A system and device for preheating alloy materials by recovering waste heat from a blast furnace slag runner

Abstract

This invention relates to the field of metallurgical auxiliary material production technology, specifically to a system and device for recovering waste heat from blast furnace slag and iron troughs to preheat alloy materials. The system includes a feeding control module, a baffle parameter configuration module, a baffle fabrication and installation module, a preheating station module, and a temperature judgment and discharge module. The feeding control module acquires the minimum particle size, melting and softening temperature, and average temperature of the radiant surface of the slag and iron material. The baffle parameter configuration module sets the baffle aperture based on the minimum particle size and iteratively solves the suspension height using the heat balance equation. The baffle fabrication and installation module fabricates perforated baffles according to the acquired parameters and installs them in the trough. The preheating station module hoists the trough above the slag and iron trough for radiant preheating and collects the temperature. The temperature judgment and discharge module releases material by illuminating a green light or forcing emergency discharge by illuminating a red light based on the temperature. This invention utilizes the radiant waste heat of the slag and iron trough to preheat the alloy and prevents high-temperature adhesion through the quantitative matching of baffle parameters and material properties.

Description

Technical Field

[0001] This invention relates to the field of metallurgical auxiliary material production technology, specifically to a system and apparatus for recovering waste heat from blast furnace slag and iron trough to preheat alloy materials. Background Technology

[0002] During the blast furnace ironmaking process, the high-temperature slag and molten iron flowing in the slag and iron trough can reach a temperature of 1400-1600℃, which will release a large amount of residual heat through radiation. At the same time, in the process of adding silicon and manganese outside the furnace to produce foundry iron, the addition of alloy materials is a key process to ensure product quality. Commonly used alloy materials are silicon-manganese alloy and ferrosilicon.

[0003] There are two prominent problems in the industry: First, a large amount of waste heat released from slag and iron ditch is not effectively utilized and is directly lost to the environment, causing energy waste and thermal pollution; Second, alloy materials are often added directly into the furnace at room temperature, which leads to a significant drop in the temperature of molten steel, with a single temperature drop of up to 80-100℃, causing alloy agglomeration, incomplete melting, and affecting the uniformity of the composition of molten steel.

[0004] Existing technologies address these issues primarily through two methods: one is to employ a blast furnace waste heat recovery device, which mainly recovers waste heat from flue gas or slag flushing steam; the other is to use methods such as electric heating or gas baking to preheat alloy materials.

[0005] However, the above solutions have certain limitations: waste heat recovery and alloy preheating are not directly coupled, resulting in low waste heat utilization efficiency; using electric heating or baking methods to preheat alloy materials will increase production costs. More importantly, conventional preheating devices, under high-temperature radiation conditions, are prone to causing alloy materials to melt and adhere to the heated surface, leading to unstable preheating effects.

[0006] Therefore, there is an urgent need for a technical solution that utilizes the radiant heat of slag iron troughs to preheat alloy materials and can actively prevent high-temperature adhesion of the alloy. Summary of the Invention

[0007] One objective of this invention is to provide a system for recovering waste heat from blast furnace slag and iron troughs to preheat alloy materials. This system obtains the particle size and temperature parameters of the alloy materials, sets the baffle aperture based on the minimum particle size, calculates the suspension height according to the heat balance equation, and hoists a trough with baffles above the slag and iron trough for radiative preheating. Simultaneously, it monitors the material temperature in real time and controls the discharge action according to a threshold, thereby solving the problems mentioned in the background art, namely: The waste heat of blast furnace slag iron trough is directly lost, the waste heat utilization efficiency is low, and the alloy materials at room temperature are prone to melting and adhesion, making it difficult to improve the preheating effect.

