A method for monitoring and adjusting the heat flux intensity of a blast furnace

Abstract

This invention discloses a method for monitoring and adjusting the heat flow intensity of a blast furnace, comprising the following steps: (1) installing a high-precision temperature sensor I at the water inlet end of each cooling wall of the blast furnace, and a high-precision temperature sensor II at its water outlet end, and installing a smart flow meter in its water outlet pipeline; (2) continuously collecting the water inlet temperature T of the corresponding cooling wall at a collection frequency of 1 time / second. 进 Outlet water temperature T 出 And cooling water mass flow rate V; (3) Preset standardized heat flow intensity calculation formula, and then collect the inlet water temperature T 进 Outlet water temperature T 出 The real-time cooling wall heat flux intensity J is calculated by substituting the cooling water mass flow rate V into the calculation; (4) a five-level grading threshold system for heat flux intensity is preset, and the grading warning result is obtained by comparing the cooling wall heat flux intensity J; (5) the cooling water volume is automatically adjusted according to the above grading warning result; (6) the blast furnace PLC / DCS control system automatically stores the data. This invention can ensure the safe and stable operation of the blast furnace.

Description

Technical Field

[0001] This invention relates to the field of blast furnace production technology, and more specifically to a method for monitoring and adjusting the heat flow intensity of a blast furnace. Background Technology

[0002] Modern blast furnaces are rapidly developing towards higher efficiency, automation, and longer service life. The furnace cooling system is a core component in ensuring the safe and stable operation of the blast furnace and extending its service life. The heat flux intensity of the cooling wall is a key indicator that directly reflects the heat load of the blast furnace wall, the stability of the slag skin, and the erosion state of the lining. The accurate monitoring and timely adjustment of its value will directly affect the stability of the blast furnace shape, production safety, and smelting efficiency.

[0003] Currently, the industry generally uses traditional manual operation methods to monitor and adjust the heat flow intensity of blast furnace cooling walls, but this is difficult to meet the needs of modern intelligent and refined blast furnace production. For example: 1) Manual measurement is the main method, which is inefficient and has large errors; 2) Real-time continuous monitoring cannot be achieved; 3) There is no unified quantitative standard, and adjustments rely on experience; 4) Data is not networked and cannot be traced; 5) The labor intensity is high and the labor cost is high.

[0004] To address the shortcomings of existing technologies, the industry currently lacks a comprehensive technical solution capable of fully automated online monitoring, precise calculation, tiered early warning, and intelligent closed-loop regulation of blast furnace heat flux intensity. This fails to meet the demands of modern blast furnaces for longer service life, greater intelligence, and environmental friendliness. Therefore, developing a fully automated, high-precision, early warning-enabled, and closed-loop-controlled method for monitoring and adjusting blast furnace heat flux intensity has become a pressing problem for the steel industry. Summary of the Invention

[0005] The technical problem to be solved by this invention is to provide a method for monitoring and adjusting the heat flux intensity of a blast furnace. This method achieves fully automatic online monitoring of the heat flux intensity and ensures the safe and stable operation of the blast furnace through precise calculation, graded early warning, and intelligent closed-loop regulation. It also extends the blast furnace's lifespan, reduces labor intensity, is compatible with various types of blast furnaces, and is easy to promote and apply.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: The innovative aspect of the present invention's method for monitoring and adjusting the heat flux intensity of a blast furnace lies in including the following steps: (1) Install high-precision temperature sensor I at the water inlet end of each cooling wall of the blast furnace, and install high-precision temperature sensor II at the water outlet end of each cooling wall of the blast furnace, and install intelligent flow meter on the water outlet pipe of each cooling wall of the blast furnace. (2) The inlet water temperature T of the corresponding cooling wall is continuously collected by a high-precision temperature sensor I at a sampling frequency of 1 time / second. 进 The outlet water temperature T of the corresponding cooling wall is continuously collected by high-precision temperature sensor II.出 The cooling water mass flow rate V is continuously collected by an intelligent flow meter, and the collected real-time data is then uploaded to the blast furnace PLC / DCS control system in real time. (3) A standardized heat flux intensity calculation formula is preset in the blast furnace PLC / DCS control system, and then the collected inlet water temperature T is used as the basis for the calculation. 进 Outlet water temperature T 出 The real-time cooling wall heat flux intensity J is calculated by substituting the cooling water mass flow rate V into the heat flux intensity calculation formula. (4) Based on the operating characteristics of blast furnaces of different volumes, a five-level classification threshold system for heat flux intensity is preset in the blast furnace PLC / DCS control system, and the heat flux intensity J of the cooling wall calculated above is compared with the five-level classification threshold system for heat flux intensity to obtain the classification warning result; (5) Based on the above-mentioned graded early warning results, the blast furnace PLC / DCS control system automatically adjusts the cooling water volume and generates a cooling water volume adjustment record, thereby forming a closed-loop control system of monitoring-calculation-judgment-adjustment-re-monitoring; (6) The blast furnace PLC / DCS control system automatically stores data with a storage period of no less than 1 year, supports historical data query, export and report generation, and realizes data traceability.

[0007] Preferably, in step (1) above, both the high-precision temperature sensor I and the high-precision temperature sensor II are made of high-temperature resistant and corrosion-resistant materials, and their measurement accuracy is ≤ ±0.1℃; the intelligent flow meter is selected as a rotor flow meter or an electromagnetic flow meter, and its measurement accuracy is ≤ ±0.5%; the high-precision temperature sensor I, the high-precision temperature sensor II and the intelligent flow meter are all electrically connected to the blast furnace PLC / DCS control system, and the collected data is uploaded to the blast furnace PLC / DCS control system in real time.

