A device for detecting and controlling harmful gases in the smelting process of wear-resistant steel

Abstract

A kind of harmful gas detection and control device in wear-resistant steel smelting process, it is characterized in that, including detection subsystem and control subsystem;Detection subsystem includes: preprocessing unit, for extracting representative gas sample from complex, harsh smelting field environment;Calibration unit, realizes the round robin detection of multiple monitoring points;Data processing unit, for according to the data generated by core analysis unit, preliminary calculation, check and format;Communication unit, for the data exchange between detection subsystem and control subsystem, ensure the reliable transmission of instruction and data.Control subsystem includes: data receiving unit, hierarchical alarm unit;Actuator linkage unit, by setting the preprocessing unit containing high-temperature filter, dehumidification module and flow regulating valve, significantly reduce the risk of sensor pollution and measurement drift, prolong the service life of equipment, ensure long time continuous stable operation.

Description

Technical Field

[0001] This invention relates to the field of steel smelting, and in particular to a device for detecting and controlling harmful gases during the smelting of wear-resistant steel. Background Technology

[0002] During the smelting of wear-resistant steel, factors such as high-temperature melting, alloy addition, and decomposition of raw material impurities generate a large amount of harmful gases, mainly including carbon monoxide, carbon dioxide, sulfur dioxide, nitrogen oxides, and hydrogen sulfide. These gases not only pose a serious threat to the health of on-site operators but may also cause safety accidents such as poisoning, suffocation, and explosions. Furthermore, if emissions exceed standards, they will pollute the surrounding environment and violate national environmental protection regulations.

[0003] Currently, fixed gas detectors are commonly used in industrial sites to monitor smelting areas, but existing systems have many problems: Poor adaptability to sampling environment: Smelting sites are characterized by high temperature, high dust, and strong corrosion. Traditional sampling probes are prone to clogging and aging, resulting in insufficient representativeness of sample gas and affecting the accuracy of analysis. Weak pre-processing capabilities: Most systems lack effective dehumidification, filtration, and flow stabilization mechanisms, and moisture condensation and particulate matter interference often lead to sensor drift or failure; Calibration relies on manual intervention: Existing equipment often requires manual zero-point and range calibration on a regular basis, which makes it difficult to guarantee measurement accuracy under long-term operation. In particular, in scenarios with multiple monitoring points, maintenance costs are high and response is slow. Simple alarm mechanism: Common systems only set a single alarm threshold, which cannot achieve hierarchical early warning, easily causing false alarms or missed alarms, and lacking the ability to dynamically respond to the evolution of risks; Disconnection between detection and control: Most detection devices only have data acquisition functions and fail to form a closed-loop control system with process equipment or environmental protection facilities. After an anomaly is detected, manual intervention is still required, resulting in slow response and significant safety hazards.

[0004] Although some integrated monitoring systems have attempted to introduce automatic calibration or remote communication functions, there are still obvious shortcomings in terms of stability, intelligence level and system-level collaborative control under complex metallurgical working conditions. For example, CN112858376A is a system that only monitors but does not control. Therefore, there is an urgent need for a comprehensive hazardous gas detection and control system that integrates high-reliability sampling, intelligent analysis, automatic calibration, graded early warning, and execution linkage to meet the dual requirements of safe production and green manufacturing in modern wear-resistant steel production. Summary of the Invention

[0005] To achieve the above objectives, the present invention provides a device for detecting and controlling harmful gases during the smelting process of wear-resistant steel, characterized in that it includes a detection subsystem and a control subsystem: Detection subsystem: The pretreatment unit is used to extract representative gas samples from the complex and harsh smelting environment and purify them to provide the core analysis unit with sample gas that meets the requirements. The calibration unit enables the sequential testing of multiple monitoring points and automatically completes the zero point and range calibration of the instrument, ensuring the accuracy of long-term monitoring. The core analysis unit is used to perform qualitative and quantitative analysis on the sample gas processed by the pretreatment unit, and to accurately measure the concentration of each target gas. The data processing unit is used to perform preliminary calculations, verification, and formatting based on the data generated by the core analysis unit. The communication unit is used for data exchange between the detection subsystem and the control subsystem to ensure reliable transmission of commands and data.