[0008] To achieve the above objectives, the system includes a feeding control module, which is used to obtain the type identifier of the alloy material and retrieve the minimum particle size, melting and softening temperature and average temperature of the slag-iron radiant surface of the alloy material. It also includes a partition parameter configuration module, a partition fabrication and installation module, a preheating station module and a temperature judgment and discharge module. The partition parameter configuration module is used to generate parameters including partition aperture and suspension height, including the following steps: The value of the partition pore size is set to be smaller than the minimum particle size; Based on the melting and softening temperature and the average temperature of the slag-iron radiating surface, a steady-state thermal balance equation for the partition is established. The suspension height is obtained by numerical iteration under the constraint that the steady-state temperature of the partition does not exceed the melting and softening temperature minus the safety margin. The partition fabrication and installation module fabricates a perforated metal partition with through holes based on the partition hole diameter and suspension height, and installs it inside the tank. It is used to set the distance between the lower surface of the partition and the inner surface of the tank bottom as the suspension height and generate an installation completion signal. The preheating station module receives the installation completion signal, lifts the tank to the top of the slag and iron ditch for radiative preheating, and collects the temperature data of the alloy material through thermocouples. The temperature judgment and discharge module receives temperature data. When the temperature is within the preset range, it lights up a green light and allows discharge. When the temperature exceeds the safety threshold, it lights up a red light and forces emergency discharge.

[0009] The reason for limiting the pore size based on the minimum particle size and then using the thermal balance equation to deduce the suspension height in the above technical solution is that if these two constraints are skipped and the holes are opened or the baffle position is fixed arbitrarily, two typical failures will occur: if the pore size is larger than the minimum particle size of the material, the fine powder will pass through the baffle and fall to the bottom of the tank, where it will be directly heated by the radiation surface at thousands of degrees and melt and adhere; if the suspension height is too small, the baffle itself will absorb too much heat, causing the temperature to exceed the softening point of the material, which in turn will bake the alloy accumulated on it and cause it to clump together; if the height is too large, the radiant heat will have difficulty penetrating the air layer, and the preheating efficiency will drop significantly. Only by simultaneously limiting the pore size to within the lower limit of the particle size and adjusting the height to a value where the baffle temperature is just below the softening point can heat be passed through without the material sticking. Subsequent manufacturing, hoisting, and real-time monitoring of temperature for graded discharge according to the calculated values ​​are to put these design parameters into practice and avoid the disconnect between theoretical calculations and actual operation.

[0010] Based on this, the partition fabrication and installation module uses heat-resistant stainless steel plate, and through holes are machined according to the partition hole diameter with uniform hole spacing. The machined partition is placed horizontally inside the tank, and the partition is welded and fixed to the side wall of the tank around its perimeter. After installation, the actual distance between the lower surface of the partition and the inner surface of the tank bottom is measured to confirm that the deviation of this distance from the suspension height is within the tolerance range recommended by the sensitivity coefficient.

[0011] In another technical solution, the thermocouples in the preheating station module are two K-type thermocouples. The two thermocouples are respectively installed at the center of both sides of the tank. Each thermocouple is covered with a heat-resistant stainless steel protective sleeve and is fixed to the side wall of the tank by threaded insertion. The measuring end of the thermocouple extends into the tank and contacts the alloy material. The two thermocouples independently collect temperature signals and take their arithmetic average as the current temperature value of the material.

[0012] In this technical solution, the through-hole machining and welding fixation are not complex in themselves. However, without actual distance measurement after installation, even the most accurate calculated suspension height cannot be implemented. Positioning errors and thermal deformation are inevitable during manufacturing and welding. If the actual deviation exceeds the tolerance range set by the sensitivity coefficient, the partition temperature will significantly deviate from the design value, either causing material overheating and adhesion or insufficient preheating. Similarly, if only one thermocouple is installed, the temperature feedback will be distorted if that point happens to be in a locally overcooled or overheated area, rendering the entire preheating control unreliable. By installing one thermocouple at the center of each side and averaging the results, a relatively accurate overall material temperature can be obtained even with localized temperature differences. Combined with a heat-resistant protective sleeve and threaded fixing, this ensures the sensor does not fail under long-term high-temperature conditions. These measures essentially use redundancy and verification to compensate for deviations between design and manufacturing, ensuring that the calculation results of the partition parameter configuration module work on the actual equipment.

