Online high-pressure gas purging cleaning method for blast furnace taphole clay sleeve

Abstract

This invention belongs to the field of metallurgical equipment technology. It provides a method for online high-pressure gas purging and cleaning of the blast furnace taphole mud jacket, comprising: Step S1: fabricating an online cleaning tool for the mud jacket, the tool including a height-adjustable bracket, a hollow universal ball mounted on the top of the bracket, at least two interchangeable cleaning nozzles, and a high-pressure gas pipe with a length of not less than 3m; connecting the tail end of the high-pressure gas pipe to a high-pressure gas source via a pressure regulating valve, a pressure gauge, and a filter dryer. By fabricating an online cleaning tool integrating an adjustable bracket, a hollow universal ball, a rotating jet linear nozzle and an adjustable fan-shaped nozzle, and a long-distance lightweight composite heat-insulated gas pipe, combined with an interference identification and adaptive compensation suppression method based on multi-parameter sensing of jet morphology, pressure fluctuation, temperature gradient, and oxygen concentration, the method achieves automatic classification and targeted suppression of complex interferences such as transverse airflow, turbulent breakup, thermal convection, and oxidizing atmosphere in front of the taphole.

Description

Technical Field

[0001] This invention belongs to the field of metallurgical equipment technology, specifically a method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket. Background Technology

[0002] During blast furnace production, molten slag and iron inside the furnace need to be periodically discharged from the taphole. The outermost structure of the taphole is called the taphole "mud sleeve". After the molten slag and iron inside the furnace has been discharged, mud guns are used to drive the mud into the taphole to achieve sealing, i.e., "plugging". In this process, the "mud sleeve" is the key contact surface between the taphole and the mud gun. Its integrity and contact quality are directly related to the plugging effect and the long-term stability of the taphole. If the mud sleeve is in poor condition, it is very easy to cause production safety accidents.

[0003] In the actual operation of slag and iron discharge, liquid slag and iron often accumulate on the surface of the taphole mud jacket. If it is not cleaned in time, it will seriously affect the reliability of the mud gun plugging operation. The traditional cleaning method mainly relies on the furnace front workers to hold high-pressure compressed air pipes and directly blow the mud jacket. This operation method is not only labor-intensive and has a high risk factor, but also requires workers to wear heavy heat-insulating protective clothing and rely on the cooperation of many people, which is inefficient and poses a great safety hazard.

[0004] Therefore, the present invention provides a method for online high-pressure gas purging and cleaning of the blast furnace taphole mud jacket. Summary of the Invention

[0005] In order to overcome the shortcomings of the prior art, at least one technical problem raised in the background art is solved.

[0006] The technical solution adopted by this invention to solve its technical problem is: a method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket, comprising the following steps:

[0007] Step S1: Construct a tool for online mud cleaning sleeve. The tool includes a height-adjustable bracket, a hollow universal ball joint mounted on the top of the bracket, at least two interchangeable cleaning nozzles, and a high-pressure air hose with a length of not less than 3m. Connect the tail end of the high-pressure air hose to a high-pressure air source through a pressure regulating valve, a pressure gauge, and a filter dryer. Connect the self-locking quick connector at the head of the high-pressure air hose to the air inlet of the universal ball joint, and install the selected nozzle to the air outlet of the universal ball joint through a quick-change connector.

[0008] Step S2: During the blast furnace slag and iron discharge process, interference identification and optimized purging and cleaning of the taphole mud sleeve are performed based on the aforementioned tool, including the following sub-steps:

[0009] Step S201: Obtain the morphological parameters of the nozzle outlet jet and the characteristics of the air pressure fluctuation, and combine them with the residual distribution on the surface of the mud jacket after cleaning to determine whether there is a jet interference type caused by the airflow or thermal effect in front of the taphole.

[0010] Step S202: Based on the determined jet interference type, select and implement compensation and suppression measures, and adjust the support positioning, execution end configuration, delivery pipeline characteristics and power source operating conditions accordingly.

[0011] Step S203: Perform dynamic purging operation based on the adjusted state, and dynamically maintain or correct compensation and inhibition measures according to the real-time monitored jet morphology and mud jacket surface cleanliness during the purging process.

[0012] Step S204: After the purging operation is completed, obtain the final cleanliness of the mud jacket surface and assess whether it meets the set requirements. If it does not meet the set requirements, re-execute compensation and inhibition measures based on the residual characteristics of the non-compliant area until the cleanliness meets the requirements.

[0013] The beneficial effects of this invention are as follows:

[0014] This invention creates an online cleaning tool that integrates an adjustable bracket, a hollow universal ball, a rotating jet linear nozzle and an adjustable fan-shaped nozzle, and a long-distance lightweight composite heat-insulating air pipe. Combined with an interference identification and adaptive compensation suppression method based on multiple parameters such as jet morphology, pressure fluctuation, temperature gradient and oxygen concentration, it achieves automatic classification and targeted suppression of complex interferences such as transverse airflow, turbulent breakup, thermal convection and oxidizing atmosphere in front of the taphole.

[0015] This invention employs pulse purging, dynamic fine-tuning, image segmentation evaluation, and closed-loop feedback learning mechanisms to improve the accuracy and cleanliness of mud jacket cleaning, reduce the safety risks and labor intensity of operators, and extend the service life of the mud jacket. It has outstanding effects of high automation, strong adaptability, safety and reliability, and easy promotion. Attached Figure Description

[0016] The invention will now be further described with reference to the accompanying drawings.

