A burden distribution method for stabilizing a blast furnace condition
By adjusting the blast furnace charging pattern to KK/KK/JJ, a thicker coke layer is formed. Combined with intelligent simulation and control technology, the problem of ore-coke mixing caused by the thin coke layer is solved, achieving efficient and stable blast furnace production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- YANGCHUN NEW STEEL CO LTD
- Filing Date
- 2026-04-08
- Publication Date
- 2026-05-29
Abstract
Description
Technical Field
[0001] This invention relates to the field of blast furnace charging methods, and in particular to a charging method for stabilizing blast furnace conditions. Background Technology
[0002] Blast furnace ironmaking is a core process in modern steel production, and its stability, smooth operation, and high efficiency are crucial to the entire production process. In blast furnace operation, the charging system is the core means of controlling the gas flow distribution, energy utilization, and chemical reactions within the furnace, directly affecting the blast furnace's permeability, reduction efficiency, fuel consumption, and ultimately, the quality and yield of pig iron.
[0003] Currently, blast furnaces generally employ a batch charging method, where coke (J) and ore (K) are charged into the furnace in a specific order and batches. A common and long-standing charging pattern is KK / JJ, where each batch consists of "two carts of ore and two carts of coke" as a cycle unit. This traditional charging method has revealed several inherent defects in long-term practice: First, the coke layer formed under this method is relatively thin. During the descent of the charge, the thin coke layer is easily impacted and penetrated by the falling ore, leading to severe ore-coke mixing. This not only damages the structural framework of the charge column, resulting in poor overall blast furnace permeability, increased pressure differential, and fluctuating blast capacity, but also hinders the uniform ascent and full utilization of gas, ultimately leading to low gas utilization, increased fuel ratio, and challenges to furnace stability.
[0004] To address the problem of uneven material distribution, several attempts have been made in existing technologies. For example, some solutions optimize the charging process by establishing complex process simulation models (such as CN113836746B). While these methods allow for pre-simulation, they are complex, costly to implement, and difficult to provide real-time, flexible guidance during production. Other technologies (such as CN110822909B) focus on controlling the uniformity of material distribution on the sintering machine table, achieving precise control through stable total material volume and bin position. However, their technical approach and application scenarios are focused on the sintering process and cannot directly solve the problems of ore-coke mixing and permeability caused by the material distribution sequence and the material layer structure within the blast furnace. In practice, operators often rely on theoretical research and experience to directly adjust and modify parameters on-site. This "trial and error" adjustment model lacks foresight and systematic approach, making it difficult to cope with increasingly complex production scheduling needs and fundamentally failing to guarantee the long-term, efficient, and stable operation of the blast furnace. Summary of the Invention
[0005] In order to overcome the above-mentioned shortcomings of the prior art, the purpose of this invention is to provide a charging method for stabilizing blast furnace conditions.
[0006] The technical solution adopted by this invention to solve its technical problem is: a method for stabilizing blast furnace conditions by charging, comprising the following steps:
[0007] The charging mode of the blast furnace will be changed from the KK / JJ and KK / JJ batch charging method to the KK / KK / JJ combined charging method;
[0008] In each of the two batches of materials, the order of feeding coke and ore is as follows: first feed two cars of ore consecutively, then feed two cars of coke.
[0009] By adjusting the order of the fabric application, the coke layer thickness was increased to 0.63m.
[0010] As a further improvement of the present invention: the material distribution is dynamically adjusted based on the blast furnace operating parameters, wherein the parameters include at least one of pressure difference, air volume, and gas utilization rate.
[0011] As a further improvement of the present invention: the material level data of the blast furnace silo is smoothed by a moving average algorithm;
[0012] Based on the fuzzy control algorithm, trend control is used when the material level is close to the target value, and parameter adaptive control is used when it is far from the target value.
[0013] As a further improvement of the present invention: a blast furnace charging simulation model is established to simulate the movement trajectory of the material flow during the bellless charging process;
[0014] The chute angle, rotation speed, or number of fabric loops are dynamically adjusted based on the simulation results.
[0015] As a further improvement of the present invention: the simulation model uses the arithmetic progression method to calculate the radius of the centroid landing point of the material flow, and dynamically and synchronously simulates the material flow trajectory based on the rotation speed of the chute.
[0016] It also includes a control system, comprising:
[0017] The memory stores program instructions for the fabric application method as described above;
[0018] The processor is used to execute program instructions and control the blast furnace charging equipment to perform corresponding charging operations.