[0006] Control subsystem: A data receiving unit is used to receive and store data sent by the communication unit; The graded alarm unit is signal-connected to the data processing unit and is used to trigger corresponding audible and visual prompts, information prompts, or system interlocking commands based on preset three-level thresholds for early warning, alarm, and high alarm. The actuator linkage unit is signal-connected to the graded alarm unit and is used to automatically adjust the operating parameters of the process equipment or environmental protection equipment related to the wear-resistant steel smelting process according to the system interlock command.

[0007] Furthermore, the pretreatment unit includes a sampling probe, a high-temperature filter, a dehumidification module, and a sample gas delivery pump; wherein, the sampling probe is set at a key position at the gas outlet of the smelting furnace or the flue, and is used to extract the original sample gas in a high-temperature, high-dust environment; the high-temperature filter is used to remove particulate matter from the sample gas, and the dehumidification module is used for condensation and dehydration to prevent moisture from interfering with the analysis results.

[0008] Furthermore, the pretreatment unit also includes a flow regulating valve and a pressure sensor for real-time monitoring and stabilizing the sample gas flow rate and system pressure to ensure consistent sample gas conditions entering the core analysis unit.

[0009] Furthermore, the calibration unit includes a multi-channel solenoid valve group, a standard gas storage tank, a zero gas generator, and an automatic switching controller; the automatic switching controller periodically introduces the sample gas from each monitoring point into the core analysis unit in turn, and automatically switches to zero gas or standard gas at a set time for zero point and range calibration.

[0010] Furthermore, the standard gas storage tank stores gases including CO, CO2, SO2, and NO. xA standard mixed gas of at least one of the following, the concentration of which covers the measurement range of the gas to be tested.

[0011] Furthermore, the core analytical unit employs at least one of non-dispersive infrared absorption technology, electrochemical sensing technology, ultraviolet differential absorption spectroscopy, or laser absorption spectroscopy for the analysis of O2, CO, CO2, SO2, and NO. x Qualitative and quantitative analysis was performed on target harmful gases such as SO2 and H2S. Specifically, differential ultraviolet absorption spectroscopy was used to analyze SO2, non-dispersive infrared absorption technology was used to analyze CO, and electrochemical sensing technology was used to analyze H2S.

[0012] Furthermore, the data processing unit has a built-in microprocessor and is equipped with a data correction algorithm for performing temperature compensation, pressure compensation, and cross-interference correction on the original concentration data, and generating a standard data packet with a timestamp.

[0013] Furthermore, the communication unit supports industrial communication protocols, including RS-485, Modbus TCP / IP, PROFIBUS, or MQTT, to enable bidirectional, real-time, and optionally encrypted transmission between the detection subsystem and the control subsystem.

[0014] Furthermore, the data receiving unit includes a local database server or edge computing device, used for classifying and storing the received data, performing trend analysis, and querying historical data.

[0015] Furthermore, the graded alarm unit is equipped with three threshold levels: Warning level: When the concentration of the target gas reaches 60% to 80% of the safety limit, an audible and visual warning will be triggered; Alarm level: When the safety limit is reached at 80%~100%, a warning will pop up on the operation interface and the event log will be recorded; High alarm level: When the safety limit is exceeded, the system interlock command is activated to cut off the power supply to the relevant equipment or close the feed valve.

[0016] Due to the adoption of the above technical solution, the technical progress achieved by this invention is as follows: 1. By setting up a pretreatment unit that includes a high-temperature filter, a dehumidification module, and a flow regulating valve, it can effectively remove particulate matter and moisture in harsh environments with high temperature, high dust, and high humidity, and stabilize the sample flow rate and pressure, significantly reducing the risk of sensor contamination and measurement drift, extending the service life of the equipment, and ensuring long-term continuous and stable operation.

[0017] 2. An independent calibration unit is set up, which uses a multi-channel solenoid valve group and an automatic switching controller to periodically import the sample gas from multiple monitoring points into the core analysis unit in turn, and automatically switches to zero gas or standard gas for zero point and range calibration. The accuracy and traceability of long-term monitoring can be guaranteed without manual intervention, which greatly improves operation and maintenance efficiency.

[0018] 3. The graded alarm unit is equipped with a three-level response mechanism of early warning, alarm, and high alarm. Based on the trend of gas concentration change, it triggers audible and visual prompts, information warnings, or system interlock commands in stages to avoid misoperation caused by "one-size-fits-all" alarms and realize progressive management of safety risks and scientific decision support. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying 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.

