and the spray gun, respectively, to obtain the position information of the pressure probe, the gas back pressure value, and the position information of the spray gun (which can be obtained from the corresponding control or operating system) in order to calculate the distance between the bottom of the spray gun 7 and the liquid surface of the solution in the top blown furnace 6.

[0029] Furthermore, in this application, the constant flow gas supply unit includes a flow controller, which is installed on the purge gas path or pressure measuring probe and is connected to the purge gas path or pressure measuring probe to limit the gas flow rate entering the pressure measuring probe.

[0030] Furthermore, in this application, the back pressure measurement unit includes a pressure transmitter. In practical applications, the pressure transmitter can be installed at the bottom of the pressure probe to collect the gas back pressure signal inside the probe. Of course, in some implementations, it can also be installed in the aforementioned purge gas path based on actual needs.

[0031] It should be noted that in this application, the pressure transmitter can be directly installed at the bottom of the pressure measuring probe, or it can be installed on the pressure tapping pipe or pressure tapping branch connected to the pressure measuring probe or the purging gas line, so as to collect data.

[0032] In practical applications, cooling devices can also be installed outside the pressure measuring probe and outside the pressure tapping pipe or pressure tapping branch. Figure 1 The number 8 shown is the cooling device installed outside the pressure probe, which is used to reduce the influence of high temperature environment on pressure measurement. The cooling device can be water-cooled, air-cooled or a combination thereof.

[0033] Furthermore, this application also includes a flow detection module installed on the purge gas path or pressure probe, which is used to trigger an alarm when the gas flow rate in the purge gas path deviates from a preset range.

[0034] Furthermore, in this application, the control and processing module includes a data processing module, a memory, and an output interface; wherein, the data processing module is used to calculate the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace based on the position information of the pressure probe, the gas back pressure value, and the position information of the spray gun; the memory is used to store the measured and acquired information, preset calculation formulas, and processing and control programs, etc.; the output interface is communicatively connected to the control system of the spray gun and is used to output the distance calculation result to the control system of the spray gun.

[0035] Figure 2 This is a flowchart illustrating the liquid level distance measurement method for a top-blown furnace based on the back pressure principle provided in this embodiment of the invention. Figure 2 As shown, in this application, the actual measurement process includes: S101, The bottom end of the control pressure probe extends along the axial direction of the spray gun of the smelting top-blown furnace into the solution in the smelting top-blown furnace.

[0036] S102. A constant flow of gas is supplied to the pressure probe through the constant flow gas supply unit.

[0037] S103. Collect the gas back pressure value in the pressure probe through the back pressure measurement unit.

[0038] S104. Based on the position information of the pressure probe, the gas back pressure value, and the position information of the spray gun, calculate the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace of smelting.

[0039] Furthermore, in order to improve measurement accuracy and system robustness, before S101 above, it also includes: controlling the pressure probe to extend along the axial direction of the spray gun of the smelting top-blown furnace to a position above the solution in the smelting top-blown furnace, and collecting the back pressure correction value corresponding to the gas flow rate.

[0040] In practical applications, the pressure probe can be pre-controlled to be positioned above the molten pool surface to collect the gas back pressure signal of the pressure probe under different gas flow conditions, so as to obtain the corresponding pipeline pressure drop information, i.e., the back pressure correction value, so as to compensate the gas back pressure value in subsequent actual measurement examples.

[0041] For example, before smelting begins, a pressure probe is placed at a known position above the liquid level in the top-blown furnace to collect back pressure signals under different gas flow rates and generate pipeline pressure drop curves.

[0042] Then, when it is necessary to measure the distance between the bottom of the spray gun and the liquid surface in the top-blown furnace during the smelting process, the pressure probe is placed below the liquid surface and a specific constant flow of inert gas is introduced. The gas back pressure signal is collected in real time and transmitted to the control and processing module, such as the data processing module.

