Intelligent heating furnace system with energy-saving self-diagnostic function and its diagnostic method

Abstract

This invention relates to an intelligent heating furnace system with energy-saving self-diagnostic function and its diagnostic method, belonging to the technical field of heating furnaces in iron and steel metallurgy. It includes a heating furnace and connected components such as exhaust pipes, combustion air pipes, gas pipes, cooling water pipes, a control system, and various detection devices and control components. During operation, each detection device collects real-time data on air flow rate, gas flow rate, flue gas oxygen content, temperature, and water level parameters and transmits this data to the control system. The control system, based on preset diagnostic logic and parameter thresholds, performs real-time diagnosis of abnormal states in the air preheater, water beam columns, furnace door, and burners, promptly issuing maintenance prompts or warning signals. This invention achieves comprehensive energy-saving self-diagnosis of the heating furnace and auxiliary equipment, reducing heat loss and fuel waste, lowering equipment failure rates, extending equipment lifespan, and ensuring heating effect and product quality. It is suitable for various heating furnace scenarios requiring precise temperature control and energy saving.

Description

Technical Field

[0001] This invention belongs to the field of heating furnace technology in iron and steel metallurgy, and relates to an intelligent heating furnace system with energy-saving self-diagnosis function and its diagnostic method. Background Technology

[0002] In the hot rolling process of the steel industry, the heating furnace is one of the core key pieces of equipment. Its main function is to heat the steel billet to the temperature required for rolling, providing the necessary temperature guarantee for subsequent rolling processes. However, the heating furnace is also the most energy-intensive equipment in the hot rolling process. According to statistics, its energy consumption accounts for 60% to 70% of the total energy consumption of the entire hot rolling process, and also accounts for 15% to 20% of the total energy consumption of steel production. It is one of the core control points for steel companies to achieve energy conservation and consumption reduction and control production costs. Its energy utilization efficiency is directly related to the company's economic benefits and the level of green and sustainable development.

[0003] The energy consumption level of a heating furnace is closely related to the operating status of its various components, including the combustion system, heat exchange system, sealing system, and temperature control system. The stability, reliability, and rationality of their operation are key factors affecting the furnace's thermal efficiency and causing energy consumption fluctuations. According to the relevant technical specifications for energy-saving design of steel rolling heating furnaces, the design of heating furnaces should focus on energy conservation and environmental protection, employing advanced technologies to ensure energy saving, low consumption, and safe and reliable operation. However, in actual long-term operation, equipment inevitably experiences abnormal conditions such as wear, aging, and parameter drift. If these are not detected and addressed in a timely manner, it will lead to a decrease in furnace thermal efficiency, a surge in fuel consumption, and may also exacerbate equipment damage, increase equipment operation and maintenance costs, and unplanned downtime losses.

[0004] Currently, the condition monitoring of hot rolling heating furnace equipment in most domestic steel enterprises still generally adopts the traditional manual inspection mode. This relies on inspectors to conduct on-site inspections, record parameters, and make experience-based judgments on each piece of equipment in the heating furnace according to fixed cycles to identify and troubleshoot equipment anomalies. However, this traditional inspection mode has many inherent defects and is no longer suitable for the urgent needs of modern industrial intelligent production and energy conservation and consumption reduction. On the one hand, the quality of manual inspections is highly dependent on the professional experience and sense of responsibility of the inspectors. Different inspectors have subjective differences in their judgment standards. In complex industrial environments, the rate of missed inspections can reach 15% to 30%, which can easily lead to the overlooking of potential minor equipment anomalies. On the other hand, the sampling frequency of manual inspections is on an hourly or daily basis, which is discrete monitoring. It is impossible to achieve real-time monitoring of equipment operating status, and it is difficult to capture transient anomalies and continuous trends in equipment operation. Problems are usually only discovered after obvious failures or even complete damage to the equipment, lacking effective early warning and prediction measures, resulting in the inability to deal with equipment anomalies in a timely manner.

[0005] When potential abnormalities in the heating furnace equipment are not detected in a timely manner, it will not only lead to a significant increase in energy consumption. For example, if the furnace mouth seal is不严 (incomplete) and heat leaks out, more fuel needs to be consumed to maintain the stability of the furnace temperature. If the flue gas waste heat recovery equipment is abnormal, the waste heat utilization rate will decrease, etc. It will also accelerate the damage process of the equipment, increase the equipment maintenance frequency and maintenance costs. In severe cases, it will even cause unplanned shutdowns, affecting the continuity of the entire hot rolling production process and resulting in greater economic losses. Although some existing technologies have taken measures such as optimizing the furnace body structure, improving burners, and adding waste heat recovery devices in terms of heating furnace energy conservation, these technologies mostly focus on passive control of energy consumption, fail to achieve source energy conservation from the perspectives of equipment status prediction and active early warning, and are difficult to handle the problem of dynamic abnormalities during equipment operation, and the energy conservation effect is still not ideal.

[0006] With the in-depth promotion of the concept of Industry 4.0 and the rapid development of industrial intelligent technologies, the steel industry is gradually transforming towards intelligence and greenness, putting forward higher requirements for the operation control of core energy-consuming equipment such as heating furnaces. It is urgent to break through the limitations of the traditional manual inspection mode and achieve intelligent monitoring, precise prediction, and early warning of the equipment operation status. Based on this, how to utilize various operation data and process parameters generated during the production process of the heating furnace, combined with intelligent data analysis technologies, to build an intelligent system that can predict the equipment operation status in advance and timely warn of potential failures, avoid energy waste and increased maintenance costs caused by equipment abnormalities from the source, and achieve energy-saving operation and intelligent self-diagnosis of the heating furnace has become a technical problem that steel enterprises urgently need to solve, and it is also the key breakthrough point to promote the upgrading of heating furnace equipment towards high efficiency, energy conservation, and intelligence. Summary of the Invention

[0007] In view of this, the purpose of the present invention is to provide an intelligent heating furnace system with an energy-saving self-diagnosis function and its diagnosis method, aiming to solve the technical problems of high energy consumption of existing heating furnaces, difficulty in timely detecting equipment abnormalities, and the expansion of failures caused by lagging maintenance.