[0013] The second objective of this invention is to provide a device for recovering waste heat from blast furnace slag iron trough and preheating alloy materials, comprising a tank body formed by welding multiple heat-resistant stainless steel plates together, an inlet at the top of the tank body, an outlet at the bottom of the tank body, and lifting lugs symmetrically distributed on the outer walls of both sides of the tank body. The tank is equipped with a horizontally arranged porous metal partition. The porous metal partition is suspended at a certain height from the bottom of the tank. The porous metal partition is uniformly provided with through holes, and the diameter of the through holes is smaller than the minimum particle size of the alloy material. Thermocouples are installed on both side walls of the tank to collect the temperature of the alloy material inside the tank; It also includes a temperature monitoring and digital display system electrically connected to the thermocouple, used to display the temperature value and illuminate an indicator light according to a preset threshold.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention determines the aperture of the baffle plate based on the minimum particle size of the alloy material, ensuring that the aperture is smaller than the minimum particle size to prevent fine powder from falling to the bottom of the high-temperature tank and adhering. At the same time, a heat balance equation is established based on the melting and softening temperature of the material and the average temperature of the slag and iron radiant surface. The suspension height of the baffle plate and the bottom of the tank is determined by iterative solution, so that the temperature of the baffle plate is controlled below the softening point of the material.

[0015] 2. The present invention uses a pore size smaller than the minimum particle size and a suspension height obtained by thermal equilibrium iteration to ensure that the partition plate's temperature remains below the material's softening point while transferring radiant heat.

[0016] 3. This invention installs two thermocouples at the center of each side of the tank, and takes the average value as the material temperature to avoid inaccurate judgments caused by local temperature differences in single-point temperature measurement. The thermocouples are covered with heat-resistant stainless steel protective sleeves and are fixed by threaded insertion to ensure reliable temperature measurement under long-term high-temperature conditions.

[0017] 4. After the partition is welded and installed, the present invention measures the deviation between the actual suspension height and the design value, and judges whether it is within the tolerance range based on the sensitivity coefficient, so as to ensure that the design parameters can be implemented on the actual equipment and avoid the partition temperature deviating from the expected value due to manufacturing deviation.

[0018] 5. This invention directly utilizes the radiant waste heat from the blast furnace slag and iron trough for preheating. The device requires no external energy source, and hoisting and unloading operations rely on on-site lifting equipment and manual switches, making maintenance convenient. The main body of the device is welded from heat-resistant stainless steel, with no complex moving parts, making it suitable for continuous blast furnace production while reducing thermal pollution caused by direct discharge of waste heat from the slag and iron trough. Attached Figure Description

[0019] Figure 1 This is a system overall structure diagram of the blast furnace slag iron trough waste heat recovery and preheating alloy materials according to the present invention; Figure 2 This is a flowchart illustrating the structure of the partition fabrication and installation module of the present invention. Figure 3 This is a flowchart illustrating the structure of the preheating station module of the present invention. Figure 4 This is a schematic diagram of the overall structure of the device for recovering waste heat from blast furnace slag and iron trough and preheating alloy materials according to the present invention. Figure 5 This is a cross-sectional view of the radiative heat and apparatus for slag and iron ditch of the present invention.

[0020] The meanings of the labels in the diagram are as follows: 100. Feeding control module; 200. Partition parameter configuration module; 300. Partition fabrication and installation module; 400. Preheating station module; 500. Temperature judgment and discharge module. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Here are some explanations of technical terms: The graduation number is the identification code of the thermocouple model, used to characterize the correspondence between the electromotive force and temperature of the thermocouple.

