Submerged arc furnace electrode depth control system, method, apparatus, and submerged arc furnace

Abstract

This application relates to a control system, method, apparatus, and submerged arc furnace (SAF) electrode depth control system, including: a control module, an electrode holding module, and a data acquisition module; the electrode holding module is used to hold the electrode; the control module is connected to both the data acquisition module and the electrode holding module; the control module is used to control the electrode holding module to perform position initialization processing so that the electrode moves to a preset initial position; a target prediction algorithm is used to process electrode position data and feedback data from an advanced process control system to determine the real-time electrode consumption; based on the preset initial position, the real-time electrode consumption, and the target electrode depth range, the control module dynamically adjusts the electrode position so that the actual electrode depth falls within the target electrode depth range. This application uses a target prediction algorithm to predict electrode consumption in real time, enabling accurate calculation of the electrode's real-time furnace entry depth, solving the problems of low accuracy and large lag in traditional manual judgment, and effectively improving the smelting efficiency of the SAF.

Description

Technical Field

[0001] This application relates to the field of industrial silicon production process optimization technology, and in particular to a submerged arc furnace electrode depth control system, method, apparatus and submerged arc furnace equipment. Background Technology

[0002] The core equipment for industrial silicon smelting is the submerged arc furnace, and the electrode insertion depth directly determines the temperature field distribution, reaction uniformity, and production safety within the furnace. Excessive electrode insertion can lead to furnace bottom overheating, refractory material erosion, gas channel blockage, sparking, charge crusting, and poor tapping. Insufficient electrode insertion results in heat loss, increased electricity consumption per ton of silicon, incomplete reduction, decreased yield, electrode oxidation and breakage, and deterioration of furnace conditions.

[0003] Traditional methods rely on operators' experience and visual judgment to determine electrode depth, which suffers from significant time lag, low accuracy, and large deviations. This makes it difficult to achieve precise and controllable smelting and can easily lead to increased energy consumption, electrode breakage, and furnace condition fluctuations. Therefore, there is an urgent need for a method and system that can predict electrode depth in real time with high accuracy to support the intelligent and stable operation of industrial silicon smelting. Summary of the Invention

[0004] Therefore, it is necessary to provide a submerged arc furnace electrode depth control system, method, apparatus, and submerged arc furnace equipment that can predict electrode depth in real time and with high accuracy, and adaptively and dynamically adjust electrode depth, in order to address the above-mentioned technical problems.

[0005] In a first aspect, this application provides an electrode depth control system for a submerged arc furnace, comprising: a control module, an electrode holding module, and a data acquisition module;

[0006] The electrode holding module is used to hold the electrode and drive the electrode to move in a preset direction according to the control signal of the control module;

[0007] The data acquisition module is used to acquire electrode position data and feedback data from advanced process control systems;

[0008] The control module is connected to the data acquisition module and the electrode holding module respectively. The control module is used to control the electrode holding module to perform position initialization processing so that the electrode moves to the preset initial position. The target prediction algorithm is used to process the electrode position data and the feedback data of the advanced process control system to determine the real-time consumption of the electrode. Based on the preset initial position, the real-time consumption of the electrode and the target electrode depth range, the control module dynamically adjusts the electrode position so that the actual depth of the electrode is within the target electrode depth range.

[0009] In one embodiment, the electrode position data includes the real-time electrode position, the electrode handover position, the electrode position before pressing and releasing, and the electrode position after pressing and releasing; the advanced process control system feedback data includes the actual C3 value and the preset C3 value; wherein, the C3 value is the Westly factor in the advanced process control system of the electric arc furnace, which is used to reflect the ratio of the total energy input in the furnace to the melting energy of the furnace charge;

[0010] The control module is used to calculate the real-time electrode consumption value based on the real-time electrode position, electrode handover position, electrode position before pressing and releasing, and electrode position after pressing and releasing.

[0011] The empirical average electrode consumption is calculated based on the average electrode consumption within a preset cycle and the preset adjustment coefficient; wherein, the preset adjustment coefficient is calculated based on the actual C3 value, the preset C3 value and the historical electrode consumption value; the historical electrode consumption value is the electrode consumption value of the previous working cycle;

[0012] The real-time consumption of the electrode is determined based on the real-time consumption value of the electrode and the average value of electrode consumption experience.

[0013] In one embodiment, the formula for calculating the preset adjustment coefficient is:

[0014]

[0015] in, The preset adjustment coefficient, The difference between the actual C3 value and the preset C3 value. This represents the historical consumption value of the electrodes.

