A method for rapidly detecting moisture content of raw fuel auxiliary materials

Abstract

This invention presents a rapid method for detecting moisture in raw materials and fuels. Addressing the problems of low efficiency, long cycle time, large human error, and significant data feedback delays associated with existing methods using manual oven drying in centralized laboratory testing, this invention provides a systematic solution for real-time, automated moisture detection at the physical testing end. The core of this method lies in the following: after raw materials are sampled upon arrival at the plant, moisture samples and analytical samples are separated. The moisture sample is directly placed in a multi-station fully automated moisture analyzer, where weighing, drying, and calculation are automatically completed. The test results are automatically uploaded to the enterprise's quality management system in real-time via a data interface for immediate production use. Simultaneously, the analytical sample is sent to the laboratory for testing according to the original process. This invention, through a combination of equipment automation and process reconfiguration, achieves on-site, parallel, automated, and real-time moisture detection, significantly improving detection efficiency and accuracy, and providing timely and reliable data support for stable blast furnace production and cost control.

Description

Technical Field

[0001] This invention relates to the field of quality inspection technology, and in particular to a rapid method for detecting moisture content in raw materials, fuels and auxiliary materials. Background Technology

[0002] Accurate moisture detection of purchased raw materials and auxiliary materials (such as iron ore, coke, and pulverized coal) is a prerequisite for "cost reduction, efficiency improvement, safety, and stability" in blast furnace smelting. The timeliness and accuracy of this detection are key factors affecting the efficiency, cost, and stability of blast furnace smelting. First, it impacts the stability of the blast furnace smelting process. Deviations in moisture detection can lead to discrepancies between the actual and theoretical proportions of raw materials and auxiliary materials, disrupting the thermal and material balance within the blast furnace, resulting in issues such as fluctuating fuel consumption, increased difficulty in furnace temperature control, and deterioration of permeability. Second, it impacts production costs and resource utilization. Accurate moisture detection is fundamental to achieving refined cost control; errors can lead to multiple economic losses, such as inflated procurement costs, increased transportation and storage costs, and resource waste. Third, it impacts equipment operation and maintenance. Abnormal moisture levels can accelerate equipment wear and tear, increase maintenance frequency and downtime risks, such as conveyor system failures, metering equipment errors, and blast furnace lining erosion. Fourth, it impacts safety, environmental protection, and quality control. Inaccurate moisture detection can also cause safety hazards and environmental problems, such as the risk of dust explosions, increased pollutant emissions, and fluctuations in product quality.

[0003] Currently, most steel companies still use the traditional manual oven drying method at the laboratory for moisture detection. This method has the following problems: At the laboratory, after sample preparation, samples need to be left for a period of time before being sent to the laboratory for testing. The entire process—sample retention, delivery, laboratory reception, and distribution to work teams—is time-consuming. This significantly impacts the timeliness of moisture detection results, affecting production and material usage. Furthermore, high temperatures in summer cause rapid moisture loss from the samples, and during the rainy season, samples absorb moisture from the air, affecting the accuracy of moisture detection and impacting production. The manual oven drying method involves heating the sample at a constant temperature to evaporate moisture, and then calculating the moisture content by weighing. However, this method has several problems affecting the accuracy and efficiency of the test results. First, the testing cycle is long and inefficient; for production processes or quality control stages requiring rapid feedback, the manual oven drying method cannot meet real-time requirements. Second, the operation is complex and prone to human error; errors can easily be introduced during manual operation, such as sample weighing, transfer, and cooling. For example, loss or contamination may occur during sample transfer, affecting the final moisture determination result. Furthermore, the operator's experience and skill level have a significant impact on the results, and there may be significant differences between different operators. Thirdly, the lack of automation makes it difficult to achieve batch testing. As the company's production continues to increase, the demand for purchased raw materials and fuels is also increasing. The manual oven drying method does not support continuous and automated testing, making it difficult to meet the company's requirements for timely and accurate moisture sample testing. Summary of the Invention

[0004] In order to overcome the above-mentioned shortcomings of the prior art, the purpose of this invention is to provide a rapid method for detecting moisture in raw materials, fuels and auxiliary materials.