[0023] Currently, the direct loss of waste heat from blast furnace slag and iron trough, low waste heat utilization efficiency, and the tendency of room-temperature alloy materials to melt and adhere, making it difficult to improve preheating effects, are problems addressed by this invention. This invention provides a system for recovering waste heat from blast furnace slag and iron trough to preheat alloy materials. (See [link to relevant documentation]). Figure 1 As shown, it includes a feeding control module 100, a partition parameter configuration module 200, a partition fabrication and installation module 300, a preheating station module 400, and a temperature judgment and discharge module 500.

[0024] This system utilizes the radiant heat of the slag and iron trough to preheat alloy materials. Through the coordinated design of the pore size and suspension height of the built-in metal porous baffle, heat is efficiently transferred while preventing the material from melting and adhering to the high-temperature trough bottom. Combined with real-time temperature monitoring and graded early warning, the system achieves a dual improvement in waste heat utilization efficiency and preheating effect, completing a safe, energy-saving, and stable preheating process for alloy materials.

[0025] In the specific implementation of the feeding control module 100, the system first completes the preparatory work before loading.

[0026] The operator places the preheating tank at the charging station next to the slag and iron trough in the blast furnace tapping area and confirms that the discharge port at the bottom of the tank has been reliably closed by the mechanical switch.

[0027] Subsequently, the operators use a forklift or hopper to add the bulk alloy material into the tank through the feed inlet at the top of the tank until the material reaches the preset loading volume.

[0028] During the above feeding process, the feeding control module 100 performs the following data acquisition and processing steps in parallel: Ⅰ: First, obtain the alloy material type identifier.

[0029] Specifically, the feed control module 100 receives material type information input by the operator through a human-machine interface. Based on the daily production plan, the operator selects the type of material for the current batch from a drop-down menu on the interface. Available types include silicon-manganese alloy and ferrosilicon. The system stores the selected type as a material type identifier.

[0030] As an alternative, the feed control module 100 automatically scans the electronic tags on the material packaging by connecting to the radio frequency reader of the material batch management system, thereby obtaining the material type identification without contact.

[0031] Regardless of the method used, the final output is a string that identifies the alloy type of the current material.

[0032] II: Based on the material type identifier, retrieve and extract the corresponding set of physical property parameters from the pre-stored alloy property database.

[0033] Specifically, the feed control module 100 integrates an alloy material property database, which pre-stores typical physical property parameters for various alloys. After obtaining the material type identifier, the module uses this identifier as an index to retrieve and read the following three parameters from the database: Minimum particle size d of the material min The database pre-stores the typical particle size distribution range for each alloy type, which includes a lower limit and an upper limit. The feed control module 100 uses the material type identifier as an index to query the lower limit of the particle size distribution for that alloy type, and uses this lower limit as the minimum particle size parameter. This parameter is used for subsequent calculation of the baffle aperture to ensure that the aperture is smaller than the minimum particle size, thereby preventing material particles from passing through the baffle and falling to the bottom of the high-temperature tank.

[0034] The melting and softening temperature T of the material soft The database pre-stores the melting onset temperature for each alloy type. This temperature value represents the theoretical critical point at which the alloy begins to transition from a solid to a molten state. The feed control module 100 uses the material type identifier as an index to query the melting onset temperature of that alloy type and subtracts a preset safety offset from this temperature value. The result is used as the melting softening temperature parameter. The purpose of this safety offset is to provide a temperature margin, ensuring that the steady-state temperature of the baffle is always lower than the actual melting point of the alloy, thereby preventing surface adhesion or aggregation of materials during preheating.

[0035] The average temperature T of the radiating surface of the slag and iron ditch slag The feeding control module 100 is connected to the temperature monitoring system at the blast furnace site via a data interface. This system has an infrared thermometer installed above the slag and iron trough. The feeding control module 100 reads the latest measurement value from the infrared thermometer in real time and performs an arithmetic average of the data from several consecutive sampling periods. The average value is used as the average temperature parameter of the slag and iron radiant surface. This parameter represents the current intensity level of the slag and iron radiant heat source and is used for the heat balance calculation of the subsequent diaphragm suspension height.