[0020] Figure 1 This is a schematic diagram illustrating the data exchange between the detection subsystem and the control subsystem of the present invention; Figure 2 This is a schematic diagram of the preprocessing unit according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the calibration unit according to an embodiment of the present invention; Detailed Implementation The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, in the following description, specific details such as particular system structures and technologies are set forth for illustrative purposes rather than for limiting purposes, in order to provide a thorough understanding of the embodiments of the present invention. However, those skilled in the art should understand that the present invention can also be implemented in other embodiments without these specific details. In other cases, detailed descriptions of well-known systems, devices, circuits, and methods are omitted so as not to obscure the description of the present invention with unnecessary details.

[0021] Example 1 According to the instruction manual Figure 1 It can be seen that this embodiment is an embodiment of a device for detecting and controlling harmful gases during the smelting process of wear-resistant steel, specifically as follows: This invention provides a device for detecting and controlling harmful gases during the smelting of wear-resistant steel, characterized by comprising a detection subsystem and a control subsystem: Detection subsystem: The pretreatment unit is used to extract representative gas samples from the complex and harsh smelting environment and purify them to provide the core analysis unit with qualified sample gas. The pretreatment unit includes a sampling probe, a high-temperature filter, a dehumidification module, and a sample gas delivery pump. The sampling probe is set at a key location at the gas outlet of the smelting furnace or in the flue to extract raw sample gas in a high-temperature, high-dust environment. The high-temperature filter is used to remove particulate matter from the sample gas, and the dehumidification module is used for condensation and dehydration to prevent moisture from interfering with the analysis results. The pretreatment unit also includes a flow regulating valve and a pressure sensor to monitor and stabilize the sample gas flow rate and system pressure in real time to ensure that the sample gas conditions entering the core analysis unit are consistent.

[0022] The calibration unit enables alternating detection of multiple monitoring points and automatically completes the instrument's zero-point and range calibration, ensuring long-term monitoring accuracy. The calibration unit includes a multi-way solenoid valve assembly, a standard gas storage tank, a zero gas generator, and an automatic switching controller. The automatic switching controller periodically imports sample gases from each monitoring point into the core analysis unit and automatically switches to zero gas or standard gas for zero-point and range calibration at set times. The standard gas storage tank stores gases containing CO, CO2, SO2, and NO. x A standard mixed gas of at least one of the following, the concentration of which covers the measurement range of the gas to be tested.

[0023] The core analysis unit is used for qualitative and quantitative analysis of the sample gas after pretreatment, accurately measuring the concentration of each target gas. The core analysis unit employs at least one of non-dispersive infrared absorption technology, electrochemical sensing technology, ultraviolet differential absorption spectroscopy, or laser absorption spectroscopy to analyze O2, CO, CO2, SO2, and NO. x Qualitative and quantitative analysis was performed on target harmful gases such as SO2 and H2S. Specifically, differential ultraviolet absorption spectroscopy was used to analyze SO2, non-dispersive infrared absorption technology was used to analyze CO, and electrochemical sensing technology was used to analyze H2S.

[0024] The data processing unit is used to perform preliminary calculations, verification, and formatting based on the data generated by the core analysis unit. The data processing unit has a built-in microprocessor and is equipped with a data correction algorithm to perform temperature compensation, pressure compensation, and cross-interference correction on the raw concentration data, and to generate a standard data packet with a timestamp.

[0025] The communication unit is used for data exchange between the detection subsystem and the control subsystem, ensuring reliable transmission of commands and data. The communication unit supports industrial communication protocols, including RS-485, Modbus TCP / IP, PROFIBUS, or MQTT, to achieve bidirectional, real-time, and optionally encrypted transmission between the detection and control subsystems.

[0026] Control subsystem: The data receiving unit is used to receive and store data sent by the communication unit; the data receiving unit includes a local database server or edge computing device, which is used to classify and store the received data, perform trend analysis, and perform historical queries.