[0005] The technical solution adopted by this invention to solve its technical problem is: a rapid detection method for moisture content in raw materials and fuels, comprising the following steps:

[0006] S1: Take samples of incoming materials and prepare moisture and analytical samples;

[0007] S2: Send the moisture sample into a multi-station fully automatic moisture analyzer for testing, and complete the weighing, drying, calculation and result output;

[0008] S3: Analytical samples are sent to the laboratory for elemental analysis.

[0009] S4: Moisture test results are automatically uploaded to the quality management system via a data interface.

[0010] As a further improvement of the present invention: the multi-station fully automatic moisture analyzer in step S2 has at least 14 detection stations.

[0011] As a further improvement of the present invention: the moisture sample is detected at the physical end in a multi-station fully automatic moisture analyzer.

[0012] As a further improvement of the present invention, it also includes the use of a fully automated moisture analyzer for sample preparation.

[0013] As a further improvement of the present invention: the test results are integrated with the enterprise's quality management system and LIMS system data.

[0014] As a further improvement of the present invention: the analytical sample enters the chemical section for detection.

[0015] As a further improvement of the present invention: the analytical sample enters the chemical section for detection.

[0016] As a further improvement of the present invention, it also includes a data interface for integration with the quality management system and LIMS system.

[0017] Compared with existing technologies, the beneficial effects of this invention are: it solves the problems of low efficiency, lack of timeliness, and large human error in the existing manual oven method for moisture detection at the laboratory end; it improves the efficiency of intelligent testing, reduces human intervention factors, and improves testing efficiency; it reduces sample retention time, avoids the situation where weather affects the accuracy of moisture results, and protects the legitimate interests of both suppliers and consumers; and it provides timely and accurate data support for production materials. Attached Figure Description

[0018] To more clearly illustrate the technical solution, the accompanying drawings used in the embodiments 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.

[0019] Figure 1 This is a schematic diagram of the process of the present invention. Detailed Implementation

[0020] 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 and corresponding drawings. 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.

[0021] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings 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 a 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.

[0022] Moisture content testing is a crucial step in the quality control of purchased raw materials and auxiliary materials (such as iron ore, coke, and pulverized coal) for steel enterprises. It directly impacts: blast furnace smelting stability: moisture deviations lead to inaccurate batching, disrupting heat and material balance, causing fuel consumption fluctuations, difficulties in furnace temperature control, and deterioration of permeability; inaccurate moisture testing results in inflated procurement costs, increased transportation and storage costs, and resource waste; abnormal moisture content may accelerate wear and tear on conveying systems and metering equipment, increasing maintenance frequency and downtime risks; uncontrolled moisture content may trigger dust explosion risks, increased pollutant emissions, and product quality fluctuations, among other safety and environmental issues. Currently, most steel companies still use the manual oven drying method at the laboratory level for moisture detection, which has the following problems: samples need to be sent for testing in a centralized manner, going through multiple steps such as retention, delivery, receipt, and distribution, which is time-consuming; it cannot meet the real-time requirements for moisture data in the production process; it relies on manual weighing, transfer, and cooling steps, which are prone to operational errors; the results are significantly affected by the experience and proficiency of the operators, resulting in poor repeatability; the traditional oven drying method does not support continuous and automated testing, cannot adapt to the needs of large-scale sample testing, and is difficult to achieve automatic data uploading and integration, relying on manual entry, which is inefficient and prone to errors; high temperatures in summer cause rapid moisture loss from samples, and samples are prone to absorbing moisture during the rainy season, affecting the accuracy of test results; moisture results need to wait for all element tests to be completed before being reported uniformly, and when production is urgently needed, multi-level authorization and decryption are required, resulting in serious data lag, affecting material ratio and production scheduling.

