A cooling system and intelligent control method for high heat load zone of blast furnace

Abstract

This invention relates to the field of blast furnace cooling systems, specifically to a cooling system and intelligent control method for high heat load zones in blast furnaces. The system includes: cooling walls, refractory bricks, copper cooling elements, a composite packing layer, and an intelligent control unit. Copper cooling elements are spaced apart in the gaps between adjacent cooling wall sections, with the hot surfaces of the copper cooling elements receding inwards relative to the hot surfaces of the cooling walls. The composite packing layer fills the gaps between the copper cooling elements and the cooling walls, comprising a high thermal conductivity packing area and a low thermal conductivity packing area. The high thermal conductivity packing area is located at the mating gap between the copper cooling elements and the cooling walls, while the low thermal conductivity packing area is located on the hot surface side of the copper cooling elements. The intelligent control unit acquires slag skin condition information from the slag skin adhesion zone and dynamically adjusts the cooling parameters flowing through the copper cooling elements based on this information. This invention can improve system heat transfer efficiency and achieve proactive and precise control of slag skin thickness and long-term stability of the blast furnace internal structure.

Description

Technical Field

[0001] This invention relates to the field of blast furnace cooling systems, and more specifically to a cooling system and intelligent control method for high heat load zones in a blast furnace. Background Technology

[0002] As a core piece of equipment in the metallurgical industry, the cooling system of the high-heat-load zone of the blast furnace plays a decisive role in ensuring its long-term stable operation. With the trend of modern blast furnaces becoming larger and more efficient, the high-heat-load zone of the blast furnace faces more severe thermal management challenges, and the design and control of the cooling system has become a key factor affecting the blast furnace's lifespan and production efficiency.

[0003] Currently, high-heat-load zones in blast furnaces commonly employ cooling wall systems. These systems involve fixing cooling walls inside the furnace shell and embedding refractory bricks within the dovetail grooves of the cooling walls to form the initial internal structure of the blast furnace. Cooling water channels are installed inside the cooling walls, circulating cooling water to remove heat from the high-temperature zones within the blast furnace, protecting the furnace lining from overheating damage. During blast furnace operation, a slag layer of a certain thickness forms on the hot surface of the cooling walls. This slag layer is both a component of the blast furnace's internal structure and an important barrier protecting the cooling walls.

[0004] The existing calculation method for blast furnace operation in the high heat load zone of a blast furnace, by collecting parameters such as the temperature of the gas at the top of the furnace, the flow rate of the cooling wall water, the inlet and outlet temperatures of the cooling water, and the temperature of the thermocouples on the cooling wall, combined with field experience data and laboratory simulation calculation results, has achieved real-time monitoring of the remaining lining thickness, slag thickness and hot surface temperature in the copper cooling wall area of ​​the blast furnace.

[0005] However, the existing cooling systems for high heat load zones in blast furnaces still have the following technical problems: First, there are structural weak points at the ends of the cooling walls. The cooling water channels within the cooling walls often have bends in the end areas, resulting in insufficient cooling intensity in these areas and making them vulnerable. Under the influence of strong edge airflow in the blast furnace, these end areas often fail first due to overheating, seriously affecting the safe operation and service life of the blast furnace.

[0006] Secondly, the heat transfer system is inefficient. In existing technologies, the ramming material between the cooling walls is of limited material type and has generally poor thermal conductivity, making it impossible to establish an efficient heat transfer channel. This leads to heat accumulation in localized areas, forming hot spots, which increases the burden on the cooling system and the risk of damage to the blast furnace lining.

[0007] Third, the cooling system lacks adaptability. Traditional cooling systems typically have a fixed cooling water volume or rely on manual adjustment based solely on experience, failing to respond in real time and adapt to dynamic changes in the thermal state within the blast furnace. This results in unstable slag thickness and difficulty in maintaining the blast furnace's internal shape in an ideal state over the long term, limiting the blast furnace's intensified smelting and efficient operation.

[0008] In summary, there is a need for a cooling system for the high-heat-load area of ​​a blast furnace that can address issues such as weak cooling wall ends, low heat transfer efficiency, and poor system adaptability, in order to improve blast furnace cooling efficiency, extend blast furnace service life, and ensure the safe and stable operation of the blast furnace. Summary of the Invention

[0009] To address the technical problem of low heat transfer efficiency in existing blast furnace high heat load zone cooling systems, this invention provides a blast furnace high heat load zone cooling system and its intelligent control method.

[0010] To achieve the above objectives, the present invention provides a cooling system for the high heat load zone of a blast furnace, comprising a cooling wall fixedly installed inside the blast furnace shell, wherein refractory bricks are inlaid in the dovetail grooves of the cooling wall, and the hot surfaces of the refractory bricks form a continuous plane as the initial internal shape of the blast furnace; the system also includes copper cooling elements, a composite packing layer, and an intelligent control unit; the copper cooling elements are spaced apart in the gaps between adjacent sections of the cooling wall, and the hot surfaces of the copper cooling elements are retracted inward relative to the hot surfaces of the cooling wall to form a protected slag adhesion zone; the composite packing layer fills the gaps between the copper cooling elements and the cooling wall. The composite packing layer includes a high thermal conductivity packing region and a low thermal conductivity packing region. The high thermal conductivity packing region is located at the gap between the copper cooling element and the cooling wall to form an efficient heat transfer channel from the end of the cooling wall to the copper cooling element. The low thermal conductivity packing region is located on the hot side of the copper cooling element to provide thermal insulation protection for the copper cooling element during the initial operation of the blast furnace. The intelligent control unit is used to acquire slag skin state information of the slag skin adhesion zone and dynamically adjust the cooling parameters flowing through the copper cooling element according to the slag skin state information to actively control the slag skin thickness of the slag skin adhesion zone and maintain the dynamic stability of the blast furnace interior.