[0027] The tiered alarm unit, connected to the data processing unit, is used to trigger corresponding audible and visual alerts, information prompts, or system interlock commands based on preset three-level thresholds: early warning, alarm, and high-alarm. The tiered alarm unit is equipped with three levels of thresholds: Warning level: When the concentration of the target gas reaches 60% to 80% of the safety limit, an audible and visual warning will be triggered; Alarm level: When the safety limit is reached at 80%~100%, a warning will pop up on the operation interface and the event log will be recorded; High alarm level: When the safety limit is exceeded, the system interlock command is activated to cut off the power supply to the relevant equipment or close the feed valve.

[0028] The actuator linkage unit is connected to the graded alarm unit and is used to automatically adjust the operating parameters of process equipment or environmental protection equipment related to the wear-resistant steel smelting process according to the system interlocking command.

[0029] The overall effect achieved in Example 1 is as follows: Overcoming the shortcomings of traditional gas monitoring systems, such as poor adaptability under complex working conditions, low degree of automation, and control disconnect, this solution provides a high-precision, high-reliability, and intelligent comprehensive management and control solution for hazardous gases, which is of great significance for protecting worker health, preventing safety accidents, and achieving green and low-carbon smelting.

[0030] Example 2 According to the instruction manual Figure 2 As can be seen, this embodiment details how the pretreatment unit in this invention achieves efficient sample gas collection and purification under extremely harsh wear-resistant steel smelting conditions, ensuring the long-term stable operation of the core analysis unit.

[0031] A large-scale special steel enterprise uses a 100-ton ultra-high power electric arc furnace to produce high-manganese and high-chromium wear-resistant steel plates. The smelting process involves the melting and alloying of large quantities of scrap steel, resulting in complex flue gas composition, temperatures reaching 280-350℃, and dust concentrations as high as 68g / m³, containing significant amounts of water vapor and corrosive gases. Under these conditions, traditional gas detection systems commonly face problems such as sampling probe clogging, condensation buildup, and sensor poisoning, leading to a mean time between failures (MTBF) of less than 15 days, severely impacting monitoring continuity and data reliability.

[0032] To address the aforementioned problems, the device of the present invention is equipped with a highly integrated preprocessing unit, comprising the following key components: High-temperature resistant sampling probe: A ceramic sintered filter probe is selected and installed 2 meters downstream of the bend in the fourth flue of the electric arc furnace. The flue gas flow field at this location is relatively stable and representative. The probe has a built-in heating device to maintain the temperature above 180℃, preventing acidic gases from condensing and forming corrosive droplets.

[0033] Multi-stage high-temperature filter: Composed of a cyclone separator and a metal membrane filter. The first-stage cyclone separator removes large particles with a diameter >10μm; the second stage uses a sintered stainless steel filter element, combined with a backflushing cleaning system, to ensure that the pressure drop does not exceed 3kPa, effectively preventing filter element clogging.

[0034] The two-stage dehumidification module consists of two stages: the first stage is a semiconductor condenser that cools the sample gas from 60°C to 15°C, removing most of the moisture; the second stage uses a permeation drying tube, which further lowers the dew point of the sample gas by utilizing the principle of dry air purging. At temperatures below 20°C, the interference of moisture on infrared and electrochemical sensors is completely eliminated.

[0035] Flow and pressure closed-loop control system: The sample gas delivery pump is a corrosion-resistant diaphragm pump, which, together with a mass flow meter and an electric regulating valve, forms a PID feedback loop. The target flow rate is set at 1.5 L / min. When the system detects an increase in upstream resistance, it automatically adjusts the valve opening and increases the pump speed to maintain output flow fluctuations ≤ ±3%. Simultaneously, a pressure sensor monitors the pipeline pressure in real time; if the pressure exceeds a set threshold, an alarm is triggered and the backup bypass channel is activated.

[0036] The entire pretreatment unit is wrapped in a stainless steel insulation layer to adapt to the site conditions. It has an ambient temperature range of 10~50℃ and is equipped with explosion-proof rating Ex d IIB T4 certification, meeting the safety requirements of metallurgical plant areas.

[0037] After 90 days of continuous operation in actual testing: No zero-point drift or slow response occurred in the core analysis unit due to sample gas contamination; The average lifespan of the sensor has been extended to 18 months, nearly double the original 8-10 months; The effective data collection rate increased from 78% to 99.1%; The maintenance frequency has been reduced from once a week to once every two months.