[0008] Preferably, in step (3) above, the formula for calculating heat flux intensity is: (1) In the formula, J represents the heat flux intensity of the cooling wall, and its unit is kcal / (m²). 2 ·h), used to quantify the thermal load state of the reaction cooling wall; V represents the cooling water mass flow rate, and its unit is kg / s; T 出 This indicates the outlet water temperature of the cooling wall, and its unit is °C; T 进 The value represents the inlet water temperature of the cooling wall, and its unit is °C; S represents the heat exchange area of ​​a single cooling wall, and its unit is m². 2 The data is pre-entered into the blast furnace PLC / DCS control system based on the model and size of the blast furnace cooling wall, and can be manually updated according to the replacement of the cooling wall.

[0009] Preferably, in step (4) above, the specific grading standard of the five-level heat flux intensity threshold system is as follows: (4.1) Heat flux intensity ≤ 8000 kcal / (m 2 ·h) is set to the normal value. At this time, the blast furnace condition is stable, the slag skin on the cooling wall is intact, the cooling system is operating normally, and no adjustment is required. (4.2) 8000 kcal / (m 2 ·h) < heat flux intensity ≤ 10000kcal (m 2 •h) is set to the alarm value. At this time, the heat flow intensity is slightly abnormal, and the system issues a first-level audible and visual alarm to remind the operator to closely monitor the furnace condition and the operating status of the cooling system. (4.3) 10000 kcal / (m 2 (·h) < heat flux intensity ≤ 12000 kcal / (m 2 •h) is set to the warning value. At this time, the heat flow intensity is obviously abnormal, the slag skin fluctuates or local erosion intensifies, and the system issues a level two audible and visual alarm. The cooling intensity needs to be adjusted in time. (4.4) 12000 kcal / (m 2 (·h) < heat flux intensity < 15000 kcal / (m 2 •h) is set to a dangerous value. At this time, the risk of furnace wall erosion is high and there is a risk of burning of the cooling wall. The system will issue a level three audible and visual alarm and the cooling water volume needs to be increased immediately. (4.5) Heat flux intensity ≥ 15000 kcal / (m 2 •h) is set to an extremely dangerous value. At this time, the system is in an emergency state and the risk of the cooling wall burning is extremely high. The system will issue an emergency audible and visual alarm and activate the emergency cooling plan.

[0010] Preferably, each cooling wall water supply pipe is equipped with an electric regulating ball valve and a flow feedback transmitter. The electric regulating ball valve receives the opening command of the PLC 4~20mA analog signal; the intelligent flow meter collects the cooling water mass flow rate V in real time and sends it back to the PLC to form a closed-loop PID control of the flow rate. Automatic adjustment of water volume at each level is achieved through real-time feedback from an electric regulating ball valve and a smart flow meter, combined with PLC closed-loop PID control. The target water supply flow V is calculated based on the real-time cooling water flow rate V0 at the moment of triggering adjustment, according to the preset proportions for each level. 目标 =V0×(1+flow adjustment coefficient), the blast furnace PLC / DCS control system outputs a 4~20mA analog signal to drive the electric regulating ball valve. Relying on the on-site intelligent flow meter to send back the actual flow in real time, the valve opening of the electric regulating ball valve is finely adjusted through PID calculation to make the actual flow close to the target flow and prevent instantaneous large fluctuations in cooling water.

[0011] Preferably, in step (5) above, the specific adjustment logic for the blast furnace PLC / DCS control system to automatically adjust the cooling water volume is as follows: (5.1) When the graded early warning result is determined to be within the normal value, the system keeps the current cooling water volume unchanged and continuously monitors the changes in various parameters and heat flux intensity; (5.2) When the graded early warning result determines that the alarm value has been reached, the system automatically increases the cooling water volume slightly by 5% to 10%. After the adjustment is in place, it is left to stand for 30 minutes and the real-time heat flow intensity J is re-measured until it falls back to the normal value range. At this time, the valve opening of the electric regulating ball valve is locked to maintain the existing water volume. (5.3) When the graded warning result is determined to reach the warning value, the system automatically increases the cooling water volume by 10% to 20%. After the adjustment is in place, it is left to stand for 60 minutes and the real-time heat flow intensity J is remeasured. If it falls back to the alarm range, the system automatically switches to the alarm value adjustment logic. If it falls back to the normal value range, the cooling water volume is fixed. (5.4) When the graded early warning result determines that the dangerous value has been reached, the system will automatically and significantly increase the cooling water volume by 20% to 30%, shorten the retest cycle, and remind the operator to check the cause of the abnormal furnace condition on site. (5.5) When the graded warning result is determined to reach the extreme danger value, the system automatically increases the cooling water volume by the maximum extent, the cooling water volume is increased by 35%, and at the same time the emergency cooling plan is activated, and the emergency water supply is fully opened; then it continuously monitors for 2 hours. When the real-time heat flow intensity J is gradually reduced, the cooling water volume is reduced step by step, and the adjustment logic of dangerous value, warning value and alarm value is switched in turn until the real-time heat flow intensity J returns to the normal value range.

[0012] Preferably, in step (5.2) above, the cooling water volume is preferably increased by 8%, and if the real-time heat flow intensity J still exceeds the upper limit, the cooling water volume is increased by 5% again based on the current cooling water volume.

[0013] Preferably, in step (6) above, the data automatically stored by the blast furnace PLC / DCS control system includes: the collected inlet water temperature T 进 Outlet water temperature T 出 In addition to the cooling water mass flow rate V, the real-time cooling wall heat flux intensity J and the cooling water flow rate adjustment record are calculated.