[0019] The data acquisition module is used to collect blast furnace operating parameters in real time.
[0020] The control module dynamically adjusts the fabric distribution strategy based on parameters.
[0021] It also includes a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the fabrication method as described above.
[0022] Compared with the prior art, the beneficial effects of the present invention are:
[0023] Changing the charging pattern to KK / KK / JJ essentially thickens the coke layer, fundamentally avoiding the ore-coke mixing problem caused by a thin coke layer. This results in a revolutionary improvement in the permeability of the charge column inside the furnace, a significant reduction in blast furnace pressure differential (up to 3-5 kPa), enhanced blast capacity, and a more stable operating line.
[0024] Improved permeability and stable airflow create conditions for intensified blast furnace smelting, allowing for higher blast volumes and oxygen enrichment rates, thereby increasing utilization coefficients and daily output. Simultaneously, the improved gas utilization rate directly reduces fuel consumption, resulting in significant economic benefits.
[0025] A thicker coke layer acts as a better "skeleton," making the gas flow distribution more stable, reducing abnormal furnace conditions such as pipeline and material slippage caused by unstable gas flow, and improving the safety and smooth operation of blast furnace production.
[0026] By changing the fabric feeding sequence and logic, this method achieves "zero-cost" innovation without requiring any hardware modifications or new equipment to the existing feeding system. The principle is clear and the operation is simple. Detailed Implementation
[0027] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.
[0028] It should be noted that the terms "first," "second," etc., used in the specification and claims of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.
[0029] In blast furnace ironmaking, a reasonable charging system is the core element for controlling the gas flow distribution within the furnace, ensuring smooth furnace operation, and achieving efficient and low-consumption smelting. Currently, most blast furnaces in the industry adopt the traditional KK / JJ batch charging mode, which involves a cyclical charging process of "two cars of ore (KK) + two cars of coke (JJ)". Under the traditional KK / JJ mode, the amount of coke charged in a single batch is limited, resulting in a thin coke layer. In the dynamic environment of high temperature and pressure within the blast furnace, the thin coke layer structure lacks sufficient strength and cannot effectively block the impact and penetration of the upper ore layer, easily leading to severe ore-coke mixing. This damages the coke layer, which forms the "skeleton" of the charge column, significantly reducing the permeability of the entire charge column, becoming the primary challenge restricting blast furnace intensification. Due to the deterioration of permeability, the blast furnace pressure differential increases, blast volume fluctuates frequently, and the blast volume receiving capacity decreases. Unstable airflow easily leads to abnormal furnace conditions such as pipe travel and material slippage, putting production operations in a passive state. Meanwhile, deteriorating permeability shortens the residence time of gas in the furnace, reducing gas utilization. To ensure output, increased fuel consumption is necessary, leading to a higher fuel ratio and becoming a bottleneck for energy conservation and consumption reduction in blast furnaces. As production scheduling becomes increasingly complex, the stability requirements for blast furnaces are becoming more stringent. Existing technological solutions either require significant investment in hardware and software or fail to fundamentally solve the problem, making it difficult for blast furnaces to simultaneously achieve efficient, stable, and low-consumption production goals without increasing additional costs.
[0030] To address the aforementioned problems, this application provides a method for stabilizing blast furnace conditions through a charging process, comprising the following steps:
[0031] The charging mode of the blast furnace will be changed from the KK / JJ and KK / JJ batch charging method to the KK / KK / JJ combined charging method;
[0032] In each of the two batches of materials, the order of feeding coke and ore is as follows: first feed two cars of ore consecutively, then feed two cars of coke.
[0033] By adjusting the order of the fabric application, the coke layer thickness was increased to 0.63m.
[0034] At the operating terminal, the material distribution pattern was changed from the original "KK / JJ" cycle to a "KK / KK / JJ" cycle. That is, a complete material distribution unit consists of four cars of ore and two cars of coke, with the specific execution sequence as follows: first car of ore (K) → second car of ore (K) → third car of ore (K) → fourth car of ore (K) → first car of coke (J) → second car of coke (J). This increases the theoretical thickness of the coke layer from approximately 0.38m to approximately 0.63m, creating a thicker "coke window" to significantly improve the overall permeability of the material column.