[0038] In addition, during a sudden operation, the dust concentration spiked to 12 g / m³ due to impurities in the raw materials. The system was still able to maintain normal sampling, triggering only one automatic backflushing action without causing any interruption.

[0039] The overall effect achieved in Example 2 is as follows: This invention significantly improves the adaptability and reliability of gas detection systems in complex metallurgical environments by constructing a pretreatment unit that integrates high-temperature filtration, deep dehumidification, and intelligent flow stabilization. It solves common problems of traditional equipment such as easy clogging, moisture susceptibility, and frequent maintenance, and achieves truly "intervention-free, long-cycle" continuous monitoring.

[0040] Example 3 According to the instruction manual Figure 3 As can be seen, this embodiment elaborates in detail how the calibration unit in this invention achieves multi-point polling detection and fully automatic instrument calibration, thereby improving measurement accuracy, reducing reliance on manual labor, and ensuring the traceability and compliance of monitoring data.

[0041] A wear-resistant materials manufacturer has three AOD refining production lines for producing Ni-Hard series wear-resistant cast iron parts. Each line has four critical emission points: furnace opening, fume hood, dust collector inlet, and chimney main exhaust outlet, requiring monitoring of a total of 12 independent measuring points. Previously, decentralized gas analyzers were used, requiring dedicated personnel to manually calibrate each device daily with standard gas cylinders. This was not only time-consuming and labor-intensive, with each complete process taking over four hours, but also suffered from problems such as untimely calibration, missing records, and inaccurate standard gas concentrations, making it difficult to meet the requirements of the ISO 14001 environmental management system and the "Technical Specification for Monitoring Exhaust Gas from Stationary Sources".

[0042] To this end, the device of the present invention deploys a centralized calibration unit as the core component of the detection subsystem, which has the following structure and functions: Multi-channel solenoid valve group: adopts 16-channel pneumatic switching valves, of which 12 are connected to the sampling pipelines of each monitoring point, 2 are connected to the standard gas storage tank, 1 is connected to the zero gas generator, and 1 is a backup channel. All valves are uniformly scheduled by the PLC controller, supporting sequential scanning or priority channel jump mode.

[0043] Standard gas storage tank system: Equipped with two high-pressure gas cylinder cabinets, storing standard mixed gases of three concentrations respectively: low concentration: 20% of capacity; medium concentration: 50%; high concentration: 80%, covering CO, CO2, SO2, and NO. x Major pollutants include [list of pollutants]. Each gas cylinder comes with a national Class II standard substance certificate, valid for two years, and the database information is automatically updated upon replacement.

[0044] Zero gas generator: It adopts catalytic oxidation + molecular sieve adsorption technology, using compressed air as raw material to generate pure zero gas with O2<1ppm, CO<0.1ppm, and H2O<1ppm, replacing traditional steel cylinder zero gas, reducing usage costs and improving safety.

[0045] Automatic controller switching: Calibration cycle is set based on a time-driven strategy: The complete process is executed every 6 hours. The sample gas from 12 monitoring points was imported sequentially to complete the basic concentration detection; Switch to zero air and continue to supply air for 2 minutes to complete the zero-point calibration; Three standard gases of different concentrations were introduced to verify the linearity and calculate the slope deviation. If the deviation exceeds ±2%, the calibration coefficient will be automatically corrected and an alarm log will be generated. All operations automatically generate electronic ledgers, including records of the most recent calibration being automatically made up after a communication interruption.

[0046] Operational data shows: A total of 240 automatic calibrations were completed within two consecutive months, with a 100% success rate. The linear correlation coefficient R² for each gas channel is greater than 0.998; Compared to manual calibration, it saves about 80% of labor costs and eliminates human error in recording. When conducting on-site inspections, auditing agencies can quickly retrieve calibration evidence from any time period through historical logs, thus successfully passing environmental protection acceptance.

[0047] The overall effect achieved in Example 3 is as follows: This invention, by setting up an independent and intelligent calibration unit, realizes multi-point alternating detection and fully automatic periodic calibration, breaking through the technical bottleneck of traditional gas monitoring systems that rely on manual maintenance. It not only improves data accuracy and compliance, but also provides a solid data foundation for enterprise digital transformation.