[0008] To achieve the above object, the present invention provides the following technical solutions: An intelligent heating furnace system with an energy-saving self-diagnosis function includes a heating furnace, an air preheater, a steam drum, as well as burners, water beam columns, and water seal grooves that are配套设置 (configured) with the heating furnace; the air preheater is connected to the burners of the heating furnace through a hot air main pipe, and the flue gas outlet of the heating furnace is connected to the air preheater through a smoke exhaust pipe; the water outlet pipe of the water beam column is connected to the steam drum, the water outlet pipe of the steam drum is connected back to the water beam column, and a water beam column cooling water makeup pipe is also provided on the water beam column; a gas pipe is also connected to the burners. The cooling water supply pipe of the water beam column is equipped with a water supply flow meter, the steam outlet of the steam drum is equipped with a steam flow meter, the outlet of the water seal trough is equipped with an outlet water thermometer, and the heating furnace is equipped with a thermometer inside. The top of the heating furnace is also equipped with a laser rangefinder to measure the distance between the furnace top and the furnace bottom.

[0009] Optionally, the heating furnace is also equipped with a discharge furnace door and a charging furnace door. A furnace door cooling water pipe is connected to the discharge furnace door. A furnace door cooling water flow meter is installed on the furnace door cooling water pipe, and a furnace door outlet water thermometer is installed on the outlet water pipe of the discharge furnace door. A thermal imager is installed at the discharge furnace door and the charging furnace door to detect and record the furnace door temperature.

[0010] Optionally, a residual oxygen detection device is installed on the exhaust pipe at the flue gas inlet of the air preheater, and a residual oxygen detection device is installed on the exhaust pipe at the flue gas outlet of the air preheater.

[0011] Optionally, a cold air main pipe flow meter is installed on the cold air main pipe connected to the air preheater inlet, and a hot air main pipe thermometer is installed on the hot air main pipe; a flue gas flow meter is also installed on the flue gas exhaust pipe at the flue gas inlet of the air preheater.

[0012] Optionally, the hot air main is also equipped with a burner air thermometer.

[0013] Optionally, the hot air main pipe is also equipped with a burner air valve and a burner air flow meter; the gas pipeline is equipped with a burner gas valve and a burner gas flow meter.

[0014] A diagnostic method employing any of the aforementioned intelligent heating furnace systems with energy-saving self-diagnostic functions, further comprising a control system electrically connected to each detection device, flow meter, thermometer, rangefinder, and thermal imager; the method includes the following: Diagnosis of abnormalities in the refractory material of the water beam column: The internal thermometer of the heating furnace monitors the furnace temperature in real time, and the steam flow meter monitors the steam output of the steam drum in real time; The control system compares the steam flow at the same furnace temperature with the historical average value. When the steam flow at the same furnace temperature is more than 15% higher than the historical average value, it is determined that the refractory material of the water beam column is damaged or detached, and an early warning signal for damage to the refractory material of the water beam column is issued. Water beam column leakage diagnosis: The water supply flow meter of the water beam column detects the water supply volume of the water beam column in real time, and the steam flow meter detects the steam output of the steam drum in real time; the control system calculates the difference between the water supply volume and the steam output. When the steam output is more than 10% less than the water supply volume, it is determined that there is a water leakage in the water beam column, and an early warning signal for water beam column leakage is issued. Abnormal diagnosis of furnace bottom refractory material and sealing box: The internal thermometer of the heating furnace monitors the furnace temperature in real time, and the outlet water temperature of the water seal tank monitors the outlet water temperature in real time; the control system compares the outlet water temperature of the water seal tank at the same furnace temperature with the historical average. When the outlet water temperature of the water seal tank at the same furnace temperature is more than 20% higher than the historical average, it is determined that there is abnormality in the furnace bottom refractory material of the heating furnace and the sealing performance of the sealing box has decreased, and a maintenance prompt signal is issued. Diagnosis of iron oxide scale buildup at the furnace bottom: A laser rangefinder monitors the distance between the furnace top and bottom in real time, with a focus on monitoring the distance between the furnace bottom and the lower burner channel. When there are no steel billets in the detection area, if the laser rangefinder shows that the distance between the furnace bottom and the lower burner channel is less than 200mm, it is determined that there is excessive iron oxide scale buildup at the furnace bottom, and a prompt signal to clean the iron oxide scale is issued.

[0015] Optionally, the heating furnace is also equipped with a discharge furnace door and a charging furnace door. A furnace door cooling water pipe is connected to the discharge furnace door, and a furnace door cooling water flow meter is installed on the furnace door cooling water pipe. A furnace door outlet water temperature meter is installed on the outlet water pipe of the discharge furnace door. Thermal imagers are installed at the discharge furnace door and the charging furnace door to detect and record the furnace door temperature. A residual oxygen detection device is installed on the exhaust pipe at the flue gas inlet of the air preheater, and a residual oxygen detection device is installed on the exhaust pipe at the flue gas outlet of the air preheater. Furnace door and furnace pressure anomaly diagnosis: The thermal imager detects and records the temperature distribution of the furnace door in real time, focusing on monitoring the temperature at the connection point A between the charging furnace door, the discharging furnace door and the heating furnace body, and the connection point B between the two furnace doors; when the furnace door is closed, if the temperature at the above connection points is more than 100°C higher than the historical average, the control system will first issue a high furnace pressure warning signal; if the furnace pressure detection data is normal at this time, it is determined that there is an abnormality of furnace door deformation or poor sealing, and a furnace door deformation warning signal will be issued; Air leakage diagnosis of furnace door and preheater maintenance door: The residual oxygen detection device in front of the preheater detects the oxygen content in the flue gas in front of the air preheater in real time, and the residual oxygen detection device after the preheater detects the oxygen content in the flue gas after the air preheater in real time; the control system compares and analyzes the two sets of oxygen content data. When the oxygen content in the flue gas in front of the air preheater is more than 3% higher than the oxygen content in the flue gas at the tail of the furnace, it is determined that there is air leakage in the charging furnace door, discharging furnace door or preheater maintenance door, and an air leakage warning signal is issued. Air preheater heat exchange component leakage diagnosis: The residual oxygen detection device before and after the preheater respectively detects the oxygen content in the flue gas before and after the air preheater in real time; the control system compares the two sets of flue gas oxygen content data, and when the oxygen content in the flue gas after the air preheater is 2% higher than the oxygen content in the flue gas before the air preheater, it is determined that there is an abnormal air leakage in the heat exchange component of the air preheater, and an early warning signal for air leakage in the heat exchange component of the preheater is issued.