[0016] In one embodiment, the control module is used to calculate the actual depth of the electrode based on the preset initial position and the real-time consumption of the electrode; when the actual depth of the electrode is less than the target electrode depth range, the control electrode holding module moves the electrode down until the electrode moves to the target value of the target electrode depth range; when the actual depth of the electrode is greater than the target electrode depth range, the control electrode holding module raises the electrode until the electrode moves to the target value of the target electrode depth range.

[0017] In one embodiment, the control module is used to dynamically adjust the alarm when the actual depth of the electrode is equal to the upper or lower limit of the target electrode depth range.

[0018] Secondly, this application also provides a method for controlling the electrode depth of a submerged arc furnace, employing the electrode depth control system of the first aspect, the method comprising:

[0019] The control electrode holding module is initialized to move the electrode to a preset initial position.

[0020] A target prediction algorithm is used to process electrode position data and feedback data from an advanced process control system to determine the real-time consumption of electrodes.

[0021] Based on the preset initial position, real-time electrode consumption, and target electrode depth range, the control electrode holding module dynamically adjusts the electrode position so that the actual electrode depth falls within the target electrode depth range.

[0022] Thirdly, this application also provides a submerged arc furnace electrode depth control device, employing the submerged arc furnace electrode depth control system of the first aspect, the device comprising:

[0023] The initialization module is used to control the electrode holding module to perform position initialization processing so that the electrode moves to the preset initial position;

[0024] The prediction module is used to process electrode position data and feedback data from advanced process control systems using a target prediction algorithm to determine the real-time consumption of electrodes.

[0025] The dynamic adjustment module is used to control the electrode holding module to dynamically adjust the electrode position based on the preset initial position, the real-time consumption of the electrode, and the target electrode depth range, so that the actual depth of the electrode belongs to the target electrode depth range.

[0026] Fourthly, this application also provides a submerged arc furnace device, including the electrode depth control system of the submerged arc furnace of the first aspect.

[0027] Fifthly, this application also provides a computer device, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps of the method for controlling the electrode depth of an electric arc furnace in the first aspect.

[0028] In a sixth aspect, this application also provides a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of the method for controlling the electrode depth of a submerged arc furnace in the first aspect.

[0029] In summary, this application proposes a control system, method, apparatus, and submerged arc furnace (SAF) electrode depth system, comprising: a control module, an electrode holding module, and a data acquisition module; the electrode holding module is used to hold the electrode; the control module is connected to both the data acquisition module and the electrode holding module; the control module is used to control the electrode holding module to perform position initialization processing so that the electrode moves to a preset initial position; a target prediction algorithm is used to process the electrode position data and feedback data from an advanced process control system to determine the real-time electrode consumption; based on the preset initial position, the real-time electrode consumption, and the target electrode depth range, the electrode holding module is controlled to dynamically adjust the electrode position so that the actual electrode depth falls within the target electrode depth range. This application uses a target prediction algorithm to predict electrode consumption in real time, enabling accurate calculation of the electrode's real-time furnace entry depth, solving the problems of low accuracy and large lag in traditional manual judgment, and effectively improving the smelting efficiency of the SAF. Attached Figure Description

[0030] Figure 1 This is a structural block diagram of the electrode depth control system for a submerged arc furnace in one embodiment;

[0031] Figure 2 This is a flowchart illustrating a method for controlling electrode depth in a submerged arc furnace in one embodiment.

[0032] Figure 3 This is a flowchart illustrating the steps of dynamically adjusting the electrode position in one embodiment;

[0033] Figure 4 This is a structural block diagram of an electrode depth control device for a submerged arc furnace in one embodiment.

[0034] Figure 5 This is an internal structural diagram of a computer device in one embodiment.

[0035] Summary of attached image labels:

[0036] Control module-110; Electrode holding module-120; Data acquisition module-130. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0038] In related technologies, industrial silicon submerged arc furnace systems are used to convert electrical energy into heat energy, reducing raw materials such as silica into industrial silicon at high temperatures. The electrode holder, an actuator mounted on top of the furnace, clamps the electrodes and transmits the strong current introduced into the electrodes into the furnace, forming an electric arc to melt the furnace charge. A hydraulic cylinder serves as the power unit for the electrode holder, lifting and pressing the electrodes via hydraulic transmission.