[0017] Figure 1 This is a flowchart of the steps in an embodiment of the present invention. Detailed Implementation

[0018] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0019] Example

[0020] Please see Figure 1As shown in the embodiment of the present invention, a method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket includes the following steps:

[0021] Step S1: Clean by blowing away mud using a tool made with an online cleaning sleeve;

[0022] Specifically, the tool for online mud cleaning includes: preparing a height-adjustable bracket, with a hollow universal ball installed at the top of the bracket, and leveling casters and a locking mechanism at the bottom of the bracket;

[0023] Based on the air outlet pipe interface size of the omnidirectional ball, at least two interchangeable cleaning nozzles are prepared;

[0024] Based on the size of the air inlet pipe interface of the omnidirectional ball and the air pressure range required for cleaning the nozzle, a high-pressure air pipe is prepared.

[0025] Connect the tail end of the high-pressure air hose to the high-pressure air source via a pressure regulating valve, pressure gauge, and filter dryer. Connect the self-locking quick connector at the head of the high-pressure air hose to the air inlet of the universal ball joint, and install the selected nozzle to the air outlet of the universal ball joint via a quick-change connector.

[0026] The universal ball has a rotation range of not less than 120° in the horizontal and vertical directions, and the universal ball is equipped with an air inlet pipe and an air outlet pipe. A high-temperature resistant sealing structure is set on the contact surface between the ball and the bracket. Based on the air outlet pipe interface size of the universal ball, at least two interchangeable cleaning nozzles are prepared.

[0027] The height of the support is adjusted by a height adjustment mechanism, which adopts a screw lifting structure or a pin-type telescopic column, with an adjustment range of not less than 0.5m to adapt to the height differences of different blast furnace tapholes from the ground.

[0028] The horizontal adjustment casters at the bottom of the bracket are swivel brake casters, and each caster can be adjusted independently to compensate for the unevenness of the ground in front of the iron tap.

[0029] The bracket locking mechanism uses a screw lock or an eccentric cam lock to ensure that the bracket does not shift during the purging process.

[0030] A high-temperature resistant sealing structure is provided between the ball and the support base of the hollow universal ball. The sealing structure is a flexible graphite ring or a ceramic fiber braided sealing ring. The sealing ring is embedded in the inner wall of the support base and forms a sliding sealing fit with the outer surface of the ball.

[0031] The air inlet and outlet pipes of the omnidirectional ball are both heat-resistant stainless steel pipes with an inner diameter of not less than 8mm. The air inlet and outlet pipes are connected inside the ball through a section of expanded-diameter buffer chamber to reduce airflow pressure pulsation.

[0032] The rotational resistance of the omnidirectional ball is adjusted by the damping adjustment bolt on the bracket. The damping adjustment bolt presses the friction plate on the surface of the ball. The friction plate is made of graphite-impregnated copper alloy.

[0033] The support bracket provides a stable and flexible foundation for the precise orientation of the subsequent nozzles;

[0034] The cleaning nozzles are made of high-temperature resistant alloy steel. The first type is a straight nozzle with multiple circumferentially distributed nozzle holes at the head and a cross-shaped or spiral guide core inside to form a rotating jet of high-pressure gas. The second type is a fan-shaped nozzle with an adjustable air outlet slit width to achieve a fan-shaped angle adjustment of 30°-120°.

[0035] The cross-sectional shape of the guide core is a cross plate or a spiral twisted blade, and the length of the guide core accounts for 1 / 3 to 1 / 2 of the total length of the nozzle;

[0036] The number of circumferentially distributed nozzles is 4-8, with the nozzle axis forming an angle of 0° to 15° with the nozzle center axis to form a focused or micro-diffusing jet.

[0037] The outlet slit width adjustment mechanism of the fan-shaped nozzle is a rotary adjustment ring. The adjustment ring is connected to the nozzle body by a thread. Rotating the adjustment ring can change the opening amount of the slit. The slit width adjustment range is 0.5mm-2.5mm, corresponding to a fan angle that is continuously adjustable from 30° to 120°. Symmetrical V-shaped guide grooves are provided on both sides of the outlet of the fan-shaped nozzle to homogenize the gas distribution of the fan-shaped jet.

[0038] Each nozzle is equipped with a snap-fit ​​quick-change connector at the rear end that matches the air outlet pipeline, and is also fitted with a high-temperature resistant ceramic protective cover.

[0039] The bayonet-type quick-change connector includes a male and a female connector. The male connector is fixed to the rear end of the nozzle, and the female connector is fixed to the air outlet of the universal ball. The male connector has at least two radial spring retaining balls on its outer periphery, and the female connector has a corresponding annular retaining groove on its inner wall. A high-temperature resistant O-ring (made of perfluoroether rubber) and a metal anti-detachment retaining ring are also provided between the male and female connectors.

[0040] The high-pressure air hose is no less than 3m long. The inner metal spiral wire is made of 304 stainless steel or 316L stainless steel spiral wound with a spiral spacing of 5mm-10mm. The outer aerogel insulation layer is 3mm-8mm thick and the thermal conductivity of the aerogel is no higher than 0.02W / (m·K). The outermost layer of the air hose is also equipped with a wear-resistant braided sheath, which is made of glass fiber or aramid fiber.