[0011] Preferably, the thermal conductivity λ1 of the high thermal conductivity filler region and the thermal conductivity λ2 of the low thermal conductivity filler region satisfy: λ1 ≥ 2λ2; the high thermal conductivity filler region is made of silicon carbide-based refractory material, and its thermal conductivity λ1 ≥ 4.0 W / (m²) K); the low thermal conductivity filler zone uses corundum-based refractory material with a thermal conductivity λ2 ≤ 2.0 W / (m²). K).

[0012] Furthermore, the inward distance H between the hot surface of the copper cooling element and the hot surface of the cooling wall is 5mm to 20mm; the inner surface of the copper cooling element is an arc surface that matches the curvature of the inner wall of the adjacent cooling wall, so that the copper cooling element and the inner wall of the cooling wall form a continuous and smooth contact surface.

[0013] Preferably, the copper cooling element has an independent cooling water channel inside, and the inlet and outlet of the cooling water channel are both connected to the blast furnace cooling water circulation system. The copper cooling elements are evenly spaced along the circumference and axial direction of the blast furnace, and the spacing between them matches the segment size of the cooling wall.

[0014] Furthermore, the intelligent control unit includes a monitoring module and a control execution module. The monitoring module includes at least one of a temperature monitoring unit, a flow monitoring unit, and a differential pressure monitoring unit, used to collect the body temperature of the cooling wall and the copper cooling element, the temperature difference between the inlet and outlet of the cooling water, and the real-time flow data of the cooling water, and to calculate the real-time slag thickness of the slag adhesion area based on the collected data, as the slag status information.

[0015] Preferably, the control execution module adjusts the cooling parameters at a preset cycle based on the slag status information. The cooling parameters include at least one of cooling water flow rate, water supply pressure, and water supply temperature. The adjustment rule is as follows: when the slag thickness T of the hot surface of the copper cooling element is greater than the slag thickness T0+H of the hot surface of the adjacent cooling wall, the cooling water flow rate through the copper cooling element is reduced; when the slag thickness T of the hot surface of the copper cooling element is less than the slag thickness T0+H of the hot surface of the adjacent cooling wall, the cooling water flow rate through the copper cooling element is increased; where H is the inward distance of the hot surface of the copper cooling element relative to the hot surface of the cooling wall.

[0016] Secondly, the present invention also provides an intelligent control method for cooling the high heat load zone of a blast furnace, based on the aforementioned cooling system for the high heat load zone of a blast furnace, comprising the following steps: S1. Assembly stage: Fix cooling walls inside the blast furnace shell, and install copper cooling elements in the gaps between adjacent cooling wall sections. Control the hot surface of the copper cooling elements to retract inward relative to the hot surface of the cooling wall. Fill the gap between the copper cooling elements and the cooling wall with high thermal conductivity filler to form a high thermal conductivity filler area, and fill the hot surface side of the copper cooling elements with low thermal conductivity filler to form a low thermal conductivity filler area. Inlay refractory bricks in the dovetail grooves of the cooling wall to form a smooth and continuous initial inner shape of the blast furnace with the hot surface of the refractory bricks and the low thermal conductivity filler area. S2. Initial Operation Protection: During the initial operation of the blast furnace, the copper cooling elements are insulated and protected by the low thermal conductivity packing zone to prevent them from being subjected to high temperature impact and material wear during the start-up phase. S3. Stable Operation and Intelligent Control: After the blast furnace enters the stable operation period, the slag skin status information of the slag skin attachment area corresponding to the copper cooling element is obtained in real time. The cooling parameters flowing through the copper cooling element are dynamically adjusted according to the slag skin status information, and the slag skin thickness in the slag skin attachment area is actively controlled so that the slag skin hot surface of the copper cooling element and the slag skin hot surface of the adjacent cooling wall are in the same radial position, maintaining the smooth and stable shape inside the blast furnace. S4. Enhanced heat transfer protection: Throughout the entire operation cycle of the blast furnace, the heat at the end of the cooling wall is quickly transferred to the copper cooling element through the high thermal conductivity packing zone. The heat is then carried away by the cooling water in the copper cooling element, eliminating the overheating weak points at the end of the cooling wall.

[0017] Preferably, in step S3, the specific rules for dynamically adjusting the cooling parameters based on the slag condition information are as follows: the real-time slag thickness T of the hot surface of the copper cooling element and the real-time slag thickness T0 of the adjacent cooling wall hot surface are calculated in real time; when T > T0 + H, the cooling water flow rate through the copper cooling element is linearly reduced; when T < T0 + H, the cooling water flow rate through the copper cooling element is linearly increased; where H is the inward distance of the hot surface of the copper cooling element relative to the hot surface of the cooling wall.

[0018] Furthermore, between steps S2 and S3, a phased adaptive control strategy is executed, specifically including: Real-time monitoring of the erosion and detachment status of the low thermal conductivity filler area; quantitative judgment of the circumferential detachment ratio of the low thermal conductivity filler area by the change of the hot surface temperature gradient between the cooling wall and the copper cooling element and the offset of the temperature difference between the inlet and outlet of the cooling water. When the proportion of the low thermal conductivity filler detachment is less than the first preset threshold, the basic cooling parameters are maintained and the cooling water flow rate of the copper cooling element is adjusted to avoid premature exposure of the copper cooling element. When the proportion of low thermal conductivity filler detachment is greater than the first preset threshold and less than the second preset threshold, the basic cooling water flow rate of the copper cooling element is increased, and the closed-loop pre-adjustment of slag thickness is initiated. A continuous pre-attached slag is gradually formed on the exposed hot surface of the copper cooling element, achieving a smooth transition from heat insulation protection to slag self-protection. When the proportion of slag shedding in the low thermal conductivity filler area exceeds the second preset threshold, the slag shedding on the hot surface of the circumferentially spaced copper cooling elements is dynamically adjusted to form a continuous anchoring support band, thereby limiting and fixing the slag shedding on the hot surface of the adjacent cooling wall in both the circumferential and axial directions, and suppressing large-area slag shedding.