[0039] The current challenge in high-temperature submerged arc furnace tapping processes lies in controlling electrode depth. Inserting the electrode too deeply or too shallowly can trigger a series of chain reactions, severely impacting production efficiency, product quality, and equipment safety. When the electrode is inserted too deeply, the arc energy is concentrated excessively at the bottom of the charge, easily disrupting the thermodynamic and chemical equilibrium within the furnace. Excessive bottom temperature and insufficient surface temperature cause the arc to burn violently at the electrode tip, leading to an abnormally high bottom temperature. Meanwhile, the charge surface, lacking sufficient heat, becomes dark, crusted, and sticky, hindering effective preheating and reaction. Furthermore, the large amount of high-temperature gas generated in the lower high-temperature zone needs to escape, but the upper charge, due to its lower temperature, hardens and crusts, blocking gas channels. Once the gas accumulates to a certain level, it breaks through the crust and erupts, creating a violent burst. After this burst, the cold charge at the top collapses. Excessively high bottom temperatures severely erode and corrode the carbonaceous refractory material at the bottom of the furnace, potentially causing the electrode to directly contact the carbon bricks and resulting in abnormal carbon brick burnout. Because the reaction zone is concentrated deep inside, the molten silicon accumulates at the bottom of the furnace hearth. When the furnace is being tapped, the cold material at the top will block the channels, causing the tapping process to be unsmooth.

[0040] When the electrode is inserted too shallowly into the furnace charge, the electrode arc is easily exposed on the surface of the charge or near the furnace opening, causing a large amount of heat to be directly dissipated into the environment. This leads to a significant increase in the electricity consumption for producing one ton of industrial silicon, substantially increasing production costs. Furthermore, the high-temperature zone is concentrated in the upper part of the charge, preventing the lower charge from being fully preheated and melted. This results in incomplete silicon reduction, increased unreacted quartz and carbonaceous reducing agent residues, directly reducing industrial silicon yield. The top of the electrode is exposed to the high-temperature oxidizing environment of the furnace opening, causing the graphite electrode surface to oxidize due to oxygen in the air, leading to electrode breakage or accelerated consumption. The rapid melting of the upper charge at high temperatures forms a hard shell, hindering the replenishment of the reaction zone from the lower charge, resulting in insufficient material in the reaction zone and ultimately deteriorating furnace conditions.

[0041] In summary, there is an urgent need for a submerged arc furnace electrode depth control scheme that can adaptively adjust the electrode insertion depth in the submerged arc furnace without relying on human experience, maintain the ideal state of high temperature, arc closure, and melting in the industrial silicon electric furnace, and provide adaptive early warning adjustment.

[0042] In one embodiment, such as Figure 1As shown, a deep electrode control system for a submerged arc furnace is provided, comprising: a control module 110, an electrode holding module 120, and a data acquisition module 130.

[0043] In this embodiment, the electrode holding module 120 is used to clamp the electrode and move it along a preset direction according to the control signal from the control module 110. Specifically, the electrode holding module 120 includes a holding cylinder, an electrode lifting device, a guide device, a conductive system, and a hydraulic pressing and releasing system. The holding cylinder is divided into an upper holding cylinder and a lower holding cylinder, used for suspending and fixing components such as copper tiles, pressure rings, and protective screens. The electrode lifting device consists of a suspended or plunger-type hydraulic cylinder, fixed to the platform steel frame, responsible for driving the entire holding device and electrode to move up and down to adjust the arc length. In practical applications, the electrode lifting device can also be called a high-pressure cylinder. The guide device is located between the holding device and the furnace cover / platform, and can be made of non-magnetic steel to ensure the electrode remains vertical during lifting and preventing skewing.

[0044] In this embodiment, movement in the preset direction refers to vertical movement (up and down). The conductive system transmits current from the transformer to the electrode. The hydraulic release system enables voltage release of the electrode, i.e., pushing the electrode downwards without disconnecting the power supply. Specifically, the hydraulic release system includes an electrode brake and a release cylinder. The electrode brake is divided into an upper brake and a lower brake. During normal smelting, the lower brake always holds the electrode tightly. During release, the upper and lower brakes work together to alternately release and clamp, completing the release action. The release cylinder is linked to the brake and is used to push the electrode downwards a predetermined distance when the brake is released.

[0045] It should be noted that the actual structural composition of the electrode holding module 120 can be determined according to the needs of the actual application scenario, and this embodiment does not limit the actual structure of the electrode holding module 120. For example, in actual application scenarios, the electrode holding module 120 also includes a corresponding cooling system and an insulation system. The cooling system is used to cool the high-temperature components to maintain a stable operating temperature. The insulation system is used to install corresponding high-temperature resistant insulating components between the upper and lower parts of the electrode holder, and between each conductive component and the grounded furnace steel structure, to prevent current short circuits.

[0046] In this embodiment, the data acquisition module 130 is used to acquire electrode position data and feedback data from the advanced process control system. Specifically, the data acquisition module 130 is connected to both the distributed control system (DCS) and the advanced process control (APC) system of the submerged arc furnace, and is used to periodically acquire furnace condition data from both the DCS and APC systems. It should be noted that the acquisition cycle can be configured according to the needs of the actual application scenario; for example, the data acquisition module 130 can be configured to acquire data once every 1 second. In actual application scenarios, the acquisition frequency is adjusted according to the real-time furnace condition requirements.