[0041] The inner layer of the high-pressure air tube is a high-temperature resistant composite material tube body reinforced with metal spiral wire, and the outer layer is covered with an aerogel heat insulation layer; the middle of the air tube is equipped with a heat insulation handle that can slide along the tube body and lock, and the front end of the air tube is equipped with a spiral heat dissipation fin near the universal ball joint.

[0042] The handle is an arc-shaped grip handle. Both ends of the handle are installed on the outer wall of the trachea via sliding collars. The inner wall of the sliding collar is equipped with a locking knob. After tightening, the handle can be fixed in any position of the trachea. The gun handle switch valve integrated on the handle is a normally closed push-button valve. Pressing the handle opens the air passage, and releasing it closes it. The pressing stroke is proportional to the gas flow rate, achieving stepless adjustment.

[0043] The spiral heat sink is made of copper alloy or aluminum alloy. The heat sink is welded to the outer wall of the front end of the air pipe in the shape of spiral blades. There are 3-6 spiral blades, the blade height is 10mm-20mm, and the spacing between adjacent blades is 15mm-30mm. The heat sink is also fitted with a heat insulation cover to prevent operators from accidentally touching it.

[0044] High-pressure air hoses serve both as air supply channels and as a safety lever for operators to stay away from high-temperature areas.

[0045] The operating pressure range is set to 0.6-1.2 MPa, and the flow rate is not less than 1.5 m³ / min;

[0046] The working process of step S1 is as follows: Based on the actual height of the iron taphole mud sleeve and the flatness of the ground, adjust the height of the support to a suitable position by lifting the screw or extending the pin column, and use the universal brake caster and locking mechanism to stabilize the support on the ground. Then, install the selected straight nozzle or fan nozzle to the air outlet of the universal ball joint through the bayonet quick-connect coupling. Then connect the self-locking quick coupling of the high-pressure air pipe head to the air inlet of the universal ball joint. The air pipe tail is connected to the high-pressure air source through the pressure regulating valve, pressure gauge and filter dryer. Finally, set the working pressure to 0.6-1.2MPa and the flow rate to not less than 1.5m³ / min. The operator slides and locks the heat insulation handle according to his own position, presses the gun handle switch valve to perform a test spray. After confirming that there is no leakage at each connection and the jet pattern is normal, all preparations before purging are completed.

[0047] Step S2: During the blast furnace slag and iron discharge process, based on the online mud sleeve cleaning tool, interference identification and optimized purging and cleaning of the taphole mud sleeve are performed, including the following sub-steps:

[0048] Step S201: Obtain the morphological parameters of the nozzle outlet jet and the characteristics of the air pressure fluctuation, and combine them with the residual distribution on the surface of the mud jacket after cleaning to determine whether there is a jet interference type caused by the airflow or thermal effect in front of the taphole.

[0049] In step S201, a high-temperature resistant industrial camera is installed on the bracket near the nozzle outlet. A dust-proof blowing device is set in front of the camera lens to continuously blow the lens surface with a small amount of gas to prevent dust from adhering.

[0050] The high-pressure gas jet at the nozzle outlet is captured in real time by a camera.

[0051] The jet images were analyzed, and the following quantitative parameters were extracted: the offset angle between the jet centerline and the nozzle geometric axis, the diffusion angle between the jet boundary and the axis, and the lateral oscillation amplitude of the jet per unit time.

[0052] Specifically, the background segmentation method is used to extract the jet region from the jet image, calculate the centroid coordinates of the jet region, and compare them with the theoretical projected coordinates of the nozzle axis to obtain the offset angle;

[0053] The diffusion angle is obtained by calculating the angle between the lines connecting the points farthest from the axis on the jet boundary;

[0054] The lateral sway amplitude is calculated by the standard deviation of the centroid coordinates of the jet in multiple consecutive frames of images.

[0055] A pressure sensor is installed on the pipeline between the pressure regulating valve and the universal ball air inlet pipe, wherein the sampling frequency of the pressure sensor is not less than 100 Hz;

[0056] The pressure sensor transmits the real-time pressure signal to the industrial control computer. The industrial control computer performs time-domain analysis on the pressure signal and extracts the following quantitative parameters: peak amplitude of pressure pulsation, main frequency of pressure pulsation, and standard deviation of pressure signal.

[0057] Specifically, the peak amplitude of pressure pulsation: within a set time window (e.g., 1 second), find the maximum and minimum values ​​of the pressure signal, and calculate the difference between the two, which is the peak amplitude within that window;

[0058] The dominant frequency of pressure pulsation: Perform a fast Fourier transform on the pressure signal to convert the time domain signal into a frequency domain signal, and find the frequency component with the largest amplitude in the frequency domain. This frequency is the dominant frequency of pressure pulsation.

[0059] Standard deviation of pressure signal: Within the same time window, calculate the dispersion of all pressure sampling points relative to the average pressure within that window. That is, first calculate the sum of squares of the deviations of each sampling point from the average value, then divide by the number of sampling points and take the square root. The resulting value is the standard deviation.

[0060] An infrared thermal imaging sensor is also installed on the bracket near the nozzle outlet. The infrared thermal imaging sensor faces the area in front of the iron tap and measures the temperature distribution in the vertical direction in front of the iron tap in real time. The infrared thermal imaging sensor transmits the collected temperature data to the industrial control computer. The industrial control computer extracts the temperature values ​​at two different heights above and below the mud sleeve of the iron tap, calculates the ratio of the temperature difference between the two points to the vertical distance between the two points, and obtains the temperature gradient in the vertical direction in front of the iron tap.