[0036] Furthermore, the above three parameters are integrated into a parameter vector. .

[0037] Ⅲ: The feeding control module 100 determines whether the material in the tank has reached the preset volume through the material level detection unit.

[0038] Specifically, the material level detection unit includes a capacitive level switch installed on the upper part of the tank side wall. When the material level reaches the installation position of the capacitive level switch, the internal circuit state of the level switch changes, and a high-level signal is output to the input terminal of the feed control module 100.

[0039] Upon receiving the high-level signal, the feeding control module 100 sets the loading completion flag to true. If the capacitive level switch is not triggered, the loading completion flag remains false, and the system continues to wait for feeding until the flag becomes true.

[0040] Finally, the feed control module 100 summarizes all the above information to construct a structured material preparation data package. This material preparation data package includes at least the following fields: material type identifier, minimum particle size d. min Melting and softening temperature T soft Average temperature T of slag-iron radiating surface slag 1. Loading completion indicator.

[0041] The feeding control module 100 transmits the loading preparation data packet to the partition parameter configuration module 200 through the internal communication interface, and at the same time sends a trigger signal to notify the downstream module to start the partition parameter configuration process.

[0042] like Figure 2 As shown, in the specific implementation of the partition parameter configuration module 200, the system receives a material preparation data packet from the feed control module 100. This data packet contains the material type identifier and the minimum particle size d. min Melting and softening temperature T soft Average temperature T of slag-iron radiating surface slag 1. Loading completion indicator.

[0043] 200 d partition parameter configuration module min T soft T slag As input, the pore size and suspension height of the porous metal partition are calculated using the following steps: Ⅰ: Calculate the aperture of the partition plate.

[0044] Specifically, the partition parameter configuration module 200 selects a specific coefficient value k from a preset safety factor range based on the material type identifier. The lower limit of this range is greater than 0, and the upper limit is less than 1.

[0045] For alloy materials with regular particle shapes and good flowability, the module selects a smaller k value; for alloy materials with irregular particle shapes and prone to jamming, the module selects a larger k value. After selection, the module uses k as a multiplier factor in subsequent calculations.

[0046] The selected safety factor k is compared with the input minimum granularity d. min Multiplying these values ​​yields an intermediate calculated value for the aperture: ;

[0047] The partition parameter configuration module 200 simultaneously ensures that the aperture value is not less than the minimum aperture allowed by the processing technology. If If the value is less than the lower limit of the process, the module will force the aperture value to be set to the lower limit of the process and record an adjustment flag.

[0048] The partition parameter configuration module 200 uses the constrained and verified aperture value as the final design parameter d. hole It is then stored in a temporary parameter set for subsequent collaborative verification.

[0049] II: Calculate the suspension height of the partition.

[0050] ①Based on the aperture d of the partition plate hole and the known minimum particle size d of the material min The module first calculates the ratio of pore size to minimum particle size: ;

[0051] This ratio reflects the relative size of the openings in the partition and directly affects the ability of radiative heat to penetrate.

[0052] To more accurately describe the actual radiative heat flow through the partition, the partition parameter configuration module 200 introduces a penetration enhancement factor η(r). The physical reason for this is that the openings in the partition allow some of the radiation that would otherwise be blocked by the solid to pass through, and the actual heat flow is greater than the theoretical value calculated based on the solid area.

[0053] The partition parameter configuration module 200 obtains η(r) from a table based on the mapping relationship calibrated in advance through experiments or simulations. This factor is greater than 1 and increases as r increases.

[0054] ② To prevent the material above from melting and adhering due to excessively high baffle temperature, a safe upper limit below the material's melting and softening temperature needs to be set for the baffle's steady-state temperature. However, the temperature of the slag-iron radiant surface is not constant but fluctuates. If a fixed safety margin is used, the heat exchange efficiency may decrease when temperature fluctuations are large, or it may still exceed the limit when fluctuations are severe.