[0047] The furnace condition data of the DCS system includes set electrode position data, pressure and temperature data from the hydraulic pressure-releasing system, and data collected by various field sensors. For example, the DCS system integrates a corresponding laser rangefinder to obtain the distance from the furnace edge to the bottom ring of the electrode in real time, thus obtaining real-time electrode position data. Corresponding displacement sensors can also be installed on the electrode holder and / or the high-pressure cylinder to obtain the movement distance of the electrode holder and the high-pressure cylinder during operation. It should be noted that the actual structural composition of the data acquisition module 130 in this embodiment can also be configured according to the needs of the actual application scenario to ensure that the data acquisition module 130 can effectively acquire the various data required for subsequent position initialization processing and the running of the target prediction algorithm.

[0048] In this embodiment, the control module 110 is connected to both the data acquisition module 130 and the electrode holding module 120. The control module 110 is connected to the data acquisition module 130 to acquire furnace condition data such as electrode position data and feedback data from the advanced process control system. The control module 110 is connected to the electrode holding module 120 to dynamically adjust the electrode position according to the predicted electrode depth, ensuring that the actual electrode depth falls within the target electrode depth range.

[0049] The control module 110 is used to control the electrode holding module 120 to perform position initialization processing so that the electrode moves to a preset initial position; the target prediction algorithm is used to process the electrode position data and the feedback data of the advanced process control system to determine the real-time consumption of the electrode; based on the preset initial position, the real-time consumption of the electrode and the target electrode depth range, the control module 120 dynamically adjusts the electrode position so that the actual depth of the electrode belongs to the target electrode depth range.

[0050] In this embodiment, after the electric arc furnace starts working, the control module 110 controls the electrode holding module 120 to perform position initialization processing. Position initialization processing is divided into two operating conditions: normal operating condition and electrode cross-section operating condition. Under normal operating condition, the electrode has not broken, and there is no cross-section at the bottom of the electrode. At this time, the control module 120 moves the electrode downwards to the bottom of the furnace, and then raises it by a preset distance to move the electrode to a preset initial position. In a feasible embodiment, under normal operating condition, the control module 110 can also control the electrode holding module 120 to first move to a first position, where the bottom of the electrode is flush with the material surface inside the electric arc furnace, and then control the electrode holding module 120 to move downwards to a second position. The distance difference between the first and second positions is the depth corresponding to the preset initial position. For example, for a 33,000 kW (kVA) submerged arc furnace, the furnace height is 3,300 mm, and the preset initial position is 2,800 mm deep. Under normal operating conditions, the control module 110 can control the electrode holding module 120 to move the electrode downward to the bottom of the furnace and then raise it 500 mm to complete the electrode position initialization. Alternatively, the control module 120 can be controlled to move the electrode downward from the first position 2,800 mm to the second position.

[0051] It should be noted that the first position can also be set as the furnace surface position according to the actual structural composition of the electric arc furnace, so as to ensure that the distance from the first position to the furnace bottom is equal to the furnace height.

[0052] In the electrode cross-section condition, if the electrode breaks and a cross-section appears at the bottom, the electrode length changes abruptly. When the control module 110 initializes the electrode holding module 120, it must first move the electrode holding module 120 to the third position, where the bottom of the electrode cross-section is flush with the material surface inside the submerged arc furnace. Then, it controls the electrode holding module 120 to move downwards to the fourth position. The distance difference between the third and fourth positions is the depth corresponding to the preset initial position. Alternatively, the control module 110 can first control the electrode holding module 120 to move the electrode downwards until the cross-section contacts the furnace bottom, and then raise it upwards a preset distance until the electrode cross-section is at the preset initial position.

[0053] In one embodiment, the control module 110 monitors whether the electrode has a cross-section. If a cross-section occurs, the control electrode holding module 120 performs position initialization processing under the cross-section condition to move the electrode cross-section to a preset initial position. In practical applications, the control module 110 can monitor the current, voltage, active power, and displacement feedback of the three-phase electrodes in real time. If the system detects that the electrode has not received a pressing command, but the position sensor detects a sudden and significant drop in the electrode bottom ring, or a violent fluctuation in current, it determines that a cross-section condition has occurred.

[0054] In this embodiment, after the control module 110 controls the electrode holding module 120 to perform position initialization processing, it can obtain the electrode position data and advanced process control system feedback data collected in real time by the data acquisition module 130, and calculate and determine the real-time consumption of the electrode through the target prediction algorithm. The actual position of the current electrode is estimated by the preset initial position and the real-time consumption of the electrode.