[0061] A gas composition sensor is installed near the nozzle or on the bracket. The gas composition sensor is used to detect the oxygen volume fraction in the ambient gas around the nozzle. The gas composition sensor transmits the detected oxygen volume fraction data to the industrial control computer in real time.

[0062] The industrial control computer compares the extracted quantization parameters with preset thresholds or feature libraries, and automatically determines the jet interference type according to the following objective rules:

[0063] If the offset angle is greater than the preset offset threshold and the peak amplitude is less than 5% of the preset peak threshold, it is determined to be a lateral airflow interference.

[0064] If the diffusion angle is greater than the preset diffusion angle threshold, the main frequency is greater than the preset frequency threshold, and the lateral oscillation amplitude is greater than the preset oscillation amplitude threshold, then it is determined to be turbulent breaking interference.

[0065] If the offset angle is greater than the preset vertical offset threshold and the offset direction is vertically upward or downward, and the vertical temperature gradient in front of the iron tap measured by the infrared thermal imaging sensor installed on the bracket is greater than the preset temperature gradient threshold, then it is determined to be thermal convection lifting or settling interference.

[0066] If the peak amplitude is less than three percent of the preset peak threshold, and the diffusion angle is less than the preset cluster diffusion angle threshold, and the oxygen volume fraction detected by the gas composition sensor installed near the nozzle is greater than the preset oxygen ratio threshold, and the surface image of the cleaned mud jacket shows red or brown areas with iron oxide characteristics, then it is determined to be oxidizing atmosphere interference.

[0067] The aforementioned thresholds are preset and stored by the industrial control computer based on historical operating data or on-site calibration results. Before initial use, standard purging tests are conducted multiple times under undisturbed operating conditions (such as when the blast furnace is shut down or there is no discharge from the taphole). Stable baseline values ​​of jet morphology and gas path pressure are recorded. The baseline values ​​of each parameter are multiplied by a certain safety factor or determined based on the empirical deviation range to form the threshold. During use, the industrial control computer can also automatically store the effective parameters after each successful cleaning into the database and periodically perform statistical analysis on historical data to dynamically update the thresholds, so as to adapt to the actual operating conditions of the blast furnace taphole at different times and ensure the adaptability and accuracy of the judgment rules.

[0068] The determined jet interference type will be output in text form. If multiple jet interference types are determined at the same time, they will be output in the order of priority: lateral airflow interference, turbulent breaking interference, thermal convection interference, and oxidizing interference.

[0069] Step S202: Based on the determined jet interference type, select and implement compensation and suppression measures, and adjust the support positioning, execution end configuration, delivery pipeline characteristics and power source operating conditions accordingly.

[0070] In step S202, if the problem is determined to be a lateral airflow disturbance, the following compensation and suppression measures are implemented:

[0071] An anti-interference guide shroud is extended or rotated and installed on the outside of the nozzle. The guide shroud is a semi-circular or conical metal shroud made of high-temperature resistant stainless steel and is driven by an electric push rod or a manual knob. The opening of the guide shroud faces the iron nozzle sleeve. The function of the guide shroud is to block the gas escaping airflow from the side and reduce the deflection effect of the lateral airflow on the jet.

[0072] Reverse adjustment support positioning: The industrial control computer controls the horizontal adjustment mechanism (such as an electric lead screw or a manual adjustment handwheel) on the bracket to move the entire bracket slightly in the opposite direction of the jet deflection, with a movement distance not exceeding 20 mm, in order to compensate for the residual deflection;

[0073] Adjusting the characteristics of the delivery pipeline: Keep the bends in the high-pressure gas pipe unchanged to ensure smooth airflow;

[0074] Power source operating condition adjustment: Maintain the current working pressure unchanged. The pressure is stable due to the interference of cross airflow and no adjustment is required.

[0075] When the disturbance is identified as turbulent breaking, the following compensation and suppression measures shall be implemented:

[0076] When switched to pulse purging mode, the industrial control computer starts the pneumatic pulse generator installed behind the handle or downstream of the pressure regulating valve. The pulse generator periodically turns the airflow on and off at a set frequency (preset by the industrial control computer, for example, between 20 Hz and 50 Hz), so that the nozzle outputs a pulse jet. The pulse jet has higher penetration ability and can resist jet divergence caused by turbulence.

[0077] Reverse adjustment execution end configuration: If a fan-shaped nozzle is currently being used, the industrial control computer controls the adjusting ring of the fan-shaped nozzle to automatically rotate to a smaller fan angle (e.g., 30 degrees) to increase the jet concentration; if a straight nozzle is currently being used, it remains unchanged.

[0078] Power source operating condition adjustment: The industrial control computer dynamically adjusts the working pressure to the upper limit of the set pressure range (not exceeding 1.2MPa) through the pressure regulating valve to enhance the jet flow and resist turbulent diffusion;

[0079] Adjusting the characteristics of the delivery pipeline: Maintaining normal pipeline conditions;

[0080] When the disturbance is determined to be caused by thermal convection uplift or sedimentation, the following compensation and suppression measures shall be implemented:

[0081] Adjust the angle between the nozzle and the mud sleeve. After the industrial control computer controls the universal ball to loosen the damping adjustment bolt, it drives the universal ball to rotate so that the nozzle axis rotates in the vertical plane, causing the nozzle to tilt downward (if the jet is lifted) or upward (if the jet is settled). The tilt angle is automatically calculated by the industrial control computer based on the temperature gradient measured by the infrared thermal imaging sensor. The tilt range is between 5 degrees and 15 degrees. After the adjustment is in place, the damping adjustment bolt is tightened again to fix the nozzle posture.