[0019] The beneficial effects of the present invention are as follows: 1. The lifespan of the cooling wall is significantly extended: by setting a high thermal conductivity filler area between the end of the cooling wall and the copper cooling element, an efficient heat transfer channel is constructed, which quickly conducts heat from the end of the cooling wall and enhances cooling by the copper cooling element, thereby reducing the temperature at the end of the cooling wall, improving the cooling wall's ability to withstand heat load, and effectively eliminating the traditional weak link at the end of the cooling wall.

[0020] 2. Expanded Blast Furnace Operating Window: The enhanced cooling system of this invention enables the blast furnace to operate safely under stronger edge airflow conditions. The upper limit of the temperature control of the thermocouple measuring point on the cooling wall can be increased from the traditional 350°C to over 450°C, providing greater operational flexibility for blast furnace operators and facilitating enhanced smelting and efficient operation of the blast furnace.

[0021] 3. Significantly enhanced internal dynamic stability: The intelligent control unit monitors the slag skin condition in real time and dynamically adjusts the cooling parameters, ensuring that the hot surface of the slag skin on the copper cooling element and the hot surface of the slag skin on the adjacent cooling wall are kept at the same radius. This ensures the smooth and continuous internal shape of the blast furnace, reduces the risk of slag skin shedding, and achieves long-term stable maintenance of the internal shape of the blast furnace.

[0022] 4. Improved system safety and economy: This invention effectively prevents serious accidents such as ramming material falling off, furnace shell red-hot, and even burn-through that are common in traditional cooling systems. It reduces unplanned shutdowns, improves blast furnace production efficiency and economic benefits, and the application of intelligent control system also optimizes the efficiency of cooling water use and reduces energy consumption.

[0023] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art based on the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0024] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein: Figure 1 This is a longitudinal sectional view of the cooling system for the high heat load zone of the blast furnace according to the present invention. Figure 2 This is a schematic diagram of the circumferential arrangement of the cooling system for the high heat load zone of the blast furnace according to the present invention; Figure 3 This is a longitudinal cross-sectional schematic diagram of the cooling system for the high heat load zone of the blast furnace according to the present invention.

[0025] Figure label: 1-Blast furnace shell; 2-Cooling wall; 3-Refractory brick; 4-Copper cooling element; 5-High thermal conductivity filling zone; 6-Low thermal conductivity filling zone. Detailed Implementation

[0026] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0027] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0028] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0029] like Figures 1 to 3 As shown, the cooling system for the high heat load zone of the blast furnace includes a cooling wall 2 fixedly installed inside the blast furnace shell 1. Refractory bricks 3 are inlaid in the dovetail grooves of the cooling wall 2, and the hot surfaces of the refractory bricks 3 form a continuous plane as the initial internal shape of the blast furnace. The cooling system also includes copper cooling elements 4, a composite packing layer, and an intelligent control unit.

[0030] Copper cooling elements 4 are spaced apart in the gaps between adjacent cooling wall sections 2, and the hot surface of the copper cooling elements 4 is recessed inward relative to the hot surface of the cooling wall 2 to form a protected slag adhesion zone. Figure 3 As shown, the inward distance H between the hot surface of the copper cooling element 4 and the hot surface of the cooling wall 2 is 10mm, and this inward distance can be selected within the range of 5mm to 20mm. The inner surface of the copper cooling element 4 is an arc surface that matches the curvature of the inner wall of the adjacent cooling wall 2, so that the copper cooling element 4 and the inner wall of the cooling wall 2 form a continuous and smooth contact surface.

[0031] A composite filler layer fills the gap between the copper cooling element 4 and the cooling wall 2. The composite filler layer includes a high thermal conductivity filler region 5 and a low thermal conductivity filler region 6. The high thermal conductivity filler region 5 is located at the mating gap between the copper cooling element 4 and the cooling wall 2, forming an efficient heat transfer channel from the end of the cooling wall 2 to the copper cooling element 4. The low thermal conductivity filler region 6 is located on the hot side of the copper cooling element 4, providing thermal insulation protection for the copper cooling element 4 during the initial operation of the blast furnace. The thermal conductivity λ1 of the high thermal conductivity filler region 5 and the thermal conductivity λ2 of the low thermal conductivity filler region 6 satisfy: λ1 ≥ 2λ2. The high thermal conductivity filler region 5 uses silicon carbide-based refractory material with a thermal conductivity λ1 ≥ 4.0 W / (m²). K); The low thermal conductivity filler zone 6 uses corundum-based refractory material with a thermal conductivity λ2 ≤ 2.0 W / (m²). K).

[0032] like Figure 2 As shown, the copper cooling element 4 has an independent cooling water channel inside, and both the inlet and outlet of the cooling water channel are connected to the blast furnace cooling water circulation system. The copper cooling elements 4 are evenly spaced along the circumference and axial direction of the blast furnace, and their spacing matches the segment size of the cooling wall 2.