[0035] As an embodiment of the present invention, before each execution of a cloth-laying command or when adjusting operating parameters, a bellless cloth-laying model is started for dynamic simulation, as follows:
[0036] Trajectory calculation: Based on the current chute angle, rotation speed and material line height, the model uses the arithmetic progression method to calculate the radius of the centroid landing point of the material flow at different heights between the end of the chute and the material line, and connects these points to generate the predicted material flow trajectory.
[0037] Process simulation: The system dynamically simulates the descent of the material level in the weighing tank and synchronously simulates the actual distribution of the furnace charge in the furnace according to the rotation speed of the chute.
[0038] Parameter optimization: Operators or the system can pre-adjust the material distribution level, number of revolutions, or rotation speed of the chute based on the material surface shape displayed in the simulation to ensure that the furnace charge forms an ideal airflow channel inside the furnace. For example, if the simulation shows that the central airflow is too strong, the number of revolutions at the edge of the distribution can be increased.
[0039] As one embodiment of the present invention, to ensure continuous and stable feeding in KK / KK / JJ mode, precise control is implemented on the bin position of the blast furnace trough unloading bin. The instantaneous flow signal of the feeding belt scale is smoothed using a moving average algorithm. When the bin position is far from the target value, a larger control parameter is used to quickly adjust the frequency of the roller feeder, causing the bin position to return to its normal position rapidly. When the bin position approaches the target value, trend control is switched to fine-tuning to avoid overshoot and ensure the bin position remains stable within the set range. This effectively solves the problem of feeding rhythm changes that may be caused by changes in the feeding mode.
[0040] Furthermore, after the blast furnace receives the production plan and begins operation:
[0041] The system initializes the status of all process equipment and executes the fabric placement according to the set order of KK / KK / JJ.
[0042] Key parameters such as pressure difference, air volume, and gas utilization rate of the blast furnace are collected in real time.
[0043] Operators can monitor the simulation screen and actual data through the terminal. When an upward trend in differential pressure is detected, the material distribution regime for the next batch can be fine-tuned in the simulation model in real time, and the optimized instructions can be issued for execution.
[0044] Under the same production conditions, if the daily output of the two Goryeo mines increases by 100 tons / day, and the profit per ton of iron is 100 yuan based on 360 days, the profit generated will be 100 * 100 * 360 * 2 = 7.2 million yuan.
[0045] Working principle of the invention:
[0046] By changing the feeding sequence, the physical structure of the material layer inside the furnace is fundamentally reconstructed, forming a thicker and more stable coke layer, thereby optimizing the gas flow channel. Combined with intelligent simulation and control technology, accurate prediction and dynamic optimization of the entire feeding process can be achieved.
[0047] The KK / KK / JJ pattern (ore|ore|ore|ore|coke|coke) is adopted. The core of this change lies in concentrating the previously dispersed four cars of ore into a single layer, followed by two cars of coke. The direct physical effect is that the coke is no longer a thin layer in the furnace, but accumulates to form a thicker coke layer. This thicker coke layer has stronger structural stability and impermeability, clearly separating the upper and lower ore layers and minimizing ore-coke mixing. This creates a durable, continuous, and highly permeable "coke window" channel within the blast furnace. Coal gas (reducing gas) can preferentially and smoothly pass through these low-resistance coke zones, fundamentally improving the permeability index of the entire blast furnace and laying a solid physical foundation for the blast furnace to accept larger air volumes and reduce pressure differentials.
[0048] The main functions of this invention are:
[0049] Changing the charging pattern to KK / KK / JJ essentially thickens the coke bed, fundamentally avoiding the ore-coke mixing problem caused by a thin coke bed. This revolutionizes the permeability of the charge column in the furnace, significantly reducing the blast furnace pressure differential (by 3-5 kPa), enhancing blast volume acceptance, and making the operating line more stable. The improved permeability and stable airflow create conditions for intensified blast furnace smelting, allowing for higher blast volumes and oxygen enrichment rates, thereby increasing the utilization coefficient and daily output. Simultaneously, the improved gas utilization rate directly reduces fuel consumption, resulting in significant economic benefits. The thicker coke bed acts as a better "skeleton," making the gas flow distribution more stable, reducing abnormal furnace conditions such as pipe and charge slippage caused by unstable airflow, and improving the safety and smoothness of blast furnace production. By changing the charging sequence and logic, no hardware modifications or new equipment are required to the existing charging system, achieving "zero-cost" innovation. The method is clear in principle and simple to operate.