[0014] The beneficial effects of this invention are: (1) This invention realizes fully automatic online monitoring of heat flow intensity, and through precise calculation, graded early warning and intelligent closed-loop regulation, it ensures the safe and stable operation of blast furnace, extends the blast furnace life, reduces labor intensity, is compatible with various types of blast furnaces, and is easy to promote and apply; (2) This invention completely solves the problems of cumbersome, time-consuming and labor-intensive traditional manual operation, reduces the labor intensity of operators, avoids the safety risks of high temperature and high dust on-site operation, and reduces the investment of human resources costs. (3) The present invention adopts a standardized calculation formula and combines the data collected by a high-precision temperature sensor. The heat flux intensity calculation accuracy is ≥99%, which eliminates human error and ensures the accuracy of heat flux intensity monitoring results, providing a reliable basis for furnace condition judgment and cooling adjustment. (4) This invention achieves early warning and graded handling of abnormal heat flow by pre-setting a five-level threshold system for heat flow intensity, which can quickly capture sudden changes in heat flow conditions, avoid major safety accidents such as cooling wall burn-out and furnace body erosion, and ensure the safe and stable operation of the blast furnace. (5) The present invention realizes automatic adjustment of cooling water volume and forms closed-loop control. The adjustment response speed is fast and the accuracy is high, realizing precise matching of cooling intensity and heat flow intensity, thereby stabilizing the blast furnace type, protecting the furnace wall lining, and extending the life of the blast furnace. (6) All data in this invention are uploaded in real time and stored for a long time, and historical queries and report generation are supported. This provides reliable data support for blast furnace body erosion analysis, cooling system optimization and smart blast furnace construction, thereby promoting the development of blast furnace ironmaking towards intelligence and refinement. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of a method for monitoring and adjusting the heat flow intensity of a blast furnace according to the present invention. Detailed Implementation

[0017] The technical solution of the present invention will be clearly and completely described below through specific embodiments.

[0018] The present invention provides a method for monitoring and adjusting the heat flux intensity of a blast furnace, such as... Figure 1 As shown, it includes the following steps: (1) Install a high-precision temperature sensor I at the water inlet end of each cooling wall of the blast furnace, and install a high-precision temperature sensor II at the water outlet end of each cooling wall of the blast furnace, and install a smart flow meter on the water outlet pipe of each cooling wall of the blast furnace.

[0019] The high-precision temperature sensor I and high-precision temperature sensor II of this invention are both made of high-temperature and corrosion-resistant materials, and their measurement accuracy is ≤ ±0.1℃, thus adapting to the high-temperature and high-dust working environment of the blast furnace and extending the service life of the sensors. The intelligent flow meter is selected as a rotor flow meter or electromagnetic flow meter, and its measurement accuracy is ≤ ±0.5%. This invention ensures the accuracy of the collected data by controlling the measurement accuracy of high-precision temperature sensor I, high-precision temperature sensor II, and intelligent flow meter, providing reliable data support for subsequent heat flux intensity calculation. The high-precision temperature sensor I, high-precision temperature sensor II, and intelligent flow meter are all electrically connected to the blast furnace PLC / DCS control system and upload the collected data to the blast furnace PLC / DCS control system in real time, realizing real-time data acquisition, transmission, display, and storage.

[0020] (2) The inlet water temperature T of the corresponding cooling wall is continuously collected by a high-precision temperature sensor I at a sampling frequency of 1 time / second. 进 The outlet water temperature T of the corresponding cooling wall is continuously collected by high-precision temperature sensor II. 出 The system continuously collects the mass flow rate V of the cooling water using an intelligent flow meter, and then uploads the collected real-time data to the blast furnace PLC / DCS control system. The blast furnace PLC / DCS control system displays the inlet water temperature T in real time. 进 Outlet water temperature T 出 The value of the cooling water mass flow rate V is also provided, allowing operators to monitor the cooling system's operating status in real time.

[0021] (3) A standardized heat flux intensity calculation formula is preset in the blast furnace PLC / DCS control system, and then the collected inlet water temperature T is used as the basis for the calculation. 进 Outlet water temperature T 出 The real-time cooling wall heat flux intensity J is calculated by substituting the cooling water mass flow rate V into the heat flux intensity calculation formula.

[0022] The formula for calculating heat flux intensity in this invention is as follows: (1) In the formula, J represents the heat flux intensity of the cooling wall, and its unit is kcal / (m²). 2 ·h), used to quantify the thermal load state of the reaction cooling wall; V represents the cooling water mass flow rate, and its unit is kg / s; T 出 This indicates the outlet water temperature of the cooling wall, and its unit is °C; T 进 The value represents the inlet water temperature of the cooling wall, and its unit is °C; S represents the heat exchange area of ​​a single cooling wall, and its unit is m². 2 The data is pre-entered into the blast furnace PLC / DCS control system based on the model and size of the blast furnace cooling wall, and can be manually updated according to the replacement of the cooling wall.

[0023] (4) Based on the operating characteristics of blast furnaces of different volumes, a five-level grading threshold system for heat flux intensity is preset in the blast furnace PLC / DCS control system, and the real-time cooling wall heat flux intensity J calculated above is compared with the five-level grading threshold system for heat flux intensity to obtain the graded early warning result.

[0024] The specific grading criteria of the five-level heat flux intensity threshold system of this invention are as follows: (4.1) Heat flux intensity ≤ 8000 kcal / (m 2 ·h) is set to the normal value. At this time, the blast furnace condition is stable, the slag skin on the cooling wall is intact, the cooling system is operating normally, and no adjustment is required.