[0055] In one embodiment, the electrode position data includes the real-time electrode position, the electrode handover position, the electrode position before pressing and releasing, and the electrode position after pressing and releasing. The advanced process control system feedback data includes the actual C3 value and the preset C3 value. The electrode holding module 120 movement data includes the movement data of the high-pressure cylinder.

[0056] In this embodiment, the C3 value refers to the Westly factor in the APC system of industrial silicon smelting. The Westly factor is a key process parameter used to describe the energy distribution and operating status of the submerged arc furnace. It reflects the ratio of total energy input in the furnace to the energy used for melting the charge and is an important indicator for measuring furnace stability and operating efficiency. The C3 value reflects the degree of matching between the operating resistance and the charge resistance. The specific calculation formula is as follows:

[0057]

[0058] in, The value is C3. For electric furnace load, This represents the amount of energy generated in the furnace charge.

[0059] The control module 110 calculates the real-time electrode consumption value based on the real-time electrode position, the electrode handover position, the electrode position before pressing, and the electrode position after pressing. Specifically, the real-time electrode position refers to the distance from the furnace edge to the bottom ring of the electrode, which is obtained in real time by a laser rangefinder installed on the furnace edge, i.e., the real-time depth of the electrode. The electrode handover position refers to the real-time electrode position recorded during the shift handover process. The electrode positions before and after pressing refer to the real-time electrode positions before and after pressing. The pressing amount refers to the difference between the electrode positions before and after pressing. It should be noted that within a shift, the pressing amount is accumulated based on the number of pressing operations performed, and the pressing amount is refreshed after the shift change and re-counted within a single shift.

[0060] Specifically, the formula for calculating the real-time consumption value of the electrode is as follows:

[0061]

[0062] in, This represents the real-time consumption value of the electrode. For the real-time position of the electrode, This is the electrode handover location. For the amount of pressure release, ,in, This is the electrode position before pressing and releasing. Electrode position after pressing and releasing.

[0063] The empirical average electrode consumption is calculated based on the average electrode consumption within a preset cycle and the preset adjustment coefficient. The preset adjustment coefficient is calculated based on the actual C3 value, the preset C3 value, and the historical electrode consumption value. The historical electrode consumption value is the electrode consumption value of the previous working cycle.

[0064] In this embodiment, the formula for calculating the preset adjustment coefficient is:

[0065]

[0066] in, The preset adjustment coefficient, The difference between the actual C3 value and the preset C3 value. This refers to the historical electrode consumption value. In this embodiment, the historical electrode consumption value refers to the electrode consumption value of the previous shift. It equals the actual C3 value minus the preset C3 value. The C3 feedback value is used to compare the actual C3 value with the preset C3 value in real time to determine whether the current heat distribution in the furnace conforms to the optimal model set by the process. If the C3 feedback value is greater than 0, it indicates that the operating resistance in the furnace is too high. If the C3 feedback value is less than 0, it indicates that the operating resistance in the furnace is too low.

[0067] The formula for calculating the empirical average of electrode consumption is:

[0068]

[0069] in, This represents the empirical average value of electrode consumption. The average electrode consumption within a preset period. This is the preset adjustment coefficient. It should be noted that the average electrode consumption within the preset period can be the average electrode consumption of all shifts within a month, for example, the average electrode consumption of 84 shifts over 28 days.

[0070] The real-time consumption of the electrode is determined based on the real-time consumption value of the electrode and the average value of electrode consumption experience.

[0071] In this embodiment, the formula for calculating the real-time consumption of the electrode is:

[0072]

[0073] in, This represents the real-time consumption of the electrodes. This represents the real-time consumption value of the electrode. This represents the empirical average value of electrode consumption.

[0074] In this embodiment, after the prediction calculation of the real-time consumption of the electrode is completed, the electrode holding module 120 can be controlled to dynamically adjust the electrode position based on the preset initial position, the real-time consumption of the electrode, and the target electrode depth range, so that the actual depth of the electrode belongs to the target electrode depth range.

[0075] Specifically, the control module 110 calculates the actual electrode depth based on a preset initial position and the real-time electrode consumption. If the actual electrode depth is less than the target electrode depth range, the control electrode holding module 120 lowers the electrode until it reaches the target value within the target electrode depth range. If the actual electrode depth is greater than the target electrode depth range, the control electrode holding module 120 raises the electrode until it reaches the target value within the target electrode depth range.

[0076] In this embodiment, the formula for calculating the actual depth of the electrode is:

[0077]

[0078] in, This represents the actual depth of the electrode. The initial depth of the electrode corresponding to the preset initial position. This represents the real-time consumption of the electrodes.