[0043] Finally, the data processing module generates a pipeline pressure drop curve based on the pre-acquired back pressure signal to compensate for the pressure drop. The distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace is calculated. At the same time, the spray gun position signal is output to the top-blown furnace or spray gun control system to guide the adjustment of the spray gun.

[0044] Understandably, the real-time measured gas back pressure value The parameters in the following formulas, such as atmospheric pressure, have the following relationship:

[0045] in, This is the real-time measured gas back pressure value. Atmospheric pressure The density of the solution in the top-blown furnace during smelting. This is the back pressure correction value. denoted by gravitational acceleration, and h is the distance between the bottom of the pressure probe and the liquid surface in the top-blown furnace of the smelting plant.

[0046] Therefore, we can obtain:

[0047] The formula for calculating the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace is as follows:

[0048] Where H is the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace of the smelting process. To measure the distance from the bottom of the pressure probe to the furnace opening of the top-blown smelting furnace, This is the distance from the bottom of the spray gun to the furnace opening of the top-blown smelting furnace (which can be obtained directly from the relevant control system).

[0049] It is understood that the data processing module in this application calculates the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace of smelting using the above formula principle.

[0050] It should be noted that the back pressure measurement method involves introducing gas into a probe immersed in liquid and detecting changes in the gas back pressure within the probe to indirectly deduce the liquid level. This method is simple in structure, highly adaptable to various environments, and theoretically suitable for harsh working conditions. However, in top-blown furnace applications, due to factors such as pipeline pressure drop, high-temperature interference, and gas flow fluctuations, the traditional back pressure method struggles to achieve stable and reliable measurements directly, and a systematic engineering solution to these problems is lacking. This application, through constant flow gas supply, back pressure signal acquisition, pipeline pressure drop compensation, and signal processing, achieves continuous, stable, and reliable measurement of the distance between the spray gun and the molten pool surface.

[0051] Based on the same inventive concept, this application also provides a method for measuring the liquid level distance in a top-blown smelting furnace based on the back pressure principle, applied to the aforementioned device for measuring the liquid level distance in a top-blown smelting furnace based on the back pressure principle, comprising: controlling the bottom end of a pressure measuring probe to extend axially along the spray gun of the top-blown smelting furnace into the solution in the top-blown smelting furnace; supplying a constant flow rate of gas to the pressure measuring probe through a constant flow gas supply unit; acquiring the gas back pressure value in the pressure measuring probe through a back pressure measuring unit; and calculating the distance between the bottom end of the spray gun and the liquid level of the solution in the top-blown smelting furnace based on the position information of the pressure measuring probe, the gas back pressure value, and the position information of the spray gun.

[0052] In some embodiments, before the bottom end of the pressure measuring probe extends axially along the nozzle of the top-blown smelting furnace into the solution in the top-blown smelting furnace, the method further includes: controlling the pressure measuring probe to extend axially along the nozzle of the top-blown smelting furnace to a position above the solution in the top-blown smelting furnace, and collecting a back pressure correction value corresponding to the gas flow rate.

[0053] Regarding the methods in the above embodiments, the specific principles of the execution of each step have been described in detail in the embodiments of the method, and will not be elaborated here.

[0054] It is understood that the same or similar parts in the above embodiments can be referred to each other, and the contents not described in detail in some embodiments can be referred to the same or similar contents in other embodiments.

[0055] It should be noted that in the description of this invention, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, in the description of this invention, unless otherwise stated, "a plurality of" means at least two.

[0056] Any process or method description in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more executable instructions for implementing a particular logical function or process, and the scope of the preferred embodiments of the invention includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as will be understood by those skilled in the art to which embodiments of the invention pertain.

[0057] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0058] Those skilled in the art will understand that all or part of the steps of the methods in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

[0059] Furthermore, the functional units in the various embodiments of the present invention can be integrated into a processing module, or each unit can exist physically separately, or two or more units can be integrated into a module. The integrated module can be implemented in hardware or as a software functional module. If the integrated module is implemented as a software functional module and sold or used as an independent product, it can also be stored in a computer-readable storage medium.