[0025] (4.2) 8000 kcal / (m 2 ·h) < heat flux intensity ≤ 10000kcal (m 2 ·h) is set to the alarm value. At this time, the heat flow intensity is slightly abnormal, which may be due to slight slag peeling or local heat load increase. The system will issue a first-level audible and visual alarm to remind the operator to closely monitor the furnace condition and the operating status of the cooling system.

[0026] (4.3) 10000 kcal / (m 2 (·h) < heat flux intensity ≤ 12000 kcal / (m 2 ·h) is set to the warning value. At this time, the heat flow intensity is obviously abnormal, the slag skin fluctuates or local erosion intensifies, and the system issues a level two audible and visual alarm. The cooling intensity needs to be adjusted in time.

[0027] (4.4) 12000 kcal / (m 2 (·h) < heat flux intensity < 15000 kcal / (m 2 ·h) is set to a dangerous value. At this time, the risk of furnace wall erosion is high and there is a risk of burning of the cooling wall. The system will issue a level three audible and visual alarm and the cooling water volume needs to be increased immediately.

[0028] (4.5) Heat flux intensity ≥ 15000 kcal / (m 2 •h) is set to an extremely dangerous value. At this time, the system is in an emergency. The risk of the cooling wall burning is extremely high, which may cause major accidents such as furnace air leakage. The system will issue an emergency audible and visual alarm and activate the emergency cooling plan at the same time.

[0029] (5) Based on the above-mentioned graded early warning results, the blast furnace PLC / DCS control system automatically adjusts the cooling water volume and generates a cooling water volume adjustment record, thereby forming a closed-loop control system of monitoring-calculation-judgment-adjustment-re-monitoring.

[0030] Each cooling wall water supply pipeline in this invention is equipped with an electric regulating ball valve and a flow feedback transmitter. The electric regulating ball valve receives a 4-20mA analog opening command from the PLC (the blast furnace PLC / DCS control system outputs a 4-20mA standard industrial current signal to drive the electric regulating ball valve; 4mA corresponds to the valve being fully closed, and 20mA corresponds to the valve being fully open. The actual flow rate is fed back by the same specification current signal from the intelligent flow meter, and precise flow control is achieved through PID closed-loop control). The intelligent flow meter collects the cooling water mass flow rate V in real time and feeds it back to the PLC to form a flow closed-loop PID regulation. Automatic adjustment of water volume at each level is achieved through real-time feedback from an electric regulating ball valve and a smart flow meter, combined with PLC closed-loop PID control. The target water supply flow V is calculated based on the real-time cooling water flow rate V0 at the moment of triggering adjustment, according to the preset proportions for each level. 目标 =V0×(1+flow adjustment coefficient), the blast furnace PLC / DCS control system outputs a 4~20mA analog signal to drive the electric regulating ball valve. Relying on the on-site intelligent flow meter to send back the actual flow in real time, the valve opening of the electric regulating ball valve is finely adjusted through PID calculation to make the actual flow close to the target flow and prevent instantaneous large fluctuations in cooling water.

[0031] In the above steps, the specific adjustment logic of the blast furnace PLC / DCS control system for automatically adjusting the cooling water volume is as follows: (5.1) When the graded early warning result is determined to be within the normal value, the system keeps the current cooling water volume unchanged and continuously monitors the changes in various parameters and heat flow intensity.

[0032] (5.2) When the graded early warning result determines that the alarm value has been reached, the system automatically increases the cooling water volume slightly by 5% to 10%. After the adjustment is in place, it is left to stand for 30 minutes and the real-time heat flow intensity J is re-measured until it falls back to the normal value range. At this time, the valve opening of the electric regulating ball valve is locked to maintain the existing water volume. The cooling water volume is preferably increased by 8%, and if the real-time heat flow intensity J still exceeds the upper limit, the cooling water volume is increased by 5% again on the basis of the current cooling water volume.

[0033] (5.3) When the graded warning result is determined to reach the warning value, the system automatically increases the cooling water volume by 10% to 20%. After the adjustment is in place, it is left to stand for 60 minutes and the real-time heat flow intensity J is remeasured. If it falls back to the alarm range, the system automatically switches to the alarm value adjustment logic. If it falls back to the normal value range, the cooling water volume is fixed.

[0034] (5.4) When the graded early warning result is determined to reach the dangerous value, the system automatically and significantly increases the cooling water volume by 20% to 30%, shortens the retest cycle, and reminds the operator to check the cause of the abnormal furnace condition on site.

[0035] (5.5) When the graded warning result is determined to reach the extreme danger value, the system automatically increases the cooling water volume by the maximum extent, the cooling water volume is increased by 35%, and at the same time the emergency cooling plan is activated, and the emergency water supply is fully opened; then it continuously monitors for 2 hours. When the real-time heat flow intensity J is gradually reduced, the cooling water volume is reduced step by step, and the adjustment logic of dangerous value, warning value and alarm value is switched in turn until the real-time heat flow intensity J returns to the normal value range.

[0036] (6) The blast furnace PLC / DCS control system automatically stores data with a storage period of no less than 1 year. It supports historical data query, export and report generation, realizes data traceability, and provides reliable data support for blast furnace body erosion trend analysis, cooling system optimization, blast furnace long life management and intelligent upgrading.

[0037] The data automatically stored by the blast furnace PLC / DCS control system of this invention includes: the collected inlet water temperature T 进 Outlet water temperature T 出 In addition to the cooling water mass flow rate V, the real-time cooling wall heat flux intensity J and the cooling water flow rate adjustment record are calculated.