[0033] The internal cooling water passage of the copper cooling element 4 can adopt a U-shaped structure to reduce the flow resistance of the cooling water and improve the heat exchange efficiency. A flow regulating valve is installed at the inlet of the cooling water passage, and a temperature sensor is installed at the outlet to monitor the cooling water outlet temperature in real time, providing data support for intelligent control. The blast furnace cooling water circulation system adopts a closed-loop circulation, using softened water to avoid scaling and blockage in the water passage, which would affect the cooling effect. The cooling water inlet temperature is controlled at 30~40℃, and the supply pressure is 0.8~1.2MPa to ensure that the cooling water can flow rapidly within the cooling water passage and efficiently remove heat.

[0034] The intelligent control unit includes a monitoring module and a control execution module. The monitoring module includes a temperature monitoring unit, a flow monitoring unit, and a differential pressure monitoring unit. These units collect data on the body temperature of the cooling wall 2 and the copper cooling element 4, the temperature difference between the cooling water inlet and outlet, and the real-time flow rate of the cooling water. Based on the collected data, the module calculates the real-time slag thickness in the slag adhesion zone, which serves as slag status information. The control execution module adjusts the cooling parameters, including cooling water flow rate, supply pressure, and supply temperature, based on the slag status information at preset intervals. The adjustment rules are as follows: when the slag thickness T on the hot surface of the copper cooling element 4 is greater than the slag thickness T0+H on the hot surface of the adjacent cooling wall 2, the cooling water flow rate through the copper cooling element 4 is reduced; when the slag thickness T on the hot surface of the copper cooling element 4 is less than the slag thickness T0+H on the hot surface of the adjacent cooling wall 2, the cooling water flow rate through the copper cooling element 4 is increased; where H is the inward distance of the hot surface of the copper cooling element 4 relative to the hot surface of the cooling wall 2.

[0035] In practical applications, the cooling wall 2 is made of ductile iron. The copper cooling element 4 and the ductile iron cooling wall 2 are compacted by ramming with high thermal conductivity ramming material as a high thermal conductivity filler zone 5. The copper cooling element 4 and the refractory brick 3 embedded in the ductile iron cooling wall 2 are cast with low thermal conductivity castable as a low thermal conductivity filler zone 6. The hot surfaces of the castable and the refractory brick 3 are flush, thus forming a smooth initial blast furnace inner shape.

[0036] Once the blast furnace is operational, a large amount of heat is transferred to the cooling wall 2. This heat is then carried away by cooling water through a highly efficient heat transfer system established by the cooling wall 2, the high thermal conductivity filler zone 5, and the copper cooling element 4. The ends of the cast iron cooling wall 2 are no longer weak points, and the heat load that the cooling wall 2 can withstand is increased by 25%. Its controlled temperature increases from 350℃ to 450℃, giving the blast furnace a wider operating range. The low thermal conductivity filler zone 6 on the hot surface of the copper cooling element 4 forms a heat insulation layer, protecting the copper cooling element 4.

[0037] After the refractory bricks 3 and the low thermal conductivity filler zone 6 fall off, a certain thickness of slag skin can be formed on the hot surface of the copper cooling element 4 by adjusting the water flow, thereby maintaining the slag skin hot surface flush with the cast iron cooling wall 2 and maintaining the stability of the blast furnace shape. At the same time, since the hot surface of the copper cooling element 4 is located outside the cooling wall 2, it can also ensure that the airflow and material flow in the furnace will not cause wear to the copper cooling element 4, protecting the copper cooling element 4. The copper cooling element 4, cast iron cooling wall 2 and high thermal conductivity filler zone 5 form an efficient heat transfer system, which can maintain the high thermal conductivity filler zone 5 at a lower operating temperature, extend its service life, and prevent the airflow in the furnace from directly contacting the furnace shell 1, thus preventing the furnace shell 1 from turning red.

[0038] Furthermore, such as Figures 1 to 3 As shown, this embodiment provides an intelligent control method for cooling the high heat load zone of a blast furnace. The structure of the cooling system for the high heat load zone of the blast furnace in this embodiment is the same as that in Embodiment 1, including a blast furnace shell 1, a cooling wall 2, refractory bricks 3, copper cooling elements 4, a high thermal conductivity filling zone 5, a low thermal conductivity filling zone 6, and an intelligent control unit.

[0039] The cooling system for the high heat load zone of the blast furnace described in Example 1 includes the following steps: S1. Assembly stage: A cooling wall 2 is fixed inside the blast furnace shell 1. Copper cooling elements 4 are installed in the gap between two adjacent cooling wall sections 2. The hot surface of the copper cooling element 4 is controlled to retract inward relative to the hot surface of the cooling wall 2. High thermal conductivity filler is filled in the gap between the copper cooling element 4 and the cooling wall 2 to form a high thermal conductivity filler area 5. Low thermal conductivity filler is filled in the hot surface side of the copper cooling element 4 to form a low thermal conductivity filler area 6. Refractory bricks 3 are inlaid in the dovetail groove of the cooling wall 2 so that the hot surface of the refractory bricks 3 and the low thermal conductivity filler area 6 form a smooth and continuous initial inner shape of the blast furnace.

[0040] S2. Initial Operation Protection: During the initial operation of the blast furnace, the copper cooling element 4 is protected by the low thermal conductivity packing zone 6 to prevent the copper cooling element 4 from being subjected to high temperature impact and material wear during the start-up stage.

[0041] During the initial operation of the blast furnace, the furnace temperature gradually rises from room temperature, and the materials inside the furnace are in an unstable state. The high-temperature gas flow and incompletely molten materials will cause strong impact and wear on the cooling system components. At this time, the low thermal conductivity packing zone 6 plays a core role in heat insulation and protection, preventing the high temperature inside the furnace from being conducted to the copper cooling element 4, avoiding structural deformation or surface oxidation of the copper cooling element 4 due to a sudden temperature rise. At the same time, it prevents the materials inside the furnace from directly scouring the hot surface of the copper cooling element 4, reducing surface wear. During this stage, the intelligent control unit maintains the basic cooling parameters stable without making significant adjustments, relying mainly on the physical heat insulation performance of the low thermal conductivity packing zone 6 to provide comprehensive protection for the copper cooling element 4, ensuring the stability of the copper cooling element 4 in the initial stage of furnace start-up and preventing damage to the components from affecting the subsequent operation of the entire cooling system.