[0082] Reverse adjustment support positioning: The industrial control computer controls the height adjustment mechanism (electric screw) of the support to raise or lower the support height, so as to reduce the height difference between the nozzle outlet and the center of the mud sleeve, thereby reducing the impact of heat convection;

[0083] Power source operating condition adjustment: The industrial control computer reduces the working pressure to the lower limit of the set pressure range (not less than 0.6MPa) through the pressure regulating valve to reduce the ability of the jet to absorb heat air, thereby reducing thermal convection interference;

[0084] Execute end-point configuration: Keep the current nozzle unchanged;

[0085] When interference is determined to be caused by an oxidizing atmosphere, the following compensation and suppression measures shall be implemented:

[0086] To switch the gas source, the industrial control computer controls the gas source switching valve to switch the gas source from compressed air to nitrogen or blast furnace gas (inert or reducing gas). When switching, first close the compressed air valve and open the nitrogen valve. After the residual compressed air in the pipeline is purged (delay for 1 to 2 seconds), the purging is resumed.

[0087] When adjusting the power source, if the gas source after switching is nitrogen, keep the pressure within the set range; if blast furnace gas is used, the pressure needs to be reduced to below 0.5MPa (because blast furnace gas contains combustible components, the flow rate needs to be controlled to prevent static electricity).

[0088] When performing end configuration, if a straight nozzle is currently being used, it remains unchanged; if a fan nozzle is being used, the fan angle can be appropriately increased to expand the purging area, because oxidative interference mainly causes surface oxide layers, which require large-area cleaning.

[0089] Adjusting the characteristics of the delivery pipeline: Ensure that the gas pipe connections are well sealed to prevent nitrogen leakage;

[0090] When multiple types of interference exist simultaneously;

[0091] The industrial control computer executes compensation and suppression measures according to the priority order of the output (lateral airflow interference takes priority over turbulent breaking interference, turbulent breaking interference takes priority over thermal convection interference, and thermal convection interference takes priority over oxidizing interference), and treats for subsequent interference types as additional adjustments.

[0092] For example, if both lateral airflow interference and turbulent breaking interference are determined at the same time, the extension of the duct and movement of the support for lateral airflow interference are executed first, and then the pulse mode switching and pressure adjustment for turbulent breaking interference are executed.

[0093] Step S203: Perform dynamic purging operation based on the adjusted state, and dynamically maintain or correct compensation and inhibition measures according to the real-time monitored jet morphology and mud jacket surface cleanliness during the purging process.

[0094] In step S203, hold the handle of the high-pressure air hose, stand at a safe position at least 3 meters away from the iron tap, press the switch valve on the gun handle, and the high-pressure gas is ejected from the nozzle through the universal ball to start purging the mud sleeve of the iron tap. At the same time, the industrial control computer starts the timer to record the purging duration.

[0095] During the purging process, the industrial control computer continuously receives real-time data and updates the following parameters at a frequency of no less than 10 times per second: jet deflection angle, diffusion angle, lateral oscillation amplitude, peak amplitude of pressure pulsation, main frequency of pressure pulsation, standard deviation of pressure signal, temperature gradient, and oxygen volume fraction.

[0096] If all real-time data are within their respective preset stable threshold ranges;

[0097] If the offset angle is less than the preset offset threshold, the diffusion angle is less than the preset diffusion angle threshold, the lateral swing amplitude is less than the preset swing amplitude threshold, the peak amplitude of the pressure pulsation is less than 5% of the preset peak value threshold, the main frequency of the pressure pulsation is less than the preset frequency threshold, and the standard deviation of the pressure signal is less than the preset standard deviation threshold, then the current jet morphology is determined to be stable, the compensation and suppression measures are effective, the industrial control computer maintains all current adjustment states unchanged, and does not issue new adjustment commands.

[0098] If any item in the real-time data exceeds the corresponding preset stability threshold, it is determined that the compensation and suppression measures are insufficient or the environmental conditions have changed. The industrial control computer, based on the type of parameter exceeding the threshold, recalculates and performs a fine-tuning of the compensation and suppression measures according to the corresponding rules in step S202 above.

[0099] If the offset angle exceeds the threshold, it is determined that the lateral airflow interference has not been completely suppressed. The industrial control computer controls the horizontal adjustment mechanism of the support to move in the opposite direction of the deflection again, with a moving distance of 5 mm to 10 mm, and re-detects the offset angle until it meets the standard.

[0100] If the diffusion angle or lateral oscillation amplitude exceeds the threshold, it is determined that the turbulent breaking interference is aggravated. The industrial control computer will increase the frequency of the pulse jet by 10 Hz (not exceeding the preset upper limit) or increase the working pressure by 0.1 MPa (not exceeding 1.2 MPa).

[0101] If the offset direction is vertical and the temperature gradient exceeds the threshold, it is determined that the thermal convection interference has changed. The industrial control computer recalculates the vertical tilt angle of the nozzle, adjusts the attitude of the omnidirectional ball, and fine-tunes the height of the bracket accordingly.