[0038] This invention is applicable to large, medium, and small blast furnaces. It can flexibly adjust the specific values ​​of the five-level heat flux intensity threshold system, the increase ratio of cooling water volume at each level, and the retest waiting time online according to the blast furnace volume and cooling wall material (copper cooling wall, cast iron cooling wall, etc.). All valve action and flow change data are automatically archived. It adapts to the operating conditions of different blast furnaces without the need for large-scale modification of the existing blast furnace system. It can be implemented based on the existing blast furnace PLC / DCS control system, with low investment cost and easy promotion and application.

[0039] Example 1 For a blast furnace with a conventional operating volume of 2000m³ The blast furnace uses cast iron cooling walls, with a heat exchange area of ​​S = 1.1212 m² per wall. The specific values ​​of the five-level heat flux intensity threshold system preset in the blast furnace PLC / DCS control system are: the normal value is ≤8000 kcal / (m²). 2 The alarm value is 8000~10000kcal (m³). 2 •h), the warning value is 10000~12000kcal (m 2 •h), the danger value is 12000~15000kcal (m³) 2 •h), Extreme danger value >15000kcal (m 2 ·h).

[0040] A method for monitoring and adjusting the heat flux intensity of a blast furnace according to the present invention includes the following steps: (1) Install a high-precision temperature sensor I at the water inlet end of each cooling wall of the blast furnace, and install a high-precision temperature sensor II at the water outlet end of each cooling wall of the blast furnace, and install a smart flow meter on the water outlet pipe of each cooling wall of the blast furnace.

[0041] (2) The inlet water temperature T of the corresponding cooling wall is collected by high-precision temperature sensor I. 进 =26.6℃, the outlet water temperature T of the corresponding cooling wall was collected by high-precision temperature sensor II. 出 =27.2℃, the mass flow rate of cooling water V=3.11kg / s was collected by an intelligent flow meter, and the collected data was uploaded to the blast furnace PLC / DCS control system in real time.

[0042] (3) Collect the inlet water temperature T 进 Outlet water temperature T 出 The real-time cooling wall heat flux intensity is calculated by substituting the cooling water mass flow rate V into the heat flux intensity calculation formula. .

[0043] (4) Based on the preset five-level heat flux intensity threshold system, and referring to the real-time cooling wall heat flux intensity J≈6011kcal (m³ / s), 2 •h) to obtain the graded early warning result, that is, because ≤8000kcal / (m² h) is considered a normal value. At this time, the blast furnace condition is stable, the slag skin on the cooling wall is intact, and the cooling system is operating normally. No adjustments are needed; simply maintain the current operating state.

[0044] (5) Since the grading warning result is determined to be within the normal value, the system maintains the current cooling water volume unchanged and continuously monitors the changes in various parameters and heat flow intensity.

[0045] (6) The blast furnace PLC / DCS control system automatically stores the inlet water temperature T. 进 Outlet water temperature T 出 Records of cooling water mass flow rate V, cooling wall heat flux intensity J, and cooling water flow rate adjustment are compiled to form a complete historical data set.

[0046] Example 2 For blast furnaces with a furnace volume of 2000m³ operating under alarm conditions The blast furnace uses cast iron cooling walls, with a heat exchange area of ​​S = 1.1212 m² per wall. The specific values ​​of the five-level heat flux intensity threshold system preset in the blast furnace PLC / DCS control system are: the normal value is ≤8000 kcal / (m²). 2 The alarm value is 8000~10000kcal (m³). 2 •h), the warning value is 10000~12000kcal (m 2•h), the danger value is 12000~15000kcal (m³) 2 •h), Extreme danger value >15000kcal (m 2 ·h).

[0047] A method for monitoring and adjusting the heat flux intensity of a blast furnace according to the present invention includes the following steps: (1) Install a high-precision temperature sensor I at the water inlet end of each cooling wall of the blast furnace, and install a high-precision temperature sensor II at the water outlet end of each cooling wall of the blast furnace, and install a smart flow meter on the water outlet pipe of each cooling wall of the blast furnace.

[0048] (2) The inlet water temperature T of the corresponding cooling wall is collected by high-precision temperature sensor I. 进 =25.6℃, the outlet water temperature T of the corresponding cooling wall was collected by high-precision temperature sensor II. 出 =26.5℃, the mass flow rate of cooling water V=2.98kg / s is collected by intelligent flow meter, and the collected data is uploaded to the blast furnace PLC / DCS control system in real time.

[0049] (3) Collect the inlet water temperature T 进 Outlet water temperature T 出 The real-time cooling wall heat flux intensity is calculated by substituting the cooling water mass flow rate V into the heat flux intensity calculation formula. .

[0050] (4) Based on the preset five-level heat flux intensity threshold system, and referring to the real-time cooling wall heat flux intensity J≈8640kcal (m³ / s), 2 The graded early warning result was obtained by ·h), that is, because it is located in the range of 8000~10000kcal (m 2 If the value is within the range of (h), it is determined to be an alarm value. At this time, the heat flow intensity is slightly abnormal, and the system issues a first-level audible and visual alarm.

[0051] (5) The system automatically increases the cooling water volume slightly by 8%, continuously monitors the heat flux intensity, and after adjustment, lets it stand for 30 minutes before retesting to collect the inlet water temperature T. 进 =25.6℃, outlet water temperature T 出 =26.2℃, cooling water mass flow rate V=3.22kg / s, substituting into formula (1) again, we get J≈6224kcal / (m²) h), when the water level drops back to the normal range, stop increasing the cooling water volume, lock the opening of the electric regulating ball valve, and maintain the current water volume.