[0042] S3. Stable Operation and Intelligent Control: After the blast furnace enters the stable operation period, the slag skin status information of the slag skin attachment area corresponding to the copper cooling element 4 is obtained in real time. The cooling parameters flowing through the copper cooling element 4 are dynamically adjusted according to the slag skin status information, and the slag skin thickness of the slag skin attachment area is actively controlled so that the hot surface of the slag skin of the copper cooling element 4 and the hot surface of the slag skin of the adjacent cooling wall 2 are in the same radial position, maintaining the smooth and stable shape inside the blast furnace.

[0043] S4. Enhanced heat transfer protection: Throughout the entire operation cycle of the blast furnace, the heat at the end of the cooling wall 2 is quickly transferred to the copper cooling element 4 through the high thermal conductivity packing zone 5. The heat is then carried out by the cooling water in the copper cooling element 4, eliminating the overheating weak point at the end of the cooling wall 2.

[0044] The intelligent control method for cooling in the high-heat-load zone of the blast furnace in this embodiment provides thermal insulation protection for the copper cooling element 4 in the initial stage of blast furnace operation, preventing it from being subjected to high-temperature impact and wear. During the stable operation period, the cooling parameters of the copper cooling element 4 are dynamically adjusted by the intelligent control unit to achieve precise control of the slag thickness and maintain the smooth and stable shape of the blast furnace interior. At the same time, the high-thermal-conductivity packing zone 5 constructs an efficient heat transfer channel from the end of the cooling wall 2 to the copper cooling element 4, eliminating the overheating weak point at the end of the cooling wall 2. The entire control process achieves a smooth transition from thermal insulation protection to slag self-protection, effectively extending the service life of the blast furnace cooling system and improving the operation of the blast furnace.

[0045] In step S3, the specific rules for dynamically adjusting the cooling parameters based on the slag condition information are as follows: the real-time slag thickness T of the hot surface of the copper cooling element 4 and the real-time slag thickness T0 of the hot surface of the adjacent cooling wall 2 are calculated in real time; when T > T0 + H, the cooling water flow rate through the copper cooling element 4 is linearly reduced; when T < T0 + H, the cooling water flow rate through the copper cooling element 4 is linearly increased; where H is the inward distance of the hot surface of the copper cooling element 4 relative to the hot surface of the cooling wall 2.

[0046] In this embodiment, the real-time slag thickness T of the hot surface of the copper cooling element 4 and the real-time slag thickness T0 of the hot surface of the adjacent cooling wall 2 are both obtained by collecting real-time operating data through the monitoring module of the intelligent control unit. The data is calculated based on the general steady-state heat conduction model of the blast furnace cooling wall. The calculation process is fully automated and requires no manual intervention. The monitoring module collects the measuring point temperature of the cooling wall 2 and the copper cooling element 4 in real time through pre-embedded K-type thermocouples. Simultaneously, it collects the cooling water inlet temperature, outlet temperature, and real-time flow rate of the corresponding cooling water path through sensors at the inlet and outlet. The design thermal conductivity and structural dimension parameters of the cooling wall 2, copper cooling element 4, slag, and refractory material, pre-stored in the intelligent control unit, serve as the basis for the calculation. The process is based on Fourier's one-dimensional steady-state heat conduction law and combined with the heat flow boundary conditions inside the blast furnace. Heat conduction equations for cooling wall 2 and copper cooling element 4 are established respectively. The heat flux density of the hot surface is calculated by back-calculating the temperature and flow data collected in real time. Finally, the real-time slag thickness T0 of the hot surface of cooling wall 2 and the real-time slag thickness T of the hot surface of copper cooling element 4 are calculated. The calculation process is synchronized with the adjustment cycle of the intelligent control unit. In each adjustment cycle, a full parameter acquisition and thickness calculation are completed to ensure the real-time performance and matching of the data. H in the formula is the preset inward distance of the hot surface of copper cooling element 4 relative to the hot surface of cooling wall 2. It is a fixed design value determined in the assembly stage and is pre-stored in the control program of the intelligent control unit. It does not need to be measured in real time and is only used as a reference parameter for adjustment and balance.

[0047] The intelligent control unit's control execution module performs a complete calculation-judgment-adjustment action once every preset fixed adjustment cycle. The adjustment cycle does not exceed 2 hours, and in this embodiment, 1 hour is preferred as one adjustment cycle. The flow rate adjustment control accuracy is not less than ±5%. A linear adjustment method is used throughout to avoid thermal shock cracking and detachment of the slag skin caused by abrupt changes in flow rate. Within each adjustment cycle, after completing the real-time calculation of T and T0, the real-time calculated T value is compared with the target equilibrium value T0+H, and the deviation value ΔT is calculated, ΔT=T-(T0+H). Then, according to the sign and absolute value of ΔT, the corresponding linear adjustment action is executed. When ΔT is positive, that is, the slag skin thickness on the hot surface of the copper cooling element 4 exceeds the equilibrium target thickness, the copper cooling element... When the hot surface of the slag skin on side 4 protrudes beyond the hot surface of the slag skin on the adjacent cooling wall 2, which will disrupt the smoothness of the blast furnace interior, the cooling water flow rate is linearly reduced. Based on the current cooling water flow rate, the cooling water flow rate through the copper cooling element 4 is reduced according to a linear slope that is positively correlated with the absolute value of ΔT. The larger the absolute value of ΔT, the greater the flow rate reduction within a unit adjustment cycle. The entire process maintains a linear reduction, and the flow rate reduction in a single adjustment does not exceed 10% of the rated flow rate to avoid sudden changes in heat flux density caused by a sudden decrease in flow rate. The core function of the flow increase adjustment is to reduce the cooling intensity of the copper cooling element 4 by reducing the cooling water flow rate, thereby increasing the temperature of the hot surface of the copper cooling element 4, causing the excessively thick slag skin to gradually fall off due to the temperature increase, until T falls back to near the target equilibrium value T0+H.