[0102] If the oxygen volume fraction exceeds the threshold and an iron oxide color area appears, confirm again that the gas source is nitrogen. If oxidation still occurs after switching to nitrogen, increase the nitrogen flow rate to 1.8 times the initial setting value.

[0103] After each fine-tuning, the industrial control computer waits for 0.5 seconds and reads the real-time parameters again. If the parameters are still out of range, the fine-tuning is repeated, up to a maximum of 3 times. If the parameters still cannot be brought back to the threshold after 3 fine-tunings, the industrial control computer outputs a compensation failure alarm, prompting the operator to stop purging and manually check the equipment.

[0104] During the purging process, the industrial control computer captures an image of the mud jacket surface every 2 seconds via a high-temperature resistant camera, and uses an image segmentation algorithm to identify the area ratio and location distribution of residual slag and iron:

[0105] If the residual area is greater than 50% of the initial residual area, continue the current purging mode;

[0106] If the residual area ratio drops to between 30% and 50% of the initial residual area, and the residual area appears as scattered dots, the industrial control computer will automatically switch the nozzle from a straight nozzle to a fan-shaped nozzle (achieved through the electric drive mechanism of the bayonet quick-change connector), and increase the fan angle to more than 90 degrees to expand the purging coverage area.

[0107] If the residual area is less than 10% of the initial residual area, it is determined that the mud sleeve is basically clean. The industrial control computer issues a command, and the operator releases the gun handle switch valve to stop purging.

[0108] Specifically, the image segmentation algorithm identifies the residual area proportion and location distribution as follows: The color image of the mud jacket surface captured by the camera is converted to a grayscale image, and Gaussian filtering is used to remove noise. Then, an adaptive threshold segmentation method is used to divide the pixels in the grayscale image into two categories: foreground (residual slag and iron area) and background (clean mud jacket area). Foreground pixels correspond to areas with higher grayscale values ​​(due to the brighter color of the slag and iron), while background pixels correspond to areas with lower grayscale values. After segmentation, the industrial control computer performs connected component analysis on the pixels in the foreground area, marking interconnected pixels as the same residual area and removing isolated noise points with an area smaller than a preset minimum area threshold (e.g., 10 pixels). Finally, the industrial control computer calculates the total pixel area of ​​all residual areas and divides it by the total pixel area of ​​the mud jacket area to obtain the residual area proportion. Simultaneously, the geometric center coordinates of each residual area are calculated relative to the center of the mud jacket area, outputting the residual location distribution (e.g., central area, edge area, upper part, lower part, left side, right side). Based on the contour shape of the residual areas, its morphological characteristics (e.g., dotted, striped, sheet-like, ring-like) are determined.

[0109] The industrial control computer continuously monitors the infrared thermal imaging temperature of the area in front of the iron tap. If the temperature exceeds the preset safety threshold (e.g., the surface temperature of the mud sleeve is higher than 1500 degrees Celsius) or the temperature of the heat sink at the front end of the air pipe exceeds 300 degrees Celsius, the gun handle switch valve will be automatically closed (through the solenoid valve linkage), the purging will be interrupted, and an audible and visual alarm will be issued. Purging can only be resumed after the temperature drops back to a safe range.

[0110] The purging operation will automatically terminate when any of the following conditions are met:

[0111] The percentage of residual area on the surface of the mud jacket was lower than the preset cleanliness threshold (e.g., 5%) in two consecutive tests.

[0112] The total duration of purging exceeds the preset maximum time (e.g., 60 seconds);

[0113] The operator manually releases the gun handle switch valve;

[0114] The security monitoring triggered an alarm and interrupted the purging process.

[0115] Step S204: After the purging operation is completed, obtain the final cleanliness of the mud jacket surface and assess whether it meets the set requirements. If it does not meet the set requirements, re-execute the compensation and inhibition measures according to the residual characteristics of the non-compliant area until the cleanliness meets the requirements.

[0116] In step S204, the industrial control computer processes the image using an image segmentation algorithm, identifies the areas of residual slag and iron on the surface of the mud jacket, and calculates the following indicators:

[0117] Residual area percentage: The percentage of the pixel area of ​​the residual slag and iron region to the total pixel area of ​​the mud jacket region;

[0118] Residual location distribution: The position of the residual area relative to the center of the mud jacket (e.g., central area, edge area, upper part, lower part, left side, right side);

[0119] Residual morphological characteristics: the shape of the residual area (dot-like, strip-like, sheet-like, ring-like);

[0120] The calculated percentage of residual area is compared with a preset cleanliness threshold (e.g., 5%).

[0121] If the residual area percentage is less than or equal to the preset cleanliness threshold, the surface of the mud jacket is determined to have met the set cleanliness requirements. The industrial control computer records the purging operation as successful and displays the cleaning completion information on the operation panel, thus terminating the purging cleaning process.

[0122] If the residual area ratio is greater than the preset cleanliness threshold, it is determined that the surface of the mud jacket has not met the set cleanliness requirements. The industrial control computer will display on the operation panel that it is not completely cleaned, and the information needs to be reprocessed before proceeding to the next step of the non-compliance processing procedure.

[0123] If the residual area is concentrated on one side of the mud jacket (such as the left or right side, the upper or lower part), it is determined that the residual is caused by jet deflection, which belongs to the incomplete suppression of lateral airflow interference or thermal convection interference.

[0124] If the residual area is scattered in a dotted pattern across the entire mud jacket surface, it is determined that the residue is caused by jet dispersion and insufficient impact force, which is due to incomplete suppression of turbulent breakup interference.