[0052] (6) The blast furnace PLC / DCS control system automatically stores the inlet water temperature T. 进 Outlet water temperature T 出Records of cooling water mass flow rate V, cooling wall heat flux intensity J, and cooling water flow rate adjustment are compiled to form a complete historical data set.

[0053] Example 3 For blast furnaces with a volume of 2000m³ under alarm operating conditions The blast furnace uses cast iron cooling walls, with a heat exchange area of ​​S = 1.1212 m² per wall. The specific values ​​of the five-level heat flux intensity threshold system preset in the blast furnace PLC / DCS control system are: the normal value is ≤8000 kcal / (m²). 2 The alarm value is 8000~10000kcal (m³). 2 •h), the warning value is 10000~12000kcal (m 2 •h), the danger value is 12000~15000kcal (m³) 2 •h), Extreme danger value >15000kcal (m 2 ·h).

[0054] A method for monitoring and adjusting the heat flux intensity of a blast furnace according to the present invention includes the following steps: (1) Install a high-precision temperature sensor I at the water inlet end of each cooling wall of the blast furnace, and install a high-precision temperature sensor II at the water outlet end of each cooling wall of the blast furnace, and install a smart flow meter on the water outlet pipe of each cooling wall of the blast furnace.

[0055] (2) The inlet water temperature T of the corresponding cooling wall is collected by high-precision temperature sensor I. 进 =26.1℃, the outlet water temperature T of the corresponding cooling wall was collected by high-precision temperature sensor II. 出 =27.2℃, the mass flow rate of cooling water V=3.11kg / s was collected by an intelligent flow meter, and the collected data was uploaded to the blast furnace PLC / DCS control system in real time.

[0056] (3) Collect the inlet water temperature T 进 Outlet water temperature T 出 The real-time cooling wall heat flux intensity is calculated by substituting the cooling water mass flow rate V into the heat flux intensity calculation formula. .

[0057] (4) Based on the preset five-level heat flux intensity threshold system, and referring to the real-time cooling wall heat flux intensity J≈10090kcal (m³ / s), 2 The graded early warning result was obtained by ·h), that is, because it is located in the range of 10000~12000kcal (m 2 Within the range of ·h), it is determined to be a warning value. At this time, the heat flow intensity is obviously abnormal, the slag skin fluctuates or local erosion intensifies, and the system issues a level two audible and visual alarm.

[0058] (5) The system automatically increases the cooling water volume by 15% and continuously monitors the heat flux intensity. After adjustment, it is left to stand for 60 minutes and then retested to collect the inlet water temperature T. 进 =26.1℃, outlet water temperature T 出 =26.8℃, cooling water mass flow rate V=3.58kg / s, substituting into formula (1) again, we get J≈8960kcal / (m²) h), it dropped back to the alarm value range, and then the water volume was increased slightly, changing to a 5% increase in cooling water volume. After 30 minutes, J dropped back to 7900 kcal / (m²). h) If the value is within the normal range, stop adjusting the cooling water flow and maintain the current water flow.

[0059] (6) The blast furnace PLC / DCS control system automatically stores the inlet water temperature T. 进 Outlet water temperature T 出 Records of cooling water mass flow rate V, cooling wall heat flux intensity J, and cooling water flow rate adjustment are compiled to form a complete historical data set.

[0060] Example 4 For blast furnaces with a volume of 2000m³ operating under extremely dangerous conditions The blast furnace uses cast iron cooling walls, with a heat exchange area of ​​S = 1.1212 m² per wall. The specific values ​​of the five-level heat flux intensity threshold system preset in the blast furnace PLC / DCS control system are: the normal value is ≤8000 kcal / (m²). 2 The alarm value is 8000~10000kcal (m³). 2 •h), the warning value is 10000~12000kcal (m 2 •h), the danger value is 12000~15000kcal (m³) 2 •h), Extreme danger value >15000kcal (m 2 ·h).

[0061] A method for monitoring and adjusting the heat flux intensity of a blast furnace according to the present invention includes the following steps: (1) Install a high-precision temperature sensor I at the water inlet end of each cooling wall of the blast furnace, and install a high-precision temperature sensor II at the water outlet end of each cooling wall of the blast furnace, and install a smart flow meter on the water outlet pipe of each cooling wall of the blast furnace.

[0062] (2) The inlet water temperature T of the corresponding cooling wall is collected by high-precision temperature sensor I. 进 =26.5℃, the outlet water temperature T of the corresponding cooling wall was collected by high-precision temperature sensor II. 出=28.8℃, the mass flow rate of cooling water V=3.11kg / s was collected by a smart flow meter, and the collected data was uploaded to the blast furnace PLC / DCS control system in real time.

[0063] (3) Collect the inlet water temperature T 进 Outlet water temperature T 出 The real-time cooling wall heat flux intensity is calculated by substituting the cooling water mass flow rate V into the heat flux intensity calculation formula. .

[0064] (4) Based on the preset five-level heat flux intensity threshold system, and referring to the real-time cooling wall heat flux intensity J≈15460kcal (m³ / h), 2 The graded early warning result is obtained by ·h), that is, due to >15000kcal (m 2 If the value is determined to be extremely dangerous (·h), an emergency situation is declared, and the risk of the cooling wall burning is extremely high. The system will issue an emergency audible and visual alarm and activate the emergency cooling plan.