[0016] Optionally, a cold air main pipe flow meter is installed on the cold air main pipe connected to the air preheater inlet, and a hot air main pipe thermometer and a burner air thermometer are installed on the hot air main pipe; a flue gas flow meter is also installed on the flue gas exhaust pipe at the air preheater flue gas inlet. Air preheater malfunction diagnosis: The cold air main pipe flow meter monitors the air volume in the cold air main pipe in real time, the flue gas flow meter monitors the flue gas volume in the exhaust pipe in real time, and the hot air main pipe thermometer monitors the air preheating temperature in real time. The residual oxygen detection devices before and after the preheater assist in collecting flue gas parameters. The control system classifies the operating conditions where the difference between air volume, flue gas volume, and exhaust temperature is within 5% as the same operating condition, and continuously records the trend of air preheating temperature change under this operating condition. When the difference in air preheating temperature exceeds 15% under the same operating condition, it is determined that the air preheater has a decrease in heat exchange efficiency or blockage, and a preheater maintenance prompt signal is immediately issued. Diagnosis of abnormal insulation in hot air ducts: The hot air main pipe thermometer monitors the air temperature after the air preheater in real time, and the burner air thermometer monitors the air temperature before the burner in real time; the control system compares the difference between the two sets of temperature data under the same air flow conditions and compares it with the historical average difference. When the temperature difference is more than 30% higher than the historical average, it is determined that the insulation material of the hot air duct is damaged or abnormally aged, and a prompt signal for maintenance of the hot air duct insulation material is issued.

[0017] Optionally, the hot air main pipe is also equipped with a burner air valve and a burner air flow meter; the gas pipeline is equipped with a burner gas valve and a burner gas flow meter. Burner and gas valve malfunction diagnosis: The burner air flow meter and burner gas flow meter detect the air flow and gas flow of each burner in real time; the control system compares the air flow and gas flow data of each burner for multiple burners in the same heating section. When a burner is in operation, if the deviation ratio of its air flow or gas flow from the corresponding flow of other burners in the same heating section exceeds 20%, it is determined that the burner is blocked or damaged, or that the burner air valve or burner gas valve has an abnormal opening, and a corresponding maintenance prompt signal is issued.

[0018] The beneficial effects of this invention are as follows: This invention can promptly identify and warn of problems occurring during the operation of a heating furnace, thereby saving energy and reducing equipment operation and maintenance costs. During operation, various detection devices collect key parameters such as air flow, gas flow, flue gas oxygen content, temperature, and water level in real time and transmit them to the control system. The control system, based on preset diagnostic logic and parameter thresholds, performs real-time diagnosis of abnormal states in equipment such as the air preheater, water beam column, furnace door, and burners, and promptly issues maintenance prompts or warning signals. This invention achieves comprehensive energy-saving self-diagnosis of the heating furnace and auxiliary equipment, reducing heat loss and fuel waste, lowering equipment failure rates, extending equipment lifespan, and ensuring heating effect and product quality. It is suitable for various heating furnace scenarios requiring precise temperature control and energy saving.

[0019] 1) Achieve comprehensive intelligent self-diagnosis and accurately identify equipment anomalies: This invention, by rationally arranging detection devices on various auxiliary systems and key equipment, combined with 10 targeted diagnostic methods, can comprehensively cover common anomalies of core auxiliary equipment such as air preheaters, furnace doors, water beam columns, and burners, including leaks, wear, refractory material damage, air leakage, and iron oxide scale accumulation. The diagnostic logic is accurate and can promptly detect early hidden anomalies, preventing the anomalies from escalating and causing equipment failure.

[0020] 2) Strengthen energy-saving monitoring and reduce energy consumption: The diagnostic methods of this invention are all closely related to the energy consumption of the heating furnace. By monitoring key energy-saving parameters such as air preheating temperature, flue gas oxygen content, steam flow rate, and hot air pipe temperature, abnormal factors that lead to increased energy consumption (such as air leakage, reduced preheater efficiency, and damaged insulation layer) can be identified in a timely manner. This reminds staff to carry out timely maintenance and optimization, effectively reducing fuel consumption and heat loss, improving the thermal efficiency of the heating furnace, and achieving energy-saving operation.

[0021] 3) Improve the intelligence level of the system and reduce manual intervention: The present invention collects parameters in real time through the detection device, and the control system automatically diagnoses and analyzes and issues early warning signals. There is no need for real-time manual inspection and experience judgment, which greatly improves the intelligent operation level of the heating furnace system, reduces the intensity of manual labor, avoids the error of manual diagnosis, and improves the accuracy and timeliness of abnormal diagnosis.

[0022] 4) Ensure production continuity and improve product quality: By promptly detecting and warning of equipment abnormalities, staff can conduct troubleshooting and maintenance in advance, avoiding production interruptions caused by equipment failures; at the same time, by optimizing furnace operating conditions (such as avoiding furnace temperature fluctuations and air leakage), the uniformity of heating in the heating furnace is ensured, effectively improving product heating quality and reducing product defect rate.