[0023] To address the aforementioned issues, this invention provides a rapid method for detecting moisture in raw materials and fuels. The method involves two improvements: First, an improved multi-station fully automated moisture analyzer replaces the traditional manual oven drying method for detecting moisture in purchased raw materials and fuels. This analyzer can simultaneously test multiple samples and automatically calculates and uploads the results, reducing human intervention, improving testing efficiency, and meeting the company's requirements for timely and accurate moisture sample testing. Second, the process flow is improved by changing the moisture detection from laboratory-based to physical-based testing. Moisture samples are tested immediately after preparation, eliminating the need to send them to the laboratory. This reduces sample dwell time, avoids the impact of weather on the accuracy of moisture results, and improves the timeliness of testing. Specifically:

[0024] A multi-station fully automatic moisture analyzer is used to replace the traditional manual oven method for testing the moisture content of purchased raw materials and fuels. It can test multiple samples simultaneously and automatically calculate and upload test results, reducing human intervention factors, improving testing efficiency, and meeting the requirements for timely and accurate moisture sample testing.

[0025] Purchase one fully automated moisture analyzer. This multi-station fully automated moisture analyzer has at least 14 testing stations and features automatic weighing, drying, calculation, and result uploading. It can process 14 samples at a time, meeting the requirements for both batch and continuous sample preparation. Test results can be integrated with the company's quality management system and LIMS system for real-time uploading, eliminating the need for manual data entry.

[0026] Eliminating the need for repeated manual weighing and calculation of test results effectively reduces the labor intensity of sample preparation personnel and improves the efficiency of automated operations. Sample preparation personnel only need to place the sample tray into the moisture analyzer station; all other steps are handled automatically by the equipment without human intervention, effectively reducing human intervention factors.

[0027] Process improvement: The moisture detection process has been changed from laboratory-based to physical detection. That is, the moisture is detected immediately after the moisture sample is prepared, without having to send it to the laboratory. This reduces the sample retention time, avoids the impact of weather on the accuracy of moisture results, and improves the timeliness of testing.

[0028] Using a fully automated moisture analyzer for sample preparation, moisture sample testing can be completed at the quality inspection site, eliminating the need to transport the samples to the laboratory for testing, which can effectively improve the timeliness of moisture result testing.

[0029] It avoids the time wasted in the sample delivery process, eliminates the steps of waiting for samples, waiting for people, verifying sample information, and registering sample handover records in the traditional sample delivery process, reduces sample retention time, avoids the impact of weather on the accuracy of moisture results, and effectively improves the timeliness of testing.

[0030] Traditional manual oven drying methods for moisture testing rely on laboratory testing, resulting in a significant delay in moisture results. This requires uploading all elemental results together to the quality control system. In urgent production situations, communication with the laboratory via telephone and multiple levels of authorization are necessary, leading to substantial delays in moisture analysis and impacting material usage. Multi-station moisture analyzers, on the other hand, automatically generate reports that can be viewed in real-time by the production plant, providing accurate data support for material selection.

[0031] The specific process is as follows: After the materials arrive at the factory, the entire batch of materials is sampled according to the inspection standards. Then, the samples are prepared, including moisture samples and analytical samples (elemental analysis). After the samples are prepared, the moisture samples are directly sent to a fully automatic moisture analyzer for moisture content testing. After the results are obtained, they are automatically uploaded to the quality control system and an internal report is generated. The production plant can view the test results in real time. The analytical samples are sent to the sample storage room to await unified sample delivery (after all samples within a time period are completed, they are delivered to the laboratory by the sample delivery personnel, once in the morning and once in the afternoon). After receiving the samples, the laboratory performs relevant elemental tests according to the inspection standards. After all elemental test results are obtained, the data entry personnel enter them into the quality control system. The system automatically judges (qualified / unqualified) according to the time period (2 hours / time). After the judgment, the system automatically generates a settlement statement according to the contract standards, and the finance department settles the accounts based on the settlement statement.