[0125] If the residual area is in the form of flakes or rings and the surface color is reddish-brown, it is determined that the oxide layer was not removed due to interference from the oxidizing atmosphere.

[0126] The control computer compares the residual characteristics with the original interference type. If the residual characteristics match the original interference type, it indicates that the original compensation and suppression measures are insufficient. The control computer will increase the corresponding adjustment amount by one level according to the rules.

[0127] For example: the horizontal movement distance of the support is increased from no more than 20 mm to no more than 30 mm; the pulse frequency is increased by 10 Hz; the nozzle tilt angle is increased by 5 degrees; and the nitrogen flow rate is increased by 1.2 times.

[0128] If the residual characteristics do not match the original interference type, for example, if the original identification was a lateral airflow interference, but the residual is scattered in a dotted pattern, the industrial control computer determines that the environmental conditions have changed, re-executes the interference type identification process, and selects compensation and suppression measures based on the new identification results.

[0129] The industrial control computer sends the reselected or adjusted compensation and suppression measures command to the corresponding actuator (diffuser, bracket adjustment mechanism, pulse generator, universal ball drive, air source switching valve, etc.), and waits for 1 second to stabilize the adjustment;

[0130] The industrial control computer will automatically or prompt the operator to restart the purging operation;

[0131] After each re-purging, a cleanliness assessment is performed again;

[0132] The industrial computer records the number of times the purging process was repeated.

[0133] If, within the preset maximum number of re-purging cycles (e.g., 3 times), the percentage of residual area after a re-purging cycle reaches the preset cleanliness threshold, the cleaning is considered successful and the process ends.

[0134] If the residual area still exceeds the preset cleanliness threshold after the maximum number of re-purging cycles has been reached, the industrial control computer will output an automatic cleaning failure alarm and display a residual image and suggested areas for manual cleaning on the operation panel, waiting for operator intervention.

[0135] Step S2 serves the following purposes: by integrating real-time perception from multiple sensors (jet morphology, pressure fluctuation, temperature gradient, oxygen concentration), automatically classifying interference types (lateral airflow, turbulent breaking, thermal convection, oxidizing atmosphere), and specifically implementing compensation and suppression measures such as guide hood adjustment, pulse purging switching, nozzle attitude and support position correction, and gas source switching, while combining image segmentation to dynamically assess the cleanliness of the mud jacket, adaptive fine-tuning and closed-loop feedback are achieved during the purging process. Ultimately, this ensures that the surface of the mud jacket meets the cleanliness standards, upgrading the traditional manual blind purging to an intelligent, precise, and safe automated cleaning process, improving the cleaning success rate and stability, and reducing the need for manual intervention and operational risks.

[0136] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for online high-pressure gas purging and cleaning of the blast furnace taphole mud jacket, characterized in that: Includes the following steps: Step S1: Construct a tool for online mud cleaning sleeve. The tool includes a height-adjustable bracket, a hollow universal ball joint mounted on the top of the bracket, at least two interchangeable cleaning nozzles, and a high-pressure air hose with a length of not less than 3m. Connect the tail end of the high-pressure air hose to a high-pressure air source through a pressure regulating valve, a pressure gauge, and a filter dryer. Connect the self-locking quick connector at the head of the high-pressure air hose to the air inlet of the universal ball joint, and install the selected nozzle to the air outlet of the universal ball joint through a quick-change connector. Step S2: During the blast furnace slag and iron discharge process, interference identification and optimized purging and cleaning of the taphole mud sleeve are performed based on the aforementioned tool, including the following sub-steps: Step S201: Obtain the morphological parameters of the nozzle outlet jet and the characteristics of the air pressure fluctuation, and combine them with the residual distribution on the surface of the mud jacket after cleaning to determine whether there is a jet interference type caused by the airflow or thermal effect in front of the taphole. Step S202: Based on the determined jet interference type, select and implement compensation and suppression measures, and adjust the support positioning, execution end configuration, delivery pipeline characteristics and power source operating conditions accordingly. Step S203: Perform dynamic purging operation based on the adjusted state, and dynamically maintain or correct compensation and inhibition measures according to the real-time monitored jet morphology and mud jacket surface cleanliness during the purging process. Step S204: After the purging operation is completed, obtain the final cleanliness of the mud jacket surface and assess whether it meets the set requirements. If it does not meet the set requirements, re-execute compensation and inhibition measures based on the residual characteristics of the non-compliant area until the cleanliness meets the requirements.

2. The method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket according to claim 1, characterized in that: In step S201, the jet interference type is automatically determined according to the following rules: If the offset angle is greater than the preset offset threshold and the peak amplitude is less than 5% of the preset peak threshold, it is determined to be a lateral airflow interference. If the diffusion angle is greater than the preset diffusion angle threshold, the main frequency is greater than the preset frequency threshold, and the lateral oscillation amplitude is greater than the preset oscillation amplitude threshold, then it is determined to be turbulent breaking interference. If the offset angle is greater than the preset vertical offset threshold and the offset direction is vertically upward or downward, and the temperature gradient is greater than the preset temperature gradient threshold, then it is determined to be thermal convection lifting or sedimentation disturbance. If the peak amplitude is less than 3% of the preset peak threshold, the diffusion angle is less than the preset bundle diffusion angle threshold, the oxygen volume fraction is greater than the preset oxygen ratio threshold, and the surface image of the cleaned mud jacket shows red or brown areas with iron oxide characteristics, then it is determined to be oxidizing atmosphere interference.