[0079] In one embodiment, the initial electrode depth changes accordingly with the pressing and releasing operations of the electrode during the operation of the electric arc furnace. Assuming the preset initial depth for the initial position is 2800 mm, then... It can be 2800mm The distance the hydraulic cylinder moves.

[0080] In this embodiment, the target electrode depth range can be configured according to the actual parameters of the submerged arc furnace in the actual application scenario. For example, for a 33000kVA submerged arc furnace with an internal height of 3300 mm, the target electrode depth range can be set to 2800 mm. 150mm. When the actual electrode depth is less than 2650mm, the control electrode holding module 120 lowers the electrode until it reaches the target value within the target electrode depth range. The target value can be set to 2800mm. When the actual electrode depth is greater than 2950mm, the control electrode holding module 120 raises the electrode until it reaches the target value within the target electrode depth range.

[0081] In this embodiment, the target value can be set as the median value of the target electrode depth range.

[0082] Based on the above steps, this embodiment uses a target prediction algorithm to determine the real-time electrode consumption during the operation of the electric arc furnace, and calculates the actual electrode depth based on a dynamically changing preset initial position. It can automatically predict the actual electrode depth during the operation of the electric arc furnace without relying on human experience. The equipment automatically collects relevant parameters and adaptively makes predictions. Combined with dynamic adjustment of electrode depth, it can keep the electrode within the target electrode depth range for optimal production of the electric arc furnace, thereby effectively improving the production efficiency of the electric arc furnace and avoiding abnormal production or increased production costs caused by electrodes that are too deep or too shallow during the production process.

[0083] In one embodiment, the control module 110 is used to dynamically adjust the alarm when the actual depth of the electrode is equal to the upper or lower limit of the target electrode depth range.

[0084] In this embodiment, the electrode depth control system for the submerged arc furnace further includes a display module and / or an alarm module, and the control module 110 is connected to the display module and / or the alarm module. When the actual electrode depth deviates from the upper or lower limit of the target electrode depth range, or is equal to the upper or lower limit of the target electrode depth range, the control module 110 controls the display module or alarm module to dynamically adjust and alarm, thereby instructing the operator or the automatic control system to control the electrode holding module 120 to perform a downward or upward movement.

[0085] In one specific embodiment, after using the electrode depth control system provided in this embodiment to control the electrode depth on a 33000kVA electric arc furnace, the electrode depth prediction error is ≤10mm, which is significantly improved compared with the traditional experience judgment accuracy. Moreover, the power consumption per ton of silicon is reduced by 3-5%, the electrode breakage accident rate is reduced by 80%, and the furnace condition stabilization cycle is extended to 1.5 times the original, resulting in obvious production improvement and efficiency enhancement effects.

[0086] In summary, this embodiment provides an electrode depth control system for an electric arc furnace. By integrating data from the DCS and APC systems and establishing a coefficient k correction model, it achieves accurate calculation of the electrode's real-time furnace entry depth. During the operation of the electric arc furnace, the system uses a target prediction algorithm to estimate the real-time electrode consumption and predict the actual electrode depth in real time. Combined with adaptive dynamic depth adjustment control, it solves the problems of low accuracy and large lag in traditional manual judgment, thereby achieving the goals of stabilizing furnace conditions, reducing power consumption, reducing electrode accidents, and increasing production efficiency.

[0087] In one embodiment, such as Figure 2 As shown, a method for controlling the electrode depth of a submerged arc furnace is provided, which can be applied to... Figure 1 Taking the control module of the electrode depth control system in a submerged arc furnace as an example, the following steps are included:

[0088] Step 201: Control the electrode holding module to perform position initialization processing so that the electrode moves to a preset initial position.

[0089] Step 202: The target prediction algorithm is used to process the electrode position data and the feedback data from the advanced process control system to determine the real-time consumption of the electrode.

[0090] Step 203: Based on the preset initial position, real-time electrode consumption, and target electrode depth range, control the electrode holding module to dynamically adjust the electrode position so that the actual electrode depth belongs to the target electrode depth range.

[0091] In one embodiment, step 203 includes the following specific steps:

[0092] Step 301: Calculate the actual depth of the electrode based on the preset initial position and the real-time consumption of the electrode.

[0093] Step 302: If the actual depth of the electrode is less than the target electrode depth range, control the electrode holding module to move the electrode down until the electrode moves to the target value of the target electrode depth range.

[0094] Step 303: If the actual depth of the electrode is greater than the target electrode depth range, control the electrode holding module to lift the electrode until the electrode moves to the target value within the target electrode depth range.

[0095] It should be noted that the specific implementation method of the electrode depth control method of the electric arc furnace in this embodiment can be referred to the specific implementation method in the foregoing system embodiment, and will not be repeated here.