[0023] 5) Reasonable structure and strong adaptability: The present invention adds detection devices and diagnostic logic to the existing heating furnace system without requiring major modifications to the main structure of the heating furnace. The structure is reasonable and the modification is easy. It can be widely adapted to various industrial heating furnaces and has strong practicality and promotion value.

[0024] 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 from 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

[0025] 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 schematic diagram of the heating furnace system of the present invention; Figure 2 This is a schematic diagram showing the division of the furnace door area.

[0026] Figure label: 1. Heating furnace; 11. Burner; 12. Discharge furnace door; 13. Charging furnace door; 14. Water beam column; 15. Water seal trough; 16. Laser rangefinder; 2. Exhaust pipe; 21. Flue gas flow meter; 22. Residual oxygen detection device before preheater; 23. Residual oxygen detection device after preheater; 3. Cold air main pipe; 31. Cold air main pipe flow meter; 32. Air preheater; 33. Hot air main pipe thermometer; 34. Burner air valve; 35. Burner air flow meter; 36. Burner air thermometer; 4. Gas pipeline; 41. Burner gas valve; 42. Burner gas flow meter; 5. Water beam column cooling water supply pipeline; 51. Water beam column supply water flow meter; 52. Steam drum; 53. Steam flow meter; 6. Water seal trough cooling water pipeline; 61. Water seal trough outlet water thermometer; 7. Furnace door cooling water pipeline; 71. Furnace door cooling water flow meter; 72. Furnace door outlet water thermometer; 8. Thermal imager. Detailed Implementation

[0027] 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.

[0028] 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.

[0029] 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.

[0030] Please see Figures 1-2 This is an intelligent heating furnace system with energy-saving self-diagnostic function, including a heating furnace 1, an air preheater 32, a steam drum 52, and other auxiliary equipment, as well as supporting equipment such as burners 11, water beam columns 14, and water seal troughs 15. The heating furnace 1 is the main heating equipment, with several burners 11 evenly arranged on its side walls. The burners 11 are used to inject a mixture of gas and air and burn it to generate heat, providing a heat source for the interior of the heating furnace 1. One end of the heating furnace 1 is equipped with a discharge door 12, and the other end is equipped with a charging door 13. The discharge door 12 is used for discharging steel billets after heating, and the charging door 13 is used for charging steel billets to be heated. The two work together to achieve continuous feeding and discharging of steel billets. Inside the heating furnace 1, at the bottom, are water beam columns 14, which support the steel billets. The bottom of the water beam columns 14 is connected to the water seal trough 15, which is used to seal the bottom of the heating furnace 1, preventing air leakage and flue gas leakage. A laser rangefinder 16 is installed on the top of the heating furnace 1. The detection direction of the laser rangefinder 16 is towards the bottom of the furnace, which is used to detect the distance between the top and bottom of the furnace in real time, with a focus on monitoring the distance between the bottom of the furnace and the channel of the lower burner 11.

[0031] The air preheater 32 is connected to the burner 11 of the heating furnace 1 through the hot air main pipe. The flue gas outlet of the heating furnace 1 is connected to the air preheater 32 through the flue gas pipe 2. The water outlet pipe of the water beam column 14 is connected to the steam drum 52. The water outlet pipe of the steam drum 52 is connected back to the water beam column 14. The water beam column 14 is also equipped with a water beam column cooling water supply pipe 5. The burner 11 is also connected to a gas pipe 4.

[0032] The furnace 1 is connected to the exhaust pipe 2, the combustion air pipe, the gas pipe 4, and the cooling pipe. All pipes work together to ensure the smooth flow of media (gas, air, cooling water, flue gas, etc.) in each system and to ensure the normal operation of the furnace 1.

[0033] One end of the flue gas duct 2 is connected to the tail of the heating furnace 1 to discharge the flue gas generated by combustion in the heating furnace 1. Along the flue gas flow direction, the flue gas duct 2 is equipped with a flue gas flow meter 21, a residual oxygen detection device 22 before the preheater, an air preheater 32, and a residual oxygen detection device 23 after the preheater. The flue gas flow meter 21 is used to monitor the flue gas flow in the flue gas duct 2 in real time, providing data support for operating condition judgment and preheater abnormality diagnosis. The residual oxygen detection device 22 before the preheater is installed on the flue gas duct 2 at the inlet end of the air preheater 32, and the residual oxygen detection device 23 after the preheater is installed on the flue gas duct 2 at the outlet end of the air preheater 32. The two work together to collect flue gas oxygen content data at different locations in real time, ensuring the accuracy of diagnosis of air leakage, heat exchange component leakage, etc.

[0034] The combustion air duct mainly includes a cold air main pipe 3 and an air preheater 32. One end of the cold air main pipe 3 is connected to the outside air, and the other end is connected to the air inlet of the air preheater 32. The air outlet of the air preheater 32 is connected to each branch air duct through a hot air main pipe. The branch air ducts are connected to the corresponding burners 11 to provide combustion air to the burners 11. To accurately collect air and gas related parameters and ensure diagnostic accuracy, an air main pipe flow meter 31 is installed on the cold air main pipe 3 to monitor the cold air flow rate in the cold air main pipe in real time. A hot air main pipe thermometer 33 is installed on the main air pipe to monitor the temperature of the preheated hot air in real time. Each branch air pipe before each burner 11 is equipped with a burner air valve 34, a burner air flow meter 35, and a burner air thermometer 36. The burner air valve 34 is used to regulate the air supply to the corresponding burner 11, the burner air flow meter 35 is used to collect the air flow at the inlet of the corresponding burner 11 in real time, and the burner air thermometer 36 is used to collect the air temperature at the inlet of the corresponding burner 11 in real time, providing support for the diagnosis of burner 11 abnormalities.