[0065] (5) The system automatically increases the cooling water volume to the maximum extent, increasing it by 35%, and simultaneously activates the emergency cooling plan. The operator immediately checks the furnace condition and fully opens the emergency water supply. Then, it continuously monitors for 2 hours, and then re-measures to collect the inlet water temperature T. 进 =26.5℃, outlet water temperature T 出 =27.5℃, cooling water mass flow rate V=4.19kg / s, substituting into formula (1) again, we get J≈9230kcal / (m²) h), the water flow rate drops back to the alarm range, and then the flow rate is increased slightly until J returns to the normal range.

[0066] (6) The blast furnace PLC / DCS control system automatically stores the inlet water temperature T. 进 Outlet water temperature T 出 Records of cooling water mass flow rate V, cooling wall heat flux intensity J, and cooling water flow rate adjustment are compiled to form a complete historical data set.

[0067] The beneficial effects of this invention are: (1) This invention realizes fully automatic online monitoring of heat flow intensity, and through precise calculation, graded early warning and intelligent closed-loop regulation, it ensures the safe and stable operation of blast furnace, extends the blast furnace life, reduces labor intensity, is compatible with various types of blast furnaces, and is easy to promote and apply; (2) This invention completely solves the problems of cumbersome, time-consuming and labor-intensive traditional manual operation, reduces the labor intensity of operators, avoids the safety risks of high temperature and high dust on-site operation, and reduces the investment of human resources costs. (3) The present invention adopts a standardized calculation formula and combines the data collected by a high-precision temperature sensor. The heat flux intensity calculation accuracy is ≥99%, which eliminates human error and ensures the accuracy of heat flux intensity monitoring results, providing a reliable basis for furnace condition judgment and cooling adjustment. (4) This invention achieves early warning and graded handling of abnormal heat flow by pre-setting a five-level threshold system for heat flow intensity, which can quickly capture sudden changes in heat flow conditions, avoid major safety accidents such as cooling wall burn-out and furnace body erosion, and ensure the safe and stable operation of the blast furnace. (5) The present invention realizes automatic adjustment of cooling water volume and forms closed-loop control. The adjustment response speed is fast and the accuracy is high, realizing precise matching of cooling intensity and heat flow intensity, thereby stabilizing the blast furnace type, protecting the furnace wall lining, and extending the life of the blast furnace. (6) All data in this invention are uploaded in real time and stored for a long time, and historical queries and report generation are supported. This provides reliable data support for blast furnace body erosion analysis, cooling system optimization and smart blast furnace construction, thereby promoting the development of blast furnace ironmaking towards intelligence and refinement.

[0068] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the concept and scope of the present invention. Without departing from the design concept of the present invention, all modifications and improvements made by those skilled in the art to the technical solutions of the present invention should fall within the protection scope of the present invention. The technical content for which protection is sought in the present invention has been fully described in the technical requirements.

Claims

1. A method for monitoring and adjusting the heat flux intensity of a blast furnace, characterized in that... Includes the following steps: (1) Install high-precision temperature sensor I at the water inlet end of each cooling wall of the blast furnace, and install high-precision temperature sensor II at the water outlet end of each cooling wall of the blast furnace, and install intelligent flow meter on the water outlet pipe of each cooling wall of the blast furnace. (2) The inlet water temperature T of the corresponding cooling wall is continuously collected by a high-precision temperature sensor I at a sampling frequency of 1 time / second. 进 The outlet water temperature T of the corresponding cooling wall is continuously collected by high-precision temperature sensor II. 出 The cooling water mass flow rate V is continuously collected by an intelligent flow meter, and the collected real-time data is then uploaded to the blast furnace PLC / DCS control system in real time. (3) A standardized heat flux intensity calculation formula is preset in the blast furnace PLC / DCS control system, and then the collected inlet water temperature T is used as the basis for the calculation. 进 Outlet water temperature T 出 The real-time cooling wall heat flux intensity J is calculated by substituting the cooling water mass flow rate V into the heat flux intensity calculation formula. (4) Based on the working characteristics of blast furnaces of different volumes, a five-level classification threshold system for heat flux intensity is preset in the blast furnace PLC / DCS control system, and the real-time cooling wall heat flux intensity J calculated above is compared with the five-level classification threshold system for heat flux intensity to obtain the classification warning result. (5) Based on the above-mentioned graded early warning results, the blast furnace PLC / DCS control system automatically adjusts the cooling water volume and generates a cooling water volume adjustment record, thereby forming a closed-loop control system of monitoring-calculation-judgment-adjustment-re-monitoring; (6) The blast furnace PLC / DCS control system automatically stores data with a storage period of no less than 1 year, supports historical data query, export and report generation, and realizes data traceability.

2. The method for monitoring and adjusting the heat flux intensity of a blast furnace according to claim 1, characterized in that: In step (1) above, both the high-precision temperature sensor I and the high-precision temperature sensor II are made of high-temperature and corrosion-resistant materials, and their measurement accuracy is ≤ ±0.1℃; the intelligent flow meter is selected as a rotor flow meter or an electromagnetic flow meter, and its measurement accuracy is ≤ ±0.5%; the high-precision temperature sensor I, the high-precision temperature sensor II and the intelligent flow meter are all electrically connected to the blast furnace PLC / DCS control system, and the collected data is uploaded to the blast furnace PLC / DCS control system in real time.

3. The method for monitoring and adjusting the heat flux intensity of a blast furnace according to claim 1, characterized in that: In step (3) above, the formula for calculating heat flux intensity is: （1） In the formula, J represents the heat flux intensity of the cooling wall, and its unit is kcal / (m²). 2 ·h), used to quantify the thermal load state of the reaction cooling wall; V represents the cooling water mass flow rate, and its unit is kg / s; T 出 This indicates the outlet water temperature of the cooling wall, and its unit is °C; T 进 The value represents the inlet water temperature of the cooling wall, and its unit is °C; S represents the heat exchange area of ​​a single cooling wall, and its unit is m². 2 The data is pre-entered into the blast furnace PLC / DCS control system based on the model and size of the blast furnace cooling wall, and can be manually updated according to the replacement of the cooling wall.