3. The method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket according to claim 1, characterized in that: In step S202, when it is determined that there is lateral airflow interference, the following compensation and suppression measures are performed: extend or rotate the anti-interference guide shroud installed on the outside of the nozzle, and move the entire bracket in the opposite direction of the jet deflection; When turbulent disruption interference is detected, switch to pulse purging mode. If a fan-shaped nozzle is currently in use, adjust it to a small fan angle and increase the working pressure. When the interference is determined to be caused by thermal convection lifting or settling, adjust the angle between the nozzle and the mud sleeve, and adjust the support height accordingly, while reducing the working pressure; when the interference is determined to be caused by an oxidizing atmosphere, switch the gas source to nitrogen or blast furnace gas.

4. The method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket according to claim 1, characterized in that: In step S202, when a lateral airflow disturbance is determined, the following compensation and suppression measures are implemented: Extend or rotate the anti-interference guide shroud installed on the outside of the nozzle, and move the entire bracket in the opposite direction of the jet deflection; When turbulent disruption is detected, switch to pulse purging mode. If a fan-shaped nozzle is currently in use, adjust it to a smaller fan angle and increase the working pressure. When the disturbance is determined to be caused by thermal convection lifting or settling, adjust the angle between the nozzle and the mud jacket, adjust the support height accordingly, and reduce the working pressure. When the interference is determined to be caused by an oxidizing atmosphere, the gas source will be switched to nitrogen or blast furnace gas.

5. The method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket according to claim 1, characterized in that: In step S203, the jet morphology parameters and pressure parameters are updated at a frequency of no less than 10 times per second during the purging process. If all real-time data are within the preset stable threshold range, the current adjustment state is maintained. If any item exceeds the threshold, a fine adjustment is performed according to the type of exceedance. The fine adjustment is repeated a maximum of 3 times. If it still cannot return to the threshold, an alarm is output.

6. The method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket according to claim 1, characterized in that: In step S203, the area ratio and location distribution of residual slag and iron on the surface of the mud jacket are identified using an image segmentation algorithm: The mud jacket surface image was converted into a grayscale image and filtered. Adaptive threshold segmentation was used to divide the pixels into foreground and background. Connectivity analysis was performed on the foreground and isolated noise points were removed. The residual area ratio, residual location distribution and residual morphological characteristics were statistically analyzed. The purging mode is dynamically adjusted based on the percentage of residual area: if the percentage of residual area is greater than 50% of the initial residual area, the current mode continues. If the concentration drops to between 30% and 50% and the residue is scattered, the nozzle will automatically switch from a straight nozzle to a fan-shaped nozzle and the fan angle will be increased. If the area of ​​residual evacuation is less than 10% of the initial residual area, purging should be stopped.

7. The method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket according to claim 1, characterized in that: In step S204, the percentage of residual area is compared with the preset cleanliness threshold. If it is less than or equal to the cleanliness threshold, the process is considered successful and terminated. If the value exceeds the cleanliness threshold, the type of interference that has not been completely suppressed will be determined based on the distribution and morphological characteristics of the residual location. The adjustment amount of the corresponding compensation and suppression measures will be increased by one level, and the purging will be re-executed. The number of purging re-executions will not exceed the preset maximum number. If the standard is still not met, an automatic cleaning failure alarm will be output.

8. The method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket according to claim 1, characterized in that: The height adjustment mechanism of the bracket adopts a screw lifting structure or a pin-type telescopic column, with an adjustment range of not less than 0.5m; The bottom of the bracket is equipped with omnidirectional brake casters and a locking mechanism; a flexible graphite ring or ceramic fiber braided sealing ring is provided between the ball of the hollow omnidirectional ball and the bracket seat; the air inlet and outlet pipes of the omnidirectional ball are both heat-resistant stainless steel pipes with an inner diameter of not less than 8mm, and are connected through an expanded diameter buffer cavity; the rotation resistance of the omnidirectional ball is adjusted by a damping adjustment bolt.

9. The method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket according to claim 1, characterized in that: The cleaning nozzle has a cross-shaped or spiral guide core inside the straight nozzle, and 4-8 circumferentially distributed spray holes at the head, with the axis of the spray holes forming an angle of 0°-15° with the central axis of the nozzle. The width of the air outlet slit of the fan-shaped nozzle can be continuously adjusted from 0.5mm to 2.5mm by a rotary adjustment ring, corresponding to a fan angle of 30° to 120°. Symmetrical V-shaped guide grooves are provided on both sides of the nozzle outlet. Each nozzle is equipped with a bayonet-type quick-change connector at the rear end and a high-temperature resistant ceramic protective cover.

10. The method for online high-pressure gas purging and cleaning of blast furnace taphole mud jacket according to claim 1, characterized in that: The inner layer of the high-pressure air pipe is a high-temperature resistant composite material tube reinforced with metal spiral wires, the outer layer is covered with an aerogel heat insulation layer, and the outermost layer is provided with a wear-resistant braided sheath. The middle of the trachea is equipped with a heat-insulated handle that can slide along the tube and lock, and the handle is integrated with a hand-operated gun handle switch valve. The front end of the air tube is equipped with a spiral heat sink near the universal ball joint, and the heat sink is covered with a heat insulation shield.

Images