[0035] The gas pipeline system 4 mainly includes gas pipeline 4, which is divided into a main gas pipeline and branch gas pipelines. One end of the main gas pipeline is connected to an external gas source, and the other end is connected to each burner 11 through the branch gas pipelines to provide the burners 11 with the gas required for combustion. Each branch gas pipeline before each burner 11 is equipped with a burner gas valve 41 and a burner gas flow meter 42. The burner gas valve 41 is used to regulate the gas supply to the corresponding burner 11, and the burner gas flow meter 42 is used to collect the gas flow at the inlet of the corresponding burner 11 in real time, and to diagnose the combustion status of the burner 11 in conjunction with air parameters.

[0036] The cooling pipeline is divided into 14 cooling branches of water beam columns, 15 cooling branches of water seal troughs, and 16 cooling branches of furnace door. Each branch is independent of the others and is connected to the external cooling water supply system to ensure the cooling effect. The cooling branch of the water beam column 14 mainly includes a water beam column cooling water pipe 5 and a steam drum 52. One end of the water beam column cooling water pipe 5 is connected to an external cooling water supply system, and the other end is connected to the cooling water inlet of the water beam column 14. The cooling water outlet of the water beam column 14 is connected to the water inlet of the steam drum 52 through a pipe. The water outlet of the steam drum 52 is then connected to the water beam column cooling water pipe 5 through a pipe, forming a cooling water circulation system. A water beam column makeup water flow meter 51 is installed on the water beam column cooling water pipe 5 to monitor the makeup water volume of the water beam column 14 in real time. The outlet of the steam drum 52 is connected to a steam pipe, and a steam flow meter 53 is installed on the steam pipe to monitor the steam output of the steam drum 52 in real time, providing data support for the diagnosis of water leakage and refractory material damage in the water beam column 14.

[0037] The cooling branch of the water seal tank mainly includes a water seal tank cooling water pipe 6, which accurately collects the outlet water temperature of the water seal tank 15 to ensure the accuracy of abnormal diagnosis of the furnace bottom refractory and sealing box. One end of the water seal tank cooling water pipe 6 is connected to the external cooling water supply system, and the other end is connected to the water seal tank 15 for cooling the water seal tank 15. A water seal tank outlet water thermometer 61 is installed at the outlet end of the water seal tank cooling water pipe 6 to monitor the outlet water temperature of the water seal tank 15 in real time and provide data input for abnormal diagnosis of the furnace bottom refractory and sealing box.

[0038] The furnace door cooling branch mainly includes a furnace door cooling water pipe 7, which is connected to the charging furnace door 13 and the discharging furnace door 12 respectively, and is used to cool the two furnace doors. A furnace door cooling water flow meter 71 is installed on the furnace door cooling water pipe 7, and a furnace door outlet water thermometer 72 is installed on the outlet water pipe of the discharging furnace door 12 and / or the charging furnace door 13. The furnace door cooling water flow meter 71 is used to monitor the flow rate of the furnace door cooling water in real time, and the furnace door outlet water thermometer 72 is used to monitor the outlet water temperature of the furnace door cooling water in real time, and to assist in the diagnosis of furnace door abnormalities.

[0039] The detection devices installed on each pipeline are used to determine whether the auxiliary equipment of the heating furnace is in normal working condition, so as to realize intelligent self-diagnosis and energy-saving monitoring functions. Each detection device is electrically connected to the control system and transmits the collected parameters to the control system in real time. All control components (burner air valve 34, burner gas valve 41) are electrically connected to the control system. The control system issues control commands based on the diagnostic results to adjust the operating status of each component, and issues corresponding maintenance prompts or warning signals for abnormal conditions.

[0040] In this embodiment, the intelligent heating furnace system first loads the steel billet to be heated into the heating furnace 1 through the charging furnace door 13. The steel billet is placed on the water beam column 14. The charging furnace door 13 and the discharge furnace door 12 are closed to ensure that the heating furnace 1 is well sealed. Then, the system is started. Gas is delivered to each burner 11 through the gas pipeline 4, and air is delivered to the air preheater 32 through the cold air main pipe 3. The hot air, preheated by the air preheater 32, is delivered to each burner 11. The gas and hot air are mixed and burned in the burner 11 to provide heat to the interior of the heating furnace 1 and heat the steel billet. The flue gas generated by combustion is discharged through the exhaust pipe 2. During the discharge process, it passes through the air preheater 32 and exchanges heat with the cold air to realize the recovery and utilization of the waste heat of the flue gas, achieving energy saving. Each cooling branch works synchronously to provide cooling for the water beam column 14, the water seal trough 15, and the furnace door to prevent the equipment from being damaged due to high temperature.

[0041] To ensure the comprehensiveness and accuracy of furnace door temperature detection, thermal imagers 8 are installed at both furnace doors of heating furnace 1 (corresponding positions on the outside of charging furnace door 13 and discharging furnace door 12). The thermal imagers 8 are positioned in front of the furnace doors, and their imaging range completely covers the entire furnace door and the connection point between the furnace door and the furnace body (e.g., ...). Figure 2 Area A), including the connecting area between furnace doors (such as... Figure 2 The middle B area is used to capture the temperature distribution at key locations of the furnace door in real time, ensuring accurate capture of the temperature distribution at key locations of the furnace door and providing reliable temperature data for the diagnosis of abnormal furnace door and furnace pressure.

[0042] The detection devices can collect key parameters of the heating furnace and its auxiliary equipment in real time during operation and transmit the collected parameters to the control system. The control system, through preset diagnostic logic and parameter thresholds, determines whether the heating furnace and its auxiliary and supporting equipment are in normal working condition and issues corresponding maintenance prompts or warning signals for different types of abnormalities. This invention also proposes a diagnostic method for the aforementioned intelligent heating furnace system with energy-saving self-diagnostic function. During system operation, each detection device collects key parameters in real time and transmits them to the control system. The control system performs real-time diagnosis of the operating status of the heating furnace 1 and its auxiliary equipment according to preset diagnostic logic and parameter thresholds. The specific diagnostic process is as follows: 1) Air preheater 32 abnormality diagnosis: The air main pipe flow meter 31 detects the air volume in the combustion air duct in real time, the flue gas flow meter 21 detects the flue gas volume in the exhaust duct in real time, the hot air main pipe thermometer 33 detects the air preheating temperature in real time, and the residual oxygen detection device 22 before the preheater and the residual oxygen detection device 23 after the preheater assist in collecting flue gas parameters; the control system judges the operating state where the difference between air volume, flue gas volume, and exhaust temperature is within 5% as the same operating condition, and continuously records the change trend of air preheating temperature under the same operating condition; when the difference in air preheating temperature under the same operating condition exceeds 15%, it is determined that the air preheater 32 has abnormalities such as decreased heat exchange efficiency or blockage, and immediately issues a preheater maintenance prompt signal to remind the staff to carry out timely maintenance to avoid heat loss and ensure energy saving effect.