[0055] To address this, the partition parameter configuration module 200 introduces an adaptive safety margin algorithm: ;

[0056] In the formula, ΔT is the basic margin; σT slag This represents the historical standard deviation of the average temperature of the radiant surface of slag and iron. α is the sensitivity coefficient of the safety margin to temperature fluctuations in slag and iron, ranging from 0 to 1. The α value is obtained through linear regression calibration of historical data. A low α value is suitable for stable temperature conditions, while a high α value is suitable for conditions with frequent temperature fluctuations. This coefficient allows the safety margin to be adaptively adjusted, avoiding overly conservative or excessively risky approaches with a fixed margin.

[0057] ③ After obtaining the penetration enhancement factor and dynamic safety margin, the partition parameter configuration module 200 needs to establish a steady-state thermal balance equation that reflects the heat transfer relationship between the partition and the material.

[0058] The steady-state heat balance equation considers both the radiation penetration enhancement effect and the natural convection heat transfer between the upper surface of the baffle and the packed material. The specific expression is as follows: ;

[0059] In the formula, σ is the Stefan-Boltzmann constant; ε is the effective emissivity of the lower surface of the partition; λ air The thermal conductivity of air; h conv This is the natural air convection coefficient, which is significant when the material is packed particles with high porosity; otherwise, it can be set to zero. T plate This is the steady-state temperature of the partition. T m0 The initial temperature of the alloy material; H gap The suspension height is the value to be determined.

[0060] The left side of the equation represents the radiation absorption term, and the right side represents the sum of the heat conduction and convection terms through the air layer.

[0061] This equation establishes the suspension height H. gap With the steady-state temperature T of the partition plate The quantitative relationship between them provides a mathematical basis for subsequent solutions.

[0062] ④ Set a safety target based on the dynamic safety margin ΔT and solve for the suspension height based on the steady-state thermal balance equation in step ③.

[0063] First, based on the dynamic safety margin ΔT, set the upper limit of the safe operating temperature of the partition: ;

[0064] This upper limit ensures that the partition remains below the material's melting softening temperature at the maximum permissible temperature, thus preventing adhesion of the upper alloy. The module will... Substituting T into the heat balance equation established in step ③ plate The term, at this time the radiation term on the left side of the equation It becomes a known constant because T plate It has been fixed as The right side of the equation contains the unknown variable H. gap and known temperature difference .

[0065] Furthermore, the equation is transformed into a equation concerning H. gap The nonlinear equation. The diaphragm parameter configuration module 200 solves the equation using a numerical iteration method: starting from an initial trial height H gap Begin by gradually adjusting H gap The value is used to calculate the sum of the heat conduction and convection terms on the right side. And compare it with the fixed radiation term on the left.

[0066] When the absolute value of the difference between the left and right sides is less than the preset convergence tolerance, the iteration stops. The current height is the suspension height H that satisfies the thermal balance requirement and makes the partition work exactly at the upper limit of the safe temperature. gap .

[0067] ⑤ Based on the suspension height H in step ④ gap Perform sensitivity analysis.

[0068] Specifically, due to factors such as welding positioning errors and thermal expansion deformation during actual manufacturing and installation, the actual height may deviate from the design value. The degree of influence of this deviation on the partition temperature needs to be evaluated through sensitivity analysis.

[0069] Therefore, the module uses H gap Use this as a reference point, and apply a small height perturbation in its vicinity. The height value after perturbation is obtained. Substitute the disturbed height value back into the heat balance equation of step ③. At this point, the T value in the equation... plate Instead of being fixed at a safe upper limit, it is treated as an unknown quantity that, together with the new height, satisfies thermal equilibrium. The module solves this equation to obtain the temperature of the partition after the disturbance. The sensitivity coefficient S is calculated as follows: ;

[0070] The coefficient S represents the increase in steady-state temperature of the partition for each unit increase in height.

[0071] Since sensitivity analysis is based on suspension height H gapThe calculation results of the heat balance equation can truly reflect the robustness of the current design parameters.