[0096] In summary, this embodiment provides a method for controlling electrode depth in a submerged arc furnace. By integrating data from DCS and APC systems, a coefficient k correction model is established to achieve accurate calculation of the electrode's real-time furnace entry depth. During the operation of the submerged arc furnace, the real-time consumption of electrodes is estimated in real time through a target prediction algorithm, and the actual electrode depth is predicted in real time. Combined with adaptive dynamic depth adjustment control, this method solves the problems of low accuracy and large lag in traditional manual judgment, thereby achieving the goals of stabilizing furnace conditions, reducing power consumption, reducing electrode accidents, and increasing production efficiency.

[0097] It should be understood that although the steps in the flowcharts of the embodiments described above are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the embodiments described above may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages of other steps.

[0098] Based on the same inventive concept, this application also provides a submerged arc furnace electrode depth control device for implementing the above-described submerged arc furnace electrode depth control method. The solution provided by this device is similar to the solution described in the above method; therefore, the specific limitations in one or more embodiments of the submerged arc furnace electrode depth control device provided below can be found in the limitations of the submerged arc furnace electrode depth control method described above, and will not be repeated here.

[0099] In one embodiment, such as Figure 4 As shown, a submerged arc furnace electrode depth control device 400 is provided, comprising: an initialization module 410, a prediction module 420, and a dynamic adjustment module 430, wherein:

[0100] The initialization module 410 is used to control the electrode holding module to perform position initialization processing so that the electrode moves to a preset initial position.

[0101] Prediction module 420 is used to process electrode position data and advanced process control system feedback data using a target prediction algorithm to determine the real-time consumption of electrodes;

[0102] The dynamic adjustment module 430 is used to control the electrode holding module to dynamically adjust the electrode position based on the preset initial position, the real-time consumption of the electrode, and the target electrode depth range, so that the actual depth of the electrode belongs to the target electrode depth range.

[0103] In one embodiment, the dynamic adjustment module 430 is further configured to calculate the actual depth of the electrode based on the preset initial position and the real-time consumption of the electrode; when the actual depth of the electrode is less than the target electrode depth range, control the electrode holding module to move the electrode down until the electrode moves to the target value of the target electrode depth range; when the actual depth of the electrode is greater than the target electrode depth range, control the electrode holding module to raise the electrode until the electrode moves to the target value of the target electrode depth range.

[0104] Each module in the aforementioned electrode depth control device for submerged arc furnaces can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in or independent of the processor in a computer device, or stored in the memory of a computer device as software, so that the processor can call and execute the corresponding operations of each module.

[0105] In one embodiment, a submerged arc furnace device is provided, which includes the submerged arc furnace electrode depth control system described in the above system embodiments. It should be noted that the actual structural composition of the submerged arc furnace device can be referred to the specific implementation methods in the foregoing system embodiments, and will not be repeated here.

[0106] In one embodiment, a computer device is provided, which may be a terminal, and its internal structure diagram may be as follows: Figure 5 As shown, the computer device includes a processor, memory, input / output interface, communication interface, display unit, and input device. The processor, memory, and input / output interface are connected via a system bus, and the communication interface, display unit, and input device are also connected to the system bus via the input / output interface. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs stored in the non-volatile storage media. The input / output interface is used for exchanging information between the processor and external devices. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, mobile cellular networks, NFC (Near Field Communication), or other technologies. When executed by the processor, the computer program implements a method for controlling the electrode depth of a submerged arc furnace. The display unit is used to form a visually visible image and can be a display screen, projection device, or virtual reality imaging device. The display screen can be an LCD screen or an e-ink screen. The input device of the computer device can be a touch layer covering the display screen, or buttons, trackballs, or touchpads set on the casing of the computer device, or external keyboards, touchpads, or mice, etc.

[0107] Those skilled in the art will understand that Figure 5 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the computer device to which the present application is applied. Specific computer devices may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0108] In one embodiment, a computer device is provided, including a memory and a processor. The memory stores a computer program, and the processor executes the computer program to implement the specific execution steps of the submerged arc furnace electrode depth control method in the foregoing method embodiments.

[0109] In one embodiment, a computer-readable storage medium is provided, on which a computer program is stored, which, when executed by a processor, implements the specific execution steps of the submerged arc furnace electrode depth control method in the foregoing method embodiments.

[0110] In one embodiment, a computer program product is provided, including a computer program that, when executed by a processor, implements the specific execution steps of the submerged arc furnace electrode depth control method in the foregoing method embodiments.