[0043] 2) Air leakage diagnosis of furnace door and preheater maintenance door: The residual oxygen detection device 22 before the preheater detects the oxygen content in the flue gas before the air preheater 32 (near the tail of the heating furnace 1) in real time, and the residual oxygen detection device 23 after the preheater detects the oxygen content in the flue gas after the air preheater 32 in real time; the control system compares and analyzes the two sets of oxygen content data. When the oxygen content in the flue gas before the air preheater 32 is more than 3% higher than the oxygen content in the flue gas at the tail of the furnace, it is determined that there is air leakage in the charging furnace door 13, the discharging furnace door 12 or the preheater maintenance door, and an air leakage warning signal is issued to prevent cold air from entering the furnace, which would cause furnace temperature fluctuations and increased fuel consumption, and at the same time prevent air leakage from affecting heat exchange efficiency.

[0044] 3) Leakage diagnosis of heat exchange components of air preheater 32: The residual oxygen detection device 22 before the preheater and the residual oxygen detection device 23 after the preheater respectively detect the oxygen content in the flue gas before and after the air preheater 32 in real time; the control system compares the two sets of flue gas oxygen content data. When the oxygen content in the flue gas after the air preheater 32 is 2% higher than the oxygen content in the flue gas before the air preheater 32, it is determined that there is an abnormal air leakage in the heat exchange components of the air preheater 32, and an early warning signal for air leakage in the heat exchange components of the preheater is issued, prompting the staff to check the leak point in time to avoid a decrease in preheating efficiency and an increase in energy consumption.

[0045] 4) Diagnosis of refractory material abnormalities in water beam column 14: The temperature detection device inside the heating furnace 1 (not labeled, but set up in conjunction with the equipment) monitors the furnace temperature of the heating furnace 1 in real time, and the steam flow meter 53 monitors the steam output of the steam drum 52 in real time; the control system compares the steam flow rate at the same furnace temperature with the historical average value. When the steam flow rate at the same furnace temperature is more than 15% higher than the historical average value, it is determined that the refractory material of the water beam column 14 is damaged or detached, which leads to increased heat dissipation and increased steam consumption of the water beam column 14. An early warning signal of damage to the refractory material of the water beam column 14 is issued to remind the staff to repair it in time, reduce steam loss, and ensure the service life of the water beam column 14.

[0046] 5) Leakage diagnosis of water beam column 14: The water supply flow meter 51 of the water beam column 14 detects the water supply in real time, and the steam flow meter 53 detects the steam output of the steam drum 52 in real time; the control system calculates the difference between the water supply and the steam output. When the steam output is more than 10% less than the water supply, it is determined that there is a water leakage in the water beam column 14, and a warning signal for water leakage in the water beam column 14 is issued to avoid water leakage causing temperature fluctuations in the furnace and affecting product quality, and at the same time to prevent water leakage from causing equipment failure.

[0047] 6) Diagnosis of abnormalities in the refractory material and sealing box of the furnace bottom of heating furnace 1: The temperature detection device inside heating furnace 1 monitors the furnace temperature of heating furnace 1 in real time, and the water outlet temperature gauge 61 of the water seal tank monitors the outlet water temperature of water seal tank 15 in real time; the control system compares the outlet water temperature of water seal tank 15 at the same furnace temperature with the historical average. When the outlet water temperature of water seal tank 15 at the same furnace temperature is more than 20% higher than the historical average, it is determined that there is an abnormality such as damage to the refractory material of the furnace bottom of heating furnace 1 or a decrease in the sealing performance of the sealing box. The control system issues a prompt signal for maintenance of the refractory material of the furnace bottom of heating furnace 1 and the sealing box, and repairs and replaces them in time to reduce heat loss in the furnace and ensure heating efficiency.

[0048] 7) Hot air duct insulation anomaly diagnosis: Hot air main pipe thermometer 33 monitors the air temperature after air preheater 32 in real time, and burner air thermometer 36 monitors the air temperature before burner 11 in real time; Under the same air flow conditions, the control system compares the difference between the two sets of temperature data and compares it with the historical average difference. When the temperature difference is more than 30% higher than the historical average, it is determined that the insulation material of the hot air duct is damaged or aged, resulting in increased heat loss. A prompt signal for repairing the hot air duct insulation material is issued to repair the insulation layer in time and reduce heat waste.

[0049] 8) Abnormal diagnosis of burner 11 and air / gas valve: The burner air flow meter 35 and burner gas flow meter 42 respectively detect the air flow and gas flow of each burner 11 in real time; the control system compares the air flow and gas flow data of each burner 11 for multiple burners 11 in the same heating section. When a certain burner 11 is in working condition, if the deviation ratio of its air flow or gas flow from the corresponding flow of other burners 11 in the same heating section exceeds 20%, it is determined that the burner 11 is blocked or damaged, or that the burner air valve 34 or burner gas valve 41 has an abnormal opening. The system issues a prompt signal to repair the burner 11 and the corresponding burner air valve 34 and burner gas valve 41 to ensure uniform combustion of each burner 11, improve fuel utilization, and reduce energy consumption.