[0048] When ΔT is negative, meaning the slag thickness on the hot surface of the copper cooling element 4 is lower than the equilibrium target thickness, and the hot surface of the slag on the side of the copper cooling element 4 has been recessed into the hot surface of the slag on the adjacent cooling wall 2, which will cause the blast furnace interior to sink and trigger local gas flow turbulence, the action of linearly increasing the cooling water flow rate is executed. Based on the current cooling water flow rate, the cooling water flow rate through the copper cooling element 4 is increased according to a linear slope that is positively correlated with the absolute value of ΔT. The larger the absolute value of ΔT, the higher the flow rate increase within a unit adjustment cycle. The flow rate increases linearly throughout the process, and the flow rate increase in a single adjustment does not exceed 10% of the rated flow rate to avoid the copper cooling element 4 becoming overcooled due to a sudden increase in flow rate. The core function of the flow increase adjustment is to increase the cooling intensity of the copper cooling element 4 by increasing the cooling water flow rate, reduce the temperature of the hot surface of the copper cooling element 4, and allow the molten slag and iron in the furnace to gradually adhere and thicken on the hot surface until T rises back to near the target equilibrium value T0+H.

[0049] During linear adjustment, upper and lower limits for cooling water flow are always set. The upper limit is the rated maximum flow rate of the cooling water circuit of copper cooling element 4 to avoid damage to the water circuit and seal failure due to overpressure. The lower limit is the minimum safe flow rate of the cooling water circuit to avoid local boiling of the cooling water and cooling failure due to excessively low flow rate. This ensures that the adjustment process is always performed within a safe range. When the temperature of copper cooling element 4 exceeds the preset safe threshold, the flow reduction adjustment is paused to prioritize cooling safety. After the temperature drops back to the safe range, closed-loop adjustment is resumed. After each adjustment cycle, the flow rate adjustment action is performed, and the calculation is recalculated in the next adjustment cycle. T and T0 are used to verify the adjustment effect. If the absolute value of ΔT does not decrease as expected, the slope of the linear adjustment is appropriately increased to speed up the adjustment. If the absolute value of ΔT decreases rapidly and approaches over-adjustment, the slope of the linear adjustment is appropriately decreased to slow down the adjustment. This achieves adaptive closed-loop correction, ensuring that the slag thickness steadily approaches the target equilibrium value without significant fluctuations. At the same time, the above adjustment logic is executed synchronously for all copper cooling elements 4 evenly spaced around the blast furnace circumference to ensure that the slag thickness deviation at each position around the circumference is controlled within a reasonable range, avoiding unevenness in the local circumferential inner shape and ensuring the continuous smoothness of the blast furnace's overall inner shape.

[0050] When a sudden change in slag thickness is detected, such as when the change in ΔT within a single adjustment cycle exceeds the preset threshold, indicating an abnormal condition of large-scale slag detachment, the linear adjustment logic is paused. A temporary safety protection mode is first triggered to maintain the current cooling water flow rate. After the furnace condition and temperature field stabilize, linear adjustment is gradually executed with smaller adjustment steps and longer intervals to allow the slag thickness to smoothly recover to the target equilibrium value. This avoids frequent adjustments under abnormal conditions that could exacerbate furnace condition fluctuations and protects the copper cooling element 4 from high-temperature damage.

[0051] In a preferred embodiment, a phased adaptive control strategy is executed between steps S2 and S3, specifically including: The erosion and shedding status of the low thermal conductivity filler area 6 is monitored in real time. The circumferential shedding ratio of the low thermal conductivity filler area 6 is quantitatively determined by the change in the hot surface temperature gradient between the cooling wall 2 and the copper cooling element 4 and the offset of the temperature difference between the inlet and outlet of the cooling water. When the proportion of the low thermal conductivity filler 6 falling off is less than the first preset threshold, the basic cooling parameters are maintained and the cooling water flow rate of the copper cooling element 4 is adjusted to prevent the copper cooling element 4 from being exposed too early. When the proportion of the low thermal conductivity filler 6 falling off is greater than the first preset threshold and less than the second preset threshold, the basic cooling water flow rate of the copper cooling element 4 is increased, and the closed-loop pre-adjustment of the slag thickness is initiated. A continuous pre-attached slag is gradually formed on the exposed hot surface of the copper cooling element 4, so as to achieve a smooth transition from heat insulation protection to slag self-protection. When the proportion of slag shedding in the low thermal conductivity filler zone 6 exceeds the second preset threshold, the slag shedding on the hot surface of the circumferentially spaced copper cooling element 4 is dynamically adjusted to form a continuous anchoring support band, thereby limiting and fixing the slag shedding on the hot surface of the adjacent cooling wall 2 in both the circumferential and axial directions, and suppressing large-area slag shedding.

[0052] The present invention adds a phased adaptive control strategy for the transition phase between the initial protection in step S2 and the intelligent control for stable operation in step S3. This strategy is designed for the transition from furnace baking and start-up to stable smelting in blast furnaces. It solves the problem of connecting physical heat insulation protection and slag skin self-protection during the gradual erosion and shedding of the low thermal conductivity packing zone 6, and avoids the occurrence of cooling protection discontinuity.