[0060] The storage media mentioned above can be read-only memory, disk, or optical disk, etc.

[0061] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0062] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle, characterized in that, It includes a pressure probe, a constant flow gas supply unit, a back pressure measurement unit, a purging gas path, and a control and processing module; The pressure probe is positioned above the top-blown smelting furnace and is configured such that its bottom end can extend along the axial direction of the lance in the top-blown smelting furnace into the solution within the furnace. The constant flow gas supply unit is connected to the top of the pressure measuring probe through the purge gas path, and is used to provide a constant flow of gas into the pressure measuring probe; The back pressure measuring unit is connected to the bottom end of the pressure measuring probe and is used to collect the gas back pressure value inside the pressure measuring probe. The control and processing module is communicatively connected to the control systems of the pressure probe, the back pressure measuring unit, and the spray gun, respectively, and is used to obtain the position information of the pressure probe, the gas back pressure value, and the spray gun position information, so as to calculate the distance between the bottom of the spray gun and the liquid surface of the solution in the top blown furnace of smelting.

2. The liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle according to claim 1, characterized in that, The constant flow gas supply unit includes a flow controller.

3. The liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle according to claim 1, characterized in that, The back pressure measurement unit includes a pressure transmitter.

4. The liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle according to claim 3, characterized in that, The pressure transmitter is connected to the bottom end of the pressure measuring probe via a pressure tapping pipe, and a cooling device is provided on the pressure tapping pipe.

5. The liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle according to claim 1, characterized in that, The pressure probe is equipped with a cooling device.

6. The liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle according to claim 1, characterized in that, The control and processing module includes a data processing module, a memory, and an output interface; The data processing module is used to calculate the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace of smelting, based on the position information of the pressure probe, the gas back pressure value and the position information of the spray gun. The output interface is communicatively connected to the spray gun's control system and is used to output the distance calculation results to the spray gun's control system.

7. The liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle according to claim 1, characterized in that, It also includes a flow detection module installed in the purging gas path; The flow detection module is used to trigger an alarm when it detects that the gas flow rate in the purge gas path deviates from the preset range.

8. A method for measuring the liquid level distance in a top-blown smelting furnace based on the back pressure principle, applied to the liquid level distance measuring device for a top-blown smelting furnace based on the back pressure principle as described in any one of claims 1-7, characterized in that, include: The bottom end of the pressure probe is controlled to extend along the axial direction of the spray gun in the top-blown smelting furnace into the solution in the top-blown smelting furnace. The constant flow gas supply unit provides a constant flow rate of gas into the pressure probe. The back pressure value of the gas inside the pressure probe is acquired by the back pressure measuring unit. Based on the position information of the pressure probe, the gas back pressure value, and the position information of the spray gun, the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace of the smelting is calculated.

9. The method for measuring the liquid level distance in a top-blown smelting furnace based on the back pressure principle according to claim 8, characterized in that, Before the bottom end of the pressure probe extends axially along the nozzle of the top-blown smelting furnace into the solution within the furnace, the following steps are also included: The pressure probe is controlled to extend along the axial direction of the spray gun in the top-blown smelting furnace to a position above the solution in the top-blown smelting furnace, and the back pressure correction value corresponding to the gas flow rate is collected.

10. The method for measuring the liquid level distance in a top-blown smelting furnace based on the back pressure principle according to claim 9, characterized in that, The formula for calculating the distance between the bottom of the spray gun and the liquid surface of the solution in the top-blown furnace is as follows: in, This is the gas back pressure value. Atmospheric pressure The density of the solution in the top-blown furnace during smelting. This is the back pressure correction value. Let be the acceleration due to gravity, h be the distance between the bottom of the pressure probe and the surface of the solution in the top-blown furnace, and H be the distance between the bottom of the spray gun and the surface of the solution in the top-blown furnace. To measure the distance from the bottom of the pressure probe to the furnace opening of the top-blown smelting furnace, This is the distance from the bottom of the spray gun to the furnace opening of the top-blown smelting furnace.

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