[0050] 9) Diagnosis of abnormal furnace door and furnace pressure: The thermal imager 8 detects and records the temperature distribution of the furnace door in real time, focusing on monitoring the temperature at the connection point A between the charging furnace door 13, the discharging furnace door 12 and the heating furnace 1, and the connection point B between the two furnace doors; when the furnace door is closed, if the temperature at the above connection points is more than 100°C higher than the historical average, the control system will first issue a high furnace pressure warning signal; if the furnace pressure detection data (collected by the matching furnace pressure detection device, without labeling) is normal at this time, it is determined that there is an abnormality such as deformation or poor sealing of the furnace door, and a warning signal of furnace door deformation is issued to remind the staff to adjust the furnace pressure or repair the furnace door in time to avoid heat loss in the furnace and ensure the stability of the atmosphere in the furnace.

[0051] 10) Diagnosis of iron oxide scale buildup at the furnace bottom: The laser rangefinder 16 detects and measures the distance between the furnace top and the furnace bottom in real time, with a focus on monitoring the distance between the furnace bottom and the lower burner 11 channel; when there is no steel billet in the detection area, if the laser rangefinder 16 shows that the distance between the furnace bottom and the lower burner 11 channel is less than 200mm, it is determined that there is a problem of excessive iron oxide scale buildup at the furnace bottom, and a prompt signal to clean the iron oxide scale is issued to avoid the iron oxide scale clogging the burner 11 channel and affecting the combustion effect, while also preventing excessive buildup from causing abnormal heat dissipation at the furnace bottom.

[0052] 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. An intelligent heating furnace system with energy-saving self-diagnosis function, characterized in that: The system includes a heating furnace (1), an air preheater (32), a steam drum (52), and burners (11), water beam columns (14), and water seal troughs (15) that are equipped with the heating furnace (1). The air preheater (32) is connected to the burners (11) of the heating furnace (1) through a hot air main pipe. The flue gas outlet of the heating furnace (1) is connected to the air preheater (32) through a flue gas pipe (2). The water outlet pipe of the water beam column (14) is connected to the steam drum (52), and the water outlet pipe of the steam drum (52) is connected back to the water beam column (14). The water beam column (14) is also equipped with a water beam column cooling water supply pipe (5). The burners (11) are also connected to a gas pipe (4). The cooling water supply pipe (5) of the water beam column is equipped with a water supply flow meter (51), the steam outlet of the steam drum (52) is equipped with a steam flow meter (53), and the outlet of the water seal trough (15) is equipped with an outlet water thermometer (61); the heating furnace (1) is equipped with a thermometer inside. The heating furnace (1) is also equipped with a laser rangefinder (16) on top to measure the distance between the furnace top and the furnace bottom.

2. The intelligent heating furnace system with energy-saving self-diagnosis function according to claim 1, characterized in that: The heating furnace (1) is also equipped with a discharge furnace door (12) and a charging furnace door (13). The furnace door cooling water pipe (7) is connected to the discharge furnace door (12) and / or the charging furnace door (13). The furnace door cooling water pipe (7) is equipped with a furnace door cooling water flow meter (71). The water outlet pipes of the discharge furnace door (12) and / or the charging furnace door (13) are equipped with furnace door water outlet thermometers (72). Thermal imagers (8) are installed at the discharge furnace door (12) and the charging furnace door (13) to detect and record the furnace door temperature.

3. The intelligent heating furnace system with energy-saving self-diagnosis function according to claim 2, characterized in that: The exhaust pipe (2) at the flue gas inlet of the air preheater (32) is equipped with a residual oxygen detection device (22) before the preheater, and the exhaust pipe (2) at the flue gas outlet of the air preheater (32) is equipped with a residual oxygen detection device (23) after the preheater.

4. The intelligent heating furnace system with energy-saving self-diagnosis function according to claim 3, characterized in that: A cold air main pipe (3) connected to the inlet of the air preheater (32) is provided with a cold air main pipe flow meter (31), and a hot air main pipe is provided with a hot air main pipe thermometer (33); a flue gas flow meter (21) is also provided on the flue gas inlet of the air preheater (32).

5. The intelligent heating furnace system with energy-saving self-diagnosis function according to claim 4, characterized in that: The hot air main is also equipped with a burner air thermometer (36).

6. The intelligent heating furnace system with energy-saving self-diagnosis function according to claim 1, characterized in that: The hot air main pipe is also equipped with a burner air valve (34) and a burner air flow meter (35); the gas pipeline (4) is equipped with a burner gas valve (41) and a burner gas flow meter (42).

7. A diagnostic method, characterized in that: The intelligent heating furnace system with energy-saving self-diagnostic function as described in any one of claims 1 to 6 further includes a control system electrically connected to each detection device, flow meter, thermometer, rangefinder, and thermal imager (8); Method Includes the following: Diagnosis of abnormal refractory material of water beam column (14): The internal thermometer of the heating furnace (1) detects the furnace temperature of the heating furnace (1) in real time, and the steam flow meter (53) detects the steam output of the steam drum (52) in real time; the control system compares the steam flow at the same furnace temperature with the historical average value. When the steam flow at the same furnace temperature is more than 15% higher than the historical average value, it is determined that the refractory material of the water beam column (14) is damaged or falls off abnormally, and an early warning signal of damage to the refractory material of the water beam column (14) is issued. Water beam column (14) leakage diagnosis: Water beam column water supply flow meter (51) detects the water supply of water beam column (14) in real time, and steam flow meter (53) detects the steam output of steam drum (52) in real time; The control system calculates the difference between water supply and steam output. When the steam output is more than 10% less than the water supply, it is determined that there is a water leakage in water beam column (14) and a warning signal for water beam column (14) leakage is issued. Diagnosis of abnormalities in the refractory material and sealing box of the heating furnace (1): The internal thermometer of the heating furnace (1) detects the furnace temperature of the heating furnace (1) in real time, and the outlet water thermometer of the water seal tank (15) detects the outlet water temperature of the water seal tank (15) in real time; the control system compares the outlet water temperature of the water seal tank (15) under the same furnace temperature with the historical average value. When the outlet water temperature of the water seal tank (15) under the same furnace temperature is more than 20% higher than the historical average value, it is determined that there is an abnormality in the refractory material of the furnace bottom of the heating furnace (1) and the sealing performance of the sealing box has decreased, and a maintenance prompt signal is issued. Diagnosis of iron oxide scale buildup at the furnace bottom: The laser rangefinder (16) detects the distance between the furnace top and the furnace bottom in real time, focusing on the distance between the furnace bottom and the lower burner (11) channel; when there is no steel billet in the detection area, if the laser rangefinder (16) shows that the distance between the furnace bottom and the lower burner (11) channel is less than 200mm, it is determined that there is too much iron oxide scale buildup at the furnace bottom, and a prompt signal to clean the iron oxide scale is issued.