4. The method for monitoring and adjusting the heat flux intensity of a blast furnace according to claim 1, characterized in that: In step (4) above, the specific grading criteria of the five-level heat flux intensity threshold system are as follows: (4.1) Heat flux intensity ≤ 8000 kcal / (m 2 ·h) is set to the normal value. At this time, the blast furnace condition is stable, the slag skin on the cooling wall is intact, the cooling system is operating normally, and no adjustment is required. (4.2) 8000 kcal / (m 2 ·h) < heat flux intensity ≤ 10000kcal (m 2 •h) is set to the alarm value. At this time, the heat flow intensity is slightly abnormal, and the system issues a first-level audible and visual alarm to remind the operator to closely monitor the furnace condition and the operating status of the cooling system. (4.3) 10000 kcal / (m 2 (·h) < heat flux intensity ≤ 12000 kcal / (m 2 •h) is set to the warning value. At this time, the heat flow intensity is obviously abnormal, the slag skin fluctuates or local erosion intensifies, and the system issues a level two audible and visual alarm. The cooling intensity needs to be adjusted in time. (4.4) 12000 kcal / (m 2 (·h) < heat flux intensity < 15000 kcal / (m 2 •h) is set to a dangerous value. At this time, the risk of furnace wall erosion is high and there is a risk of burning of the cooling wall. The system will issue a level three audible and visual alarm and the cooling water volume needs to be increased immediately. (4.5) Heat flux intensity ≥ 15000 kcal / (m 2 •h) is set to an extremely dangerous value. At this time, the system is in an emergency state and the risk of the cooling wall burning is extremely high. The system will issue an emergency audible and visual alarm and activate the emergency cooling plan.

5. The method for monitoring and adjusting the heat flux intensity of a blast furnace according to claim 1, characterized in that: Each cooling wall water supply pipe is equipped with an electric regulating ball valve and a flow feedback transmitter. The electric regulating ball valve receives the opening command of the PLC 4-20mA analog quantity; the intelligent flow meter collects the cooling water mass flow rate V in real time and sends it back to the PLC to form a closed-loop PID regulation of the flow. Automatic adjustment of water volume at each level is achieved through real-time feedback from an electric regulating ball valve and a smart flow meter, combined with PLC closed-loop PID control. The target water supply flow V is calculated based on the real-time cooling water flow rate V0 at the moment of triggering adjustment, according to the preset proportions for each level. 目标 =V0×(1+flow adjustment coefficient), the blast furnace PLC / DCS control system outputs a 4~20mA analog signal to drive the electric regulating ball valve. Relying on the on-site intelligent flow meter to send back the actual flow in real time, the valve opening of the electric regulating ball valve is finely adjusted through PID calculation to make the actual flow close to the target flow and prevent instantaneous large fluctuations in cooling water.

6. The method for monitoring and adjusting the heat flux intensity of a blast furnace according to claim 5, characterized in that: In step (5) above, the specific adjustment logic of the blast furnace PLC / DCS control system for automatically adjusting the cooling water volume is as follows: (5.1) When the graded early warning result is determined to be within the normal value, the system keeps the current cooling water volume unchanged and continuously monitors the changes in various parameters and heat flux intensity; (5.2) When the graded early warning result determines that the alarm value has been reached, the system automatically increases the cooling water volume slightly by 5% to 10%. After the adjustment is in place, it is left to stand for 30 minutes and the real-time heat flow intensity J is re-measured until it falls back to the normal value range. At this time, the valve opening of the electric regulating ball valve is locked to maintain the existing water volume. (5.3) When the graded warning result is determined to reach the warning value, the system automatically increases the cooling water volume by 10% to 20%. After the adjustment is in place, it is left to stand for 60 minutes and the real-time heat flow intensity J is remeasured. If it falls back to the alarm range, the system automatically switches to the alarm value adjustment logic. If it falls back to the normal value range, the cooling water volume is fixed. (5.4) When the graded early warning result determines that the dangerous value has been reached, the system will automatically and significantly increase the cooling water volume by 20% to 30%, shorten the retest cycle, and remind the operator to check the cause of the abnormal furnace condition on site. (5.5) When the graded warning result is determined to reach the extreme danger value, the system will automatically increase the cooling water volume by the maximum extent, the cooling water volume will be increased by 35%, and the emergency cooling plan will be activated at the same time, and the emergency water supply opening will be fully opened. Then, continuous monitoring for 2 hours was conducted. As the real-time heat flux intensity J gradually decreased, the cooling water volume was reduced step by step. The adjustment logic was switched to the dangerous value, warning value, and alarm value levels in sequence until the real-time heat flux intensity J returned to the normal range.

7. The method for monitoring and adjusting the heat flux intensity of a blast furnace according to claim 6, characterized in that: In step (5.2) above, the cooling water volume is preferably increased by 8%, and if the real-time heat flow intensity J still exceeds the upper limit, the cooling water volume is increased by 5% again based on the current cooling water volume.

8. The method for monitoring and adjusting the heat flux intensity of a blast furnace according to claim 1, characterized in that: In step (6) above, the data automatically stored by the blast furnace PLC / DCS control system includes: the collected inlet water temperature T 进 Outlet water temperature T 出 In addition to the cooling water mass flow rate V, the real-time cooling wall heat flux intensity J and the cooling water flow rate adjustment record are calculated.

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