[0111] Those skilled in the art will understand that all or part of the processes in the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When executed, the computer program can include the processes of the embodiments described above. Any references to memory, databases, or other media used in the embodiments provided in this application can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, optical memory, high-density embedded non-volatile memory, resistive random access memory (ReRAM), magnetic random access memory (MRAM), ferroelectric random access memory (FRAM), phase change memory (PCM), graphene memory, etc. Volatile memory can include random access memory (RAM) or external cache memory, etc. By way of illustration and not limitation, RAM can take many forms, such as Static Random Access Memory (SRAM) or Dynamic Random Access Memory (DRAM). The databases involved in the embodiments provided in this application may include at least one type of relational database and non-relational database. Non-relational databases may include, but are not limited to, blockchain-based distributed databases. The processors involved in the embodiments provided in this application may be general-purpose processors, central processing units, graphics processing units, digital signal processors, programmable logic devices, quantum computing-based data processing logic devices, etc., and are not limited to these.

[0112] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0113] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A depth control system for electrodes in a submerged arc furnace, characterized in that, include: Control module, electrode holding module, and data acquisition module; The electrode holding module is used to hold the electrode and drive the electrode to move along a preset direction according to the control signal of the control module; The data acquisition module is used to acquire electrode position data and feedback data from the advanced process control system. The control module is connected to the data acquisition module and the electrode holding module respectively; The control module is used to control the electrode holding module to perform position initialization processing so that the electrode moves to a preset initial position; to process the electrode position data and the feedback data of the advanced process control system using a target prediction algorithm to determine the real-time consumption of the electrode; and to control the electrode holding module to dynamically adjust the electrode position based on the preset initial position, the real-time consumption of the electrode, and the target electrode depth range so that the actual depth of the electrode belongs to the target electrode depth range.

2. The system according to claim 1, characterized in that, The electrode position data includes real-time electrode position, electrode handover position, electrode position before pressing and releasing, and electrode position after pressing and releasing; the advanced process control system feedback data includes actual C3 value and preset C3 value. The control module is used to calculate the real-time electrode consumption value based on the real-time electrode position, the electrode handover position, the electrode position before pressing and releasing, and the electrode position after pressing and releasing. The empirical average electrode consumption is calculated based on the average electrode consumption within a preset cycle and a preset adjustment coefficient; wherein, the preset adjustment coefficient is calculated based on the actual C3 value, the preset C3 value, and the historical electrode consumption value; the historical electrode consumption value is the electrode consumption value of the previous working cycle; The real-time consumption of the electrode is determined based on the real-time consumption value of the electrode and the average value of the electrode consumption experience.

3. The system according to claim 2, characterized in that, The formula for calculating the preset adjustment coefficient is as follows: in, The preset adjustment coefficient, The difference between the actual C3 value and the preset C3 value. This represents the historical consumption value of the electrodes.

4. The system according to claim 1, characterized in that, The control module is used to calculate the actual depth of the electrode based on the preset initial position and the real-time consumption of the electrode; when the actual depth of the electrode is less than the target electrode depth range, the control module is used to move the electrode downward until the electrode moves to the target value of the target electrode depth range; when the actual depth of the electrode is greater than the target electrode depth range, the control module is used to raise the electrode until the electrode moves to the target value of the target electrode depth range.

5. The system according to claim 4, characterized in that, The control module is used to dynamically adjust the alarm when the actual depth of the electrode is equal to the upper or lower limit of the target electrode depth range.

6. A method for controlling electrode depth in a submerged arc furnace, characterized in that, The method of using the electrode depth control system for a submerged arc furnace according to any one of claims 1-5 includes: The control electrode holding module is initialized to move the electrode to a preset initial position. A target prediction algorithm is used to process electrode position data and feedback data from an advanced process control system to determine the real-time consumption of electrodes. Based on the preset initial position, the real-time consumption of the electrode, and the target electrode depth range, the electrode holding module is controlled to dynamically adjust the electrode position so that the actual depth of the electrode belongs to the target electrode depth range.

7. A device for controlling the electrode depth of a submerged arc furnace, characterized in that, The device employs the electrode depth control system for a submerged arc furnace according to any one of claims 1-5, the device comprising: The initialization module is used to control the electrode holding module to perform position initialization processing so that the electrode moves to the preset initial position; The prediction module is used to process electrode position data and feedback data from advanced process control systems using a target prediction algorithm to determine the real-time consumption of electrodes. The dynamic adjustment module is used to control the electrode holding module to dynamically adjust the electrode position based on the preset initial position, the real-time consumption of the electrode, and the target electrode depth range, so that the actual depth of the electrode belongs to the target electrode depth range.

8. A type of electric arc furnace equipment, characterized in that, Includes the electrode depth control system for submerged arc furnaces as described in any one of claims 1-5.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the electric arc furnace electrode depth control method according to claim 6.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the steps of the method for controlling the electrode depth of a submerged arc furnace as described in claim 6.

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