[0048] Example 4 This embodiment describes in detail how the graded alarm unit in this invention implements progressive early warning and intelligent linkage control based on the trend of changes in the concentration of harmful gases, so as to ensure safe production and avoid economic losses caused by unnecessary shutdowns.

[0049] During the production of ZGMn13 wear-resistant cast steel, a special steel plant experienced a large-scale generation of H2S gas under a high-temperature reducing atmosphere due to the presence of recycled slag with a high sulfur content in the raw material warehouse. Initially undetected, the device of this invention quickly detected the increasing concentration and activated a three-level alarm mechanism, successfully preventing a potential poisoning incident.

[0050] The specific response process is as follows: Phase 1: Warning Level Trigger The H2S concentration slowly increased from a background value of <1 mg / m³ to 10.5 mg / m³; The system has determined that the alert level has been reached and will immediately execute the following actions: The detection subsystem's audible and visual warning light started flashing yellow; A yellow pop-up window appeared on the control room terminal: "H2S concentration is abnormal. Please check the feeding system and raw material drying status." The data processing unit marks the current batch as "key focus" and pushes the trend chart to the squad leader's mobile app; It does not affect normal production, but this incident is recorded for future reference.

[0051] At this point, the operator's initial inspection revealed that there might be damp material on the feeding conveyor belt, but no forceful measures were taken.

[0052] Second stage: Five minutes after the alarm was triggered, the H2S concentration continued to climb to 13.8 mg / m³, reaching 92% of the limit; The system has been upgraded to "Alarm Level" and the following enhanced response has been implemented: The yellow light turns into a solid red light, and the buzzer emits an intermittent alarm sound. A red full-screen warning popped up on the control panel: "H2S concentration is approaching the safety limit! It is recommended to stop feeding and increase ventilation." Automatically sends SMS and WeChat notifications to the workshop director and the person in charge of the safety and environmental protection department; Record the event log, retrieve the on-site camera footage, and initiate video linkage; At the same time, the auxiliary fan frequency converter is activated and adjusted to 70% to enhance the local exhaust capacity.

[0053] At this time, the on-duty engineer rushed to the scene, confirmed that the problem was caused by wet material, and prepared to intervene manually.

[0054] Phase 3: Two minutes after the high alert level was triggered, the concentration suddenly increased to 16.3 mg / m³, exceeding the limit by 8.7%, and was determined to be "high alert level". The system immediately activates the system interlock command and automatically performs the following safety protection actions without manual confirmation: Send a DO signal to cut off the power supply to the upstream screw feeder and stop feeding; The PLC is linked to adjust the rooftop emergency fan to its maximum speed to accelerate the dilution of toxic gases; The nitrogen protection system is activated to inject inert gas into the furnace area to suppress further reactions; Lock the access control system in dangerous areas to prevent unauthorized personnel from entering; A voice prompt was broadcast to the entire plant: "H2S levels are too high. Please take precautions."

[0055] The entire response time was less than 3 seconds. Subsequent testing showed that without timely intervention, the concentration was expected to exceed 30 mg / m³ within 8 minutes, sufficient to cause acute poisoning.

[0056] Post-event statistics show that: This incident averted a potential occupational health accident; Production was interrupted for only 22 minutes, far less than the average downtime under the traditional "one overload, one stop" model; The alarm mechanism is scientific and reasonable, which not only ensures the bottom line of safety, but also minimizes the production capacity loss caused by malfunctions.

[0057] The overall effect of Example 4 is as follows: By setting up a three-level response mechanism of early warning, alarm, and high-risk reporting, a dynamic safety management model based on risk evolution is constructed, realizing the transformation from "passive response" to "proactive prevention and control." This mechanism can not only effectively prevent safety accidents, but also optimize emergency decision-making paths, taking into account both safety and production goals, and has significant social and economic benefits.