[0072] like The smaller value indicates that the actual installation error has little impact on the temperature, and the manufacturing tolerance can be appropriately relaxed; if A large value indicates that the height is highly sensitive to temperature, requiring strict control of tolerances, and the tolerance range must be clearly defined in subsequent outputs.

[0073] Furthermore, this coefficient can also be used for on-site debugging: if actual temperature measurement reveals that the partition temperature is too high, the required height adjustment can be estimated based on S, and the adjustment amount is approximately the temperature deviation value divided by S. Step ⑤ finally outputs the sensitivity coefficient S and the manufacturing tolerance suggestion based on this coefficient, which is compared with the H output in step ④. gap Together they constitute the set of partition design parameters.

[0074] III: Based on the suspension height H output in step ④ gap The sensitivity coefficient S output from step ⑤, combined with the penetration enhancement factor η(r), is used to calculate the overall performance index Q:

[0075] In the formula, the numerator is the design margin, the denominator is the total available temperature rise, and the ratio of the two reflects the relative safety level of the design; In the second term, β is a preset weighting coefficient; η max This represents the theoretical maximum value of the penetration enhancement factor.

[0076] Furthermore, the partition parameter configuration module 200 compares the calculated Q value with a preset acceptable threshold.

[0077] If the calculated Q is lower than the preset threshold, the partition parameter configuration module 200 reduces the sensitivity coefficient α in step ② to reduce the dynamic safety margin, thereby allowing the partition to operate at a higher temperature to improve heat exchange efficiency.

[0078] The adjusted α is substituted back into step ②, and the heat balance equation in step ③, the suspension height in step ④, the sensitivity analysis in step ⑤, and the comprehensive index calculation are executed again to obtain a new set of design parameters and Q value.

[0079] The partition parameter configuration module 200 can perform a maximum of two iterations. If Q still does not meet the standard after two iterations, a warning will be issued indicating that the current material or heat source conditions exceed the ideal applicable range of the design.

[0080] The partition parameter configuration module 200 will output the final confirmed design parameters, including the partition aperture from the aperture calculation results, the partition suspension height from the suspension height solution results, the expected maximum operating temperature of the partition from the safety target setting, and the sensitivity coefficient from the sensitivity analysis.

[0081] Based on the sensitivity coefficient, the partition parameter configuration module 200 generates manufacturing tolerance suggestions: if the absolute value of the sensitivity is small, the machining tolerance of the suspension height adopts the conventional grade; if the absolute value of the sensitivity is large, the tolerance grade is increased and a specific range is given.

[0082] The above parameters are packaged and transmitted to the partition fabrication and installation module 300.

[0083] like Figure 3 As shown, the partition fabrication and installation module 300 receives a set of partition parameters from the partition parameter configuration module 200. The set of parameters includes at least the partition hole diameter and the partition suspension height. Based on these parameters, the metal porous partition is fabricated and installed and fixed inside the tank.

[0084] Specifically, 15 mm thick 310S heat-resistant stainless steel sheet is selected as the substrate of the partition. This material has good high-temperature oxidation resistance and thermal strength, and can work stably for a long time in the radiant heat environment of the slag and iron ditch. Its continuous operating temperature can reach 1150 degrees Celsius, and its intermittent operating temperature can reach 1200 degrees Celsius, which meets the temperature resistance requirements of the partition under preheating conditions.

[0085] The partition fabrication and installation module 300 performs through-hole processing on the plate according to the received partition hole diameter parameters. The processing method is mechanical drilling or laser drilling. The through holes are evenly distributed on the surface of the plate, and the hole spacing is kept consistent to ensure the uniformity of radiative heat transfer.

[0086] After processing, the partition is visually inspected to confirm that all through holes are unobstructed and that the hole diameter deviation is controlled within the allowable range.

[0087] The partition is then installed by placing the processed partition horizontally inside the tank, ensuring that the distance between its lower surface and the inner surface of the tank bottom is precisely equal to the received partition suspension height.