[0032] Working principle of the invention:

[0033] Equipment level: Automated testing replaces manual operation;

[0034] Functional replacement: A multi-station fully automatic moisture analyzer is used to directly replace the manual drying oven. This equipment integrates functional modules such as automatic weighing, programmed heating and drying, real-time weighing monitoring, and automatic moisture content calculation.

[0035] Parallel processing: The equipment has multiple independent workstations (such as 14 workstations), which can simultaneously put in multiple samples to achieve batch and continuous automated testing, breaking through the speed bottleneck of single sample serial processing.

[0036] Simplified human-computer interaction: Operators only need to complete two actions: "place the sample" and "start the test". The subsequent weighing, heating, calculation, and endpoint determination are all completed automatically by the equipment, which minimizes human error and subjective judgment.

[0037] Process layer: Pre-detection and direct data connection;

[0038] Detection location restructuring: The moisture detection process is moved from the back-end laboratory to the physical end of raw material inspection upon arrival at the plant (such as the quality control station or sample preparation room). After sample preparation, the moisture sample can be tested locally without waiting or transportation.

[0039] Data flow optimization: The moisture analyzer is equipped with a data interface that directly connects to the enterprise's quality management system and LIMS (Laboratory Information Management System). Once the test results are generated, they are automatically and in real time uploaded to the central database via a preset communication protocol, eliminating the need for manual transcription or secondary data entry.

[0040] Information flow separation: Separate the information flow of moisture data from that of elemental data requiring complex chemical analysis. Moisture, as a key process parameter, is prioritized for independent detection and release to meet the real-time needs of production scheduling; elemental detection continues in batches according to the original schedule, balancing efficiency and cost.

[0041] Step 1: Sampling and diversion;

[0042] After the materials arrive at the factory, they are sampled according to standards and prepared in a unified manner, resulting in two subsamples: a moisture sample and an analytical sample.

[0043] Step 2: Parallel detection and real-time feedback;

[0044] Moisture sample: Immediately placed in any idle position of the fully automatic moisture analyzer, and the test is started. The equipment automatically executes a closed-loop process of "initial weighing → heating and dehumidification → process weighing → calculating moisture percentage → generating electronic results".

[0045] The analytical samples are temporarily stored, awaiting centralized delivery to the laboratory for subsequent elemental analysis. Thus, moisture detection and elemental detection are decoupled in both time and space.

[0046] Step 3: Automatic data integration and publishing;

[0047] After completing the test of a single sample, the moisture analyzer automatically pushes a standardized data packet containing the sample ID, moisture value, and timestamp to the enterprise quality management system via the internal network. Upon receiving the packet, the system updates its database in real time and generates internal reports.

[0048] Step 4: Real-time production call;

[0049] Production control systems or managers can retrieve the latest moisture data from the quality management system in real time to accurately calculate the dry weight of raw materials entering the furnace and adjust the batching model in real time, thereby achieving refined production control.

[0050] Addressing issues of low efficiency and long cycles: "Pre-detection" eliminates sample delivery waiting time, and "multi-station parallel processing" increases throughput per unit time. Addressing issues of high human error: "Fully automated measurement" replaces manual weighing, transfer, and calculation, achieving process objectivity and standardization. Addressing issues of environmental interference accuracy: "Instant detection" significantly shortens the exposure time from sample preparation to detection, greatly reducing the impact of environmental temperature and humidity on sample moisture changes. Addressing issues of delayed data feedback: "Direct data connection and real-time upload" breaks down information barriers between the detection end and the production management system, achieving "zero delay" from moisture data generation to availability. Addressing issues of difficulty in batch processing: The inherent properties of multi-station fully automated instruments make them naturally suitable for batch and continuous operation modes.