[0058] 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 the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. A device for detecting and controlling harmful gases during the smelting of wear-resistant steel, characterized in that, Includes a detection subsystem and a control subsystem: Detection subsystem: The pretreatment unit is used to extract representative gas samples from the complex and harsh smelting environment and purify them to provide sample gases that meet the requirements. The calibration unit enables the sequential testing of multiple monitoring points and automatically completes the zero point and range calibration of the instrument, ensuring the accuracy of long-term monitoring. The core analysis unit is used to perform qualitative and quantitative analysis on the sample gas processed by the pretreatment unit, and to accurately measure the concentration of each target gas. The data processing unit is used to perform preliminary calculations, verification, and formatting based on the data generated by the core analysis unit. The communication unit is used for data exchange between the detection subsystem and the control subsystem to ensure reliable transmission of commands and data. Control subsystem: A data receiving unit is used to receive and store data sent by the communication unit; The graded alarm unit is signal-connected to the data processing unit and is used to trigger corresponding audible and visual prompts, information prompts, or system interlock commands based on preset three-level thresholds. The actuator linkage unit is signal-connected to the graded alarm unit and is used to automatically adjust the operating parameters of the process equipment or environmental protection equipment related to the wear-resistant steel smelting process according to the system interlock command.

2. The device for detecting and controlling harmful gases during the smelting process of wear-resistant steel according to claim 1, characterized in that, The pretreatment unit includes a sampling probe, a high-temperature filter, a dehumidification module, and a sample gas delivery pump. The sampling probe is located at a key position in the gas outlet or flue of the smelting furnace to extract raw sample gas in a high-temperature, high-dust environment. The high-temperature filter is used to remove particulate matter from the sample gas, and the dehumidification module is used for condensation and dehydration to prevent moisture from interfering with the analysis results.

3. The device for detecting and controlling harmful gases during the smelting process of wear-resistant steel according to claim 2, characterized in that, The pretreatment unit also includes a flow regulating valve and a pressure sensor, which are used to monitor and stabilize the sample gas flow rate and system pressure in real time to ensure that the sample gas conditions entering the core analysis unit are consistent.

4. The device for detecting and controlling harmful gases during the smelting process of wear-resistant steel according to claim 1, characterized in that, The calibration unit includes a multi-channel solenoid valve group, a standard gas storage tank, a zero gas generator, and an automatic switching controller. The automatic switching controller periodically imports the sample gas from each monitoring point into the core analysis unit in turn, and automatically switches to zero gas or standard gas at a set time for zero point and range calibration.

5. The device for detecting and controlling harmful gases during the smelting process of wear-resistant steel according to claim 4, characterized in that, The standard gas storage tank contains CO, CO2, SO2, and NO. x A standard mixed gas of at least one of the following, the concentration of which covers the measurement range of the gas to be tested.

6. The device for detecting and controlling harmful gases during the smelting process of wear-resistant steel according to claim 1, characterized in that, The core analytical unit employs at least one of non-dispersive infrared absorption technology, electrochemical sensing technology, ultraviolet differential absorption spectroscopy, or laser absorption spectroscopy for the analysis of O2, CO, CO2, SO2, and NO. x Qualitative and quantitative analysis was performed on target harmful gases such as SO2 and H2S. Specifically, differential ultraviolet absorption spectroscopy was used to analyze SO2, non-dispersive infrared absorption technology was used to analyze CO, and electrochemical sensing technology was used to analyze H2S.

7. The device for detecting and controlling harmful gases during the smelting process of wear-resistant steel according to claim 1, characterized in that, The data processing unit has a built-in microprocessor and is equipped with a data correction algorithm to perform temperature compensation, pressure compensation, and cross-interference correction on the original concentration data, and to generate a standard data packet with a timestamp.

8. The device for detecting and controlling harmful gases during the smelting process of wear-resistant steel according to claim 1, characterized in that, The communication unit supports industrial communication protocols, including RS-485, Modbus TCP / IP, PROFIBUS, or MQTT, to enable bidirectional, real-time, and optionally encrypted transmission between the detection subsystem and the control subsystem.

9. The device for detecting and controlling harmful gases during the smelting process of wear-resistant steel according to claim 1, characterized in that, The data receiving unit includes a local database server or edge computing device, used for classifying and storing the received data, performing trend analysis, and querying historical data.

10. The device for detecting and controlling harmful gases during the smelting process of wear-resistant steel according to claim 1, characterized in that, The graded alarm unit is equipped with three threshold levels: Warning level: When the concentration of the target gas reaches 60% to 80% of the safety limit, an audible and visual warning will be triggered; Alarm level: When the safety limit is reached at 80%~100%, a warning will pop up on the operation interface and the event log will be recorded; High alarm level: When the safety limit is exceeded, the system interlock command is activated to cut off the power supply to the relevant equipment or close the feed valve.

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