[0050] On the other hand, the present invention provides another embodiment: a computer device including a memory, a processor, and a computer program stored on the memory and executable on the processor, wherein the processor, when executing the computer program, implements the above-described method for stabilizing blast furnace conditions. The steps of the methods or algorithms described in conjunction with the embodiments disclosed herein can be embodied directly in hardware, in a software module executed by a processor, or in a combination of both. The software module can reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, removable disk, CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to a processor such that the processor can read and write information from / to the storage medium. In an alternative, the storage medium can be integrated into the processor. The processor and storage medium can reside in an ASIC. The ASIC can reside in a user terminal. In an alternative, the processor and storage medium can reside as discrete components in the user terminal.
[0051] On the other hand, the present invention provides another embodiment: a computer-readable storage medium storing a computer program that, when executed by a processor, implements the aforementioned method for stabilizing blast furnace conditions through a charging process. A computer-readable medium includes both computer storage media and communication media, encompassing any medium that facilitates the transfer of a computer program from one location to another. The storage medium can be any available medium accessible to a computer. By way of example and not limitation, such a computer-readable medium may include RAM, ROM, EEPROM, CD-ROM or other optical disc storage, disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and is accessible to a computer. Any connection is also legitimately referred to as a computer-readable medium.
[0052] The functions described herein can be implemented in hardware, software executed by a processor, firmware, or any combination thereof. If implemented in software executed by a processor, the functions can be stored as one or more instructions or codes on or transmitted via a computer-readable medium. Other examples and embodiments are within the scope and spirit of this invention and the appended claims. For example, due to the nature of software, the functions described above can be implemented using software executed by a processor, hardware, firmware, hardwired, or any combination thereof. Furthermore, the functional units can be integrated into a single processing unit, or each unit can exist physically separately, or two or more units can be integrated into a single unit.
[0053] In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. The device embodiments described above are merely illustrative; for example, the division of units can be a logical functional division, and in actual implementation, there may be other division methods. For instance, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the displayed or discussed mutual coupling, direct coupling, or communication connection may be through some interfaces; the indirect coupling or communication connection between units or modules may be electrical or other forms.
[0054] The units described as separate components may or may not be physically separate. Similarly, the components of the control device may or may not be physical units; they may be located in one place or distributed across multiple units. Some or all of the units can be selected to achieve the purpose of this embodiment, depending on actual needs.
[0055] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.
[0056] In summary, after reading this invention document, those skilled in the art can make various other corresponding modifications to the technical solutions and concepts based on this invention without creative mental effort, and all of these modifications fall within the scope of protection of this invention.
Claims
1. A method for stabilizing blast furnace conditions by charging, characterized in that, Includes the following steps: The charging mode of the blast furnace will be changed from the KK / JJ and KK / JJ batch charging method to the KK / KK / JJ combined charging method; In each of the two batches of materials, the order of feeding coke and ore is as follows: first feed two cars of ore consecutively, then feed two cars of coke. By adjusting the order of the fabric application, the coke layer thickness was increased to 0.63m.
2. The method for stabilizing blast furnace conditions according to claim 1, characterized in that, The material distribution is dynamically adjusted based on the blast furnace operating parameters, including at least one of differential pressure, air volume, and gas utilization rate.
3. The method for stabilizing blast furnace conditions according to claim 1, characterized in that, The moving average algorithm is used to smooth the material level data of the blast furnace silo; Based on the fuzzy control algorithm, trend control is used when the material level is close to the target value, and parameter adaptive control is used when it is far from the target value.
4. The method for stabilizing blast furnace conditions according to claim 1, characterized in that, Establish a blast furnace charging simulation model to simulate the movement trajectory of the material flow during bell-less charging; The chute angle, rotation speed, or number of fabric loops are dynamically adjusted based on the simulation results.
5. The method for stabilizing blast furnace conditions according to claim 1, characterized in that, The simulation model uses the arithmetic progression method to calculate the radius of the centroid landing point of the material flow, and dynamically and synchronously simulates the material flow trajectory based on the rotation speed of the chute.
6. A control system, characterized in that, include: A memory storing program instructions for the fabric-making method as described in any one of claims 1-5; The processor is used to execute program instructions and control the blast furnace charging equipment to perform corresponding charging operations. The data acquisition module is used to collect blast furnace operating parameters in real time. The control module dynamically adjusts the fabric distribution strategy based on parameters.
7. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the program is executed by the processor, it implements the cloth-making method as described in any one of claims 1-5.