[0053] The real-time monitoring of this strategy is achieved through the monitoring module of the intelligent control unit. With a fixed acquisition cycle of no more than 10 minutes, it simultaneously acquires temperature data from multiple pre-embedded thermocouples at the ends of cooling wall 2 and the body of copper cooling element 4, calculating the real-time temperature gradient change of their hot surfaces. Simultaneously, it acquires the real-time temperature difference between the inlet and outlet of the cooling water in the independent cooling water path corresponding to copper cooling element 4, comparing it with the reference temperature difference calibrated at the initial start-up stage to obtain the temperature difference offset. Based on the coupled thermodynamic calculation of the temperature gradient and temperature difference offset, the circumferential shedding ratio of the low thermal conductivity packing zone 6 is quantified, which is combined with the blast furnace drying curve... The melting characteristics of the furnace charge and the erosion law of refractory materials are preset with a first preset threshold of 30% and a second preset threshold of 80%, both of which are pre-stored in the control program of the intelligent control unit. When the circumferential shedding ratio of the low thermal conductivity packing area 6 is less than 30%, the intelligent control unit maintains the basic cooling parameters of the copper cooling element 4 stable, and only performs small fine adjustments within ±10% to the cooling water flow rate. It prioritizes the preservation of the heat insulation protection capability of the remaining low thermal conductivity packing area 6, avoids excessive cooling intensity from accelerating the cracking and shedding of the packing, and prevents the copper cooling element 4 from being exposed to the high temperature gas flow and material scouring environment too early.

[0054] In another preferred embodiment, when the blast furnace experiences extreme conditions such as strong edge airflow or a sudden increase in heat load, the monitoring module quickly detects signals such as a sudden increase in the temperature at the end of the cooling wall 2 and abnormal temperature differences between the inlet and outlet of the cooling water. The control execution module immediately triggers the emergency control mode, instantly increasing the cooling water flow rate of the copper cooling element 4 to its rated maximum value, while adjusting the water supply pressure to 1.2 MPa to enhance heat removal and quickly control the temperature at the end of the cooling wall 2 within the safe threshold of 450°C, preventing safety hazards such as the furnace shell 1 turning red or burning through. During the emergency control period, the intelligent control unit simultaneously outputs edge airflow control suggestions to the blast furnace central control system, coordinating with adjustments to the blast furnace charging angle and air supply speed to achieve coordinated linkage between the cooling system and the blast furnace smelting operation. This ensures cooling safety while avoiding impacts on blast furnace production efficiency due to extreme conditions. Furthermore, the slag deposit area formed on the hot surface of the copper cooling element 4 not only maintains the stability of the blast furnace internal structure but also reduces local eddies in the gas flow, reduces material wear inside the furnace, further extends the service life of the cooling wall 2 and refractory bricks 3, and reduces blast furnace maintenance costs.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A cooling system for a high-heat-load zone of a blast furnace, comprising a cooling wall (2) fixedly disposed on the inner side of the blast furnace shell (1), wherein refractory bricks (3) are inlaid in the dovetail grooves of the cooling wall (2), and the hot surfaces of the refractory bricks (3) form a continuous plane as the initial inner shape of the blast furnace, characterized in that, It also includes copper cooling elements (4), composite filler layer and intelligent control unit; the copper cooling elements (4) are spaced apart in the gap between two adjacent sections of the cooling wall (2), and the hot surface of the copper cooling elements (4) is retracted inward relative to the hot surface of the cooling wall (2) to form a protected slag adhesion area. The composite filler layer fills the gap between the copper cooling element (4) and the cooling wall (2). The composite filler layer includes a high thermal conductivity filler area (5) and a low thermal conductivity filler area (6). The high thermal conductivity filler area (5) is located at the fitting gap between the copper cooling element (4) and the cooling wall (2) to construct an efficient heat transfer channel from the end of the cooling wall (2) to the copper cooling element (4). The low thermal conductivity filler area (6) is located on the hot side of the copper cooling element (4) to form thermal insulation protection for the copper cooling element (4) during the initial operation of the blast furnace. The intelligent control unit is used to obtain the slag skin state information of the slag skin attachment area and dynamically adjust the cooling parameters flowing through the copper cooling element (4) according to the slag skin state information, so as to actively control the slag skin thickness of the slag skin attachment area and maintain the dynamic stability of the blast furnace.

2. The blast furnace high heat load zone cooling system according to claim 1, characterized in that, The thermal conductivity λ1 of the high thermal conductivity packing region (5) and the thermal conductivity λ2 of the low thermal conductivity packing region (6) satisfy the following condition: λ1 ≥ 2λ2; the high thermal conductivity packing region (5) is made of silicon carbide-based refractory material, and its thermal conductivity λ1 ≥ 4.0 W / (m K); The low thermal conductivity filler region (6) is made of corundum-based refractory material with a thermal conductivity λ2≤2.0W / (m K).

3. The blast furnace high heat load zone cooling system according to claim 1, characterized in that, The inward distance H between the hot surface of the copper cooling element (4) and the hot surface of the cooling wall (2) is 5mm to 20mm; the inner surface of the copper cooling element (4) is an arc surface that matches the curvature of the inner wall of the adjacent cooling wall (2), so that the copper cooling element (4) and the inner wall of the cooling wall (2) form a continuous and smooth contact surface.

4. The blast furnace high heat load zone cooling system according to claim 1, characterized in that, The copper cooling element (4) has an independent cooling water channel inside. The inlet and outlet of the cooling water channel are connected to the blast furnace cooling water circulation system. The copper cooling element (4) is evenly spaced along the circumference and axial direction of the blast furnace, and its arrangement spacing matches the segment size of the cooling wall (2).