[0051] The main functions of this invention are:

[0052] Employing a multi-station (e.g., 14-station) fully automated moisture analyzer, multiple samples can be processed simultaneously, greatly increasing the detection throughput per unit time and meeting the testing needs of continuously incoming materials. The equipment integrates automatic weighing, programmed temperature-controlled drying, process weighing monitoring, automatic moisture content calculation, and result output functions, achieving "testing immediately upon placement" and completely eliminating errors introduced by manual operation. By moving the testing process forward to the sample preparation site (physical end), immediate testing after sample preparation is achieved, minimizing the time the sample is exposed to the environment and effectively avoiding result distortion caused by high-temperature water loss or moisture absorption.

[0053] Moisture detection and elemental analysis are separated in the workflow. Moisture samples are tested on-site and immediately after preparation, eliminating the need to wait and transport them to the laboratory. This solves the serious delays caused by sample delivery, handover, and queuing in the traditional model. It also eliminates multiple intermediate steps such as sample transportation, laboratory sample reception, manual distribution, and ledger registration, simplifying the management process and improving overall operational efficiency.

[0054] The moisture analyzer interfaces with the company's quality management system and LIMS system, automatically and in real-time uploading test results to the central database, eliminating errors and delays that may result from manual data entry. Once the moisture test results are generated, production units can view them in real time through the system, providing immediate and accurate data support for production decisions such as blast furnace batching and cost accounting, achieving "zero-delay" connection between test data and production applications. The fully automated testing process reduces human intervention, lowers the risk of data tampering or errors caused by human factors, and enhances the impartiality of the quality inspection process and the ability to prevent and control corruption risks.

[0055] Providing real-time and accurate moisture data for blast furnaces is a prerequisite for achieving precise material and heat balance calculations, which helps stabilize furnace conditions and optimize fuel consumption. Accurate moisture data is the direct basis for calculating dry basis weight, which can effectively avoid inflated procurement costs or waste of resources due to moisture deviations, thus protecting the interests of both suppliers and consumers. By improving detection efficiency and accelerating data feedback, the cycle from raw materials entering the plant to usable data is shortened, improving the responsiveness of the entire supply chain and the flexibility of production organization.

[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 rapid method for detecting moisture content in raw materials, fuels, and auxiliary materials, characterized in that, Includes the following steps: S1: Take samples of incoming materials and prepare moisture and analytical samples; S2: Send the moisture sample into a multi-station fully automatic moisture analyzer for testing, and complete the weighing, drying, calculation and result output; S3: Analytical samples are sent to the laboratory for elemental analysis. S4: Moisture test results are automatically uploaded to the quality management system via a data interface.

2. The method for rapid detection of moisture in raw materials, fuels, and auxiliary materials according to claim 1, characterized in that, The multi-station fully automatic moisture analyzer in step S2 has at least 14 detection stations.

3. The rapid detection method for moisture content of raw materials, fuels, and auxiliary materials according to claim 1, characterized in that, The moisture sample is detected at the physical end of a multi-station fully automatic moisture analyzer.

4. The rapid detection method for moisture content of raw materials, fuels, and auxiliary materials according to claim 1, characterized in that, It also includes using a fully automated moisture analyzer for sample preparation.

5. The method for rapid detection of moisture in raw materials, fuels, and auxiliary materials according to claim 1, characterized in that, The test results are integrated with the company's quality management system and LIMS system.

6. The method for rapid detection of moisture in raw materials, fuels, and auxiliary materials according to claim 1, characterized in that, The analytical sample enters the chemical section for testing.

7. The rapid detection method for moisture content of raw materials, fuels, and auxiliary materials according to claim 6, characterized in that, The detection data of the moisture sample and the analytical sample are entered into the quality measurement system.

8. The method for rapid detection of moisture in raw materials, fuels, and auxiliary materials according to claim 1, characterized in that, It also includes data interfaces for integration with quality management systems and LIMS systems.

Images