8. The diagnostic method according to claim 7, characterized in that: The heating furnace (1) is also equipped with a discharge furnace door (12) and a charging furnace door (13). The furnace door cooling water pipe (7) is connected to the discharge furnace door (12). The furnace door cooling water pipe (7) is equipped with a furnace door cooling water flow meter (71). The discharge water pipe of the discharge furnace door (12) is equipped with a furnace door outlet water thermometer (72). Thermal imagers (8) are installed at the discharge furnace door (12) and the charging furnace door (13) to detect and record the furnace door temperature. The exhaust pipe (2) at the flue gas inlet of the air preheater (32) is equipped with a preheater residual oxygen detection device (22). The exhaust pipe (2) at the flue gas outlet of the air preheater (32) is equipped with a preheater residual oxygen detection device (23). Furnace door and furnace pressure abnormality diagnosis: The thermal imager (8) detects and records the temperature distribution of the furnace door in real time, focusing on monitoring the temperature at the connection point A between the charging furnace door (13), the discharging furnace door (12) and the heating furnace (1), and the connection point B between the two furnace doors; when the furnace door is closed, if the temperature at the above connection point is more than 100°C higher than the historical average, the control system will first issue a high furnace pressure warning signal; If the furnace pressure detection data is normal at this time, it is determined that there is an abnormality of deformation or poor sealing of the furnace door, and a warning signal of furnace door deformation is issued. Air leakage diagnosis of furnace door and preheater maintenance door: The residual oxygen detection device (22) in front of the preheater detects the oxygen content in the flue gas in front of the air preheater (32) in real time, and the residual oxygen detection device (23) in the back of the preheater detects the oxygen content in the flue gas after the air preheater (32) in real time; the control system compares and analyzes the two sets of oxygen content data. When the oxygen content in the flue gas in front of the air preheater (32) is more than 3% higher than the oxygen content in the flue gas at the tail of the furnace, it is determined that there is air leakage in the charging furnace door (13), the discharging furnace door (12) or the preheater maintenance door, and an air leakage warning signal is issued. Air preheater (32) heat exchange component leakage diagnosis: The residual oxygen detection device (22) before the preheater and the residual oxygen detection device (23) after the preheater detect the oxygen content in the flue gas before and after the air preheater (32) in real time; the control system compares the two sets of flue gas oxygen content data, and when the oxygen content in the flue gas after the air preheater (32) is 2% higher than the oxygen content in the flue gas before the air preheater (32), it determines that there is an abnormal air leakage in the heat exchange component of the air preheater (32) and issues an early warning signal for air leakage in the heat exchange component of the preheater.

9. The diagnostic method according to claim 8, characterized in that: A cold air main pipe (3) connected to the inlet of the air preheater (32) is provided with a cold air main pipe flow meter (31), and a hot air main pipe thermometer (33) and a burner air thermometer (36) are provided on the hot air main pipe; a flue gas flow meter (21) is also provided on the flue gas inlet of the air preheater (32). Air preheater (32) abnormal diagnosis: The cold air main pipe flow meter (31) detects the air volume of the cold air main pipe (3) in real time, the flue gas flow meter (21) detects the flue gas volume of the exhaust pipe (2) in real time, the hot air main pipe thermometer (33) detects the air preheating temperature in real time, and the residual oxygen detection device (22) before the preheater and the residual oxygen detection device (23) after the preheater assist in collecting flue gas parameters; the control system judges the operating state where the difference between air volume, flue gas volume and exhaust temperature is within 5% as the same working condition, and continuously records the change trend of air preheating temperature under the working condition; when the difference between air preheating temperature under the same working condition exceeds 15%, it is determined that the air preheater (32) has a decrease in heat exchange efficiency or blockage abnormality, and immediately issues a preheater maintenance prompt signal; Diagnosis of abnormal heat insulation in hot air duct: The hot air main pipe thermometer (33) detects the air temperature after the air preheater (32) in real time, and the burner air thermometer (36) detects the air temperature before the burner (11) in real time; the control system compares the difference between the two sets of temperature data under the same air flow conditions and compares it with the historical average difference. When the temperature difference is more than 30% higher than the historical average, it is determined that the heat insulation material of the hot air duct is damaged or aged abnormally, and a prompt signal for repairing the heat insulation material of the hot air duct is issued.

10. The diagnostic method according to claim 7, characterized in that: The hot air main is also equipped with a burner air valve (34) and a burner air flow meter (35); the gas pipeline (4) is equipped with a burner gas valve (41) and a burner gas flow meter (42). Abnormal diagnosis of burner (11) and air / gas valve: The burner air flow meter (35) and burner gas flow meter (42) respectively detect the air flow and gas flow of each burner (11) in real time; the control system compares the air flow and gas flow data of each burner (11) for multiple burners (11) in the same heating section. When a certain burner (11) is in working state, if its air flow or gas flow deviates from the corresponding flow of other burners (11) in the same heating section by more than 20%, it is determined that the burner (11) is blocked or damaged, or the burner air valve (34) and burner gas valve (41) have abnormal opening, and the corresponding maintenance prompt signal is issued.

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