5. The blast furnace high heat load zone cooling system according to claim 1, characterized in that, The intelligent control unit includes a monitoring module and a control execution module. The monitoring module includes at least one of a temperature monitoring unit, a flow monitoring unit, and a differential pressure monitoring unit. It is used to collect the body temperature of the cooling wall (2) and the copper cooling element (4), the temperature difference between the inlet and outlet of the cooling water, and the real-time flow data of the cooling water. Based on the collected data, it calculates the real-time slag thickness of the slag adhesion area as the slag status information.

6. The blast furnace high heat load zone cooling system according to claim 5, characterized in that, The control execution module adjusts the cooling parameters according to the slag status information at a preset cycle. The cooling parameters include at least one of cooling water flow rate, water supply pressure, and water supply temperature. The adjustment rule is as follows: when the slag thickness T of the hot surface of the copper cooling element (4) is greater than the slag thickness T0+H of the hot surface of the adjacent cooling wall (2), the cooling water flow rate through the copper cooling element (4) is reduced; when the slag thickness T of the hot surface of the copper cooling element (4) is less than the slag thickness T0+H of the hot surface of the adjacent cooling wall (2), the cooling water flow rate through the copper cooling element (4) is increased; where H is the inward distance of the hot surface of the copper cooling element (4) relative to the hot surface of the cooling wall (2).

7. A method for intelligent control of cooling in high heat load zones of a blast furnace, characterized in that, The blast furnace high heat load zone cooling system based on any one of claims 1-6 is implemented by the following steps: S1. Assembly stage: Fix cooling wall (2) inside the blast furnace shell (1), and set copper cooling element (4) in the gap between two adjacent cooling wall sections (2), and control the hot surface of copper cooling element (4) to shrink inward relative to the hot surface of cooling wall (2); fill the gap between copper cooling element (4) and cooling wall (2) with high thermal conductivity filler to form high thermal conductivity filler area (5), fill the hot surface of copper cooling element (4) with low thermal conductivity filler to form low thermal conductivity filler area (6), and inlay refractory brick (3) in the dovetail groove of cooling wall (2) so that refractory brick (3) and the hot surface of low thermal conductivity filler area (6) form a smooth and continuous initial inner shape of blast furnace; S2. Initial operation protection: During the initial operation of the blast furnace, the copper cooling element (4) is protected by the low thermal conductivity packing zone (6) to prevent the copper cooling element (4) from being subjected to high temperature impact and material wear during the start-up stage. S3. Stable operation and intelligent control: After the blast furnace enters the stable operation period, the slag skin status information of the slag skin attachment area corresponding to the copper cooling element (4) is obtained in real time. The cooling parameters flowing through the copper cooling element (4) are dynamically adjusted according to the slag skin status information, and the slag skin thickness of the slag skin attachment area is actively controlled so that the slag skin hot surface of the copper cooling element (4) and the slag skin hot surface of the adjacent cooling wall (2) are in the same radial position, maintaining the smooth and stable shape inside the blast furnace. S4. Strengthen heat transfer protection: During the entire operation cycle of the blast furnace, the heat at the end of the cooling wall (2) is quickly transferred to the copper cooling element (4) through the high thermal conductivity packing area (5), and the heat is carried out by the cooling water in the copper cooling element (4), eliminating the overheating weak point at the end of the cooling wall (2).

8. The intelligent control method for cooling in the high heat load zone of a blast furnace according to claim 7, characterized in that, In step S3, the specific rules for dynamically adjusting the cooling parameters based on the slag condition information are as follows: the real-time slag thickness T of the hot surface of the copper cooling element (4) and the real-time slag thickness T0 of the hot surface of the adjacent cooling wall (2) are calculated in real time; when T > T0 + H, the cooling water flow rate through the copper cooling element (4) is linearly reduced; when T < T0 + H, the cooling water flow rate through the copper cooling element (4) is linearly increased; where H is the inward distance of the hot surface of the copper cooling element (4) relative to the hot surface of the cooling wall (2).

9. The intelligent control method for cooling in the high heat load zone of a blast furnace according to claim 7, characterized in that, Between steps S2 and S3, a phased adaptive control strategy is executed, specifically including: The erosion and shedding status of the low thermal conductivity filler area (6) is monitored in real time. The circumferential shedding ratio of the low thermal conductivity filler area (6) is quantitatively determined by the change of the hot surface temperature gradient between the cooling wall (2) and the copper cooling element (4) and the offset of the temperature difference between the inlet and outlet of the cooling water. When the proportion of the low thermal conductivity filler area (6) falling off is less than the first preset threshold, the basic cooling parameters are maintained and the cooling water flow rate of the copper cooling element (4) is adjusted to avoid premature exposure of the copper cooling element (4). When the proportion of the low thermal conductivity filler area (6) falling off is greater than the first preset threshold and less than the second preset threshold, the basic cooling water flow rate of the copper cooling element (4) is increased, the closed-loop pre-adjustment of the slag thickness is started, and a continuous pre-attached slag is gradually formed on the exposed hot surface of the copper cooling element (4), so as to achieve a smooth transition from heat insulation protection to slag self-protection. When the proportion of the low thermal conductivity filler area (6) falling off is greater than the second preset threshold, the slag skin thickness is dynamically adjusted so that the slag skin on the hot surface of the circumferentially spaced copper cooling element (4) forms a continuous anchoring support band, which limits and fixes the slag skin on the hot surface of the adjacent cooling wall (2) in the circumferential and axial directions, and suppresses the large-area falling off of the slag skin.

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