[0088] The partition is welded to the side wall of the tank on all four sides. The welding process uses heat-resistant steel welding method to ensure that the partition will not fall off or shift during long-term use.

[0089] After welding is completed, check the levelness of the partition and the actual deviation of the suspension height to confirm that the deviation is within the tolerance range recommended by the sensitivity analysis.

[0090] The installed baffle divides the interior space of the tank into two areas: the lower area is a radiant heat buffer layer, which is the air gap layer between the baffle and the bottom of the tank; the upper area is the material preheating zone, which is the space above the baffle used to accommodate alloy materials.

[0091] This structure allows the high-temperature radiant heat absorbed at the bottom of the tank to be transferred to the air gap layer during the preheating process, and then evenly penetrated to the upper material through the micropores on the partition. At the same time, the partition itself prevents the material from directly contacting the high-temperature tank bottom, thereby actively preventing the alloy material from melting and adhering while ensuring efficient heat exchange.

[0092] After installation is completed, the partition fabrication and installation module 300 outputs an installation completion signal, and the system enters the preheating execution phase.

[0093] The preheating station module 400 receives an installation completion signal from the partition fabrication and installation module 300, and simultaneously receives the material type identifier from the loading preparation data packet from the feeding control module 100. This module is responsible for transferring the tank containing the alloy material from the loading station to the preheating station above the slag and iron trough, and for performing temperature monitoring and data display during the radiant preheating process.

[0094] The preheating station module 400 first connects to the hooks of the lifting equipment through four lifting lugs located on the outer walls of both sides of the tank. Specifically, the operator controls the lifting equipment to lift the tank smoothly and move it to a position directly above the slag and iron trough in the blast furnace tapping area. After the tank is in place, its bottom faces the high-temperature liquid slag and molten iron flowing in the slag and iron trough. An appropriate distance is maintained between the bottom of the tank and the radiant surface of the slag and iron to ensure that the radiant heat can be effectively transferred to the bottom of the tank without affecting the normal flow of slag and iron.

[0095] After confirming that the tank is placed stably, a preheating start signal is issued.

[0096] After preheating, the bottom of the tank absorbs high-temperature heat from the radiant surface of the slag and iron. The heat is first transferred to the air gap layer between the bottom of the tank and the baffle. The thickness of this gap layer is the suspension height value determined by the baffle fabrication and installation module 300.

[0097] Heat is transferred upward through the air layer to the lower surface of the porous metal partition. Since the partition is uniformly covered with micropores, some of the radiant heat is directly transferred upward through the micropores, while the other part of the heat is absorbed by the solid part of the partition and transferred to the upper surface of the partition through heat conduction. Then, the alloy material above is heated through convection and radiation.

[0098] Throughout the heat transfer process, the temperature of the partition itself is controlled below the melting and softening temperature of the material, thereby preventing the material from melting and adhering to the partition while heating the material.

[0099] During the preheating process, two K-type thermocouples installed at the center of both sides of the tank work continuously. Specifically, the measuring ends of the thermocouples extend into the tank and directly contact the alloy material or indirectly sense the material temperature through the protective sleeve. The two thermocouples independently collect temperature data at their respective positions and convert the temperature signals into electrical signals, which are then transmitted to the digital display temperature control instrument.

[0100] The digital temperature controller receives and displays the temperature readings from the two thermocouples in real time, and simultaneously calculates and displays the average temperature value. Operators can understand the overall temperature status of the material in the tank by observing the digital display.

[0101] The preheating station module 400 operates continuously throughout the preheating period until it receives a status switching signal from the subsequent temperature judgment and discharge module 500 or a lifting command manually issued by the operator. Upon receiving the lifting command, the module, in conjunction with the lifting equipment, lifts the trough from above the slag and iron trough and transfers it to the discharge station.

[0102] The temperature judgment and discharge module 500 receives temperature monitoring data from the preheating station module 400 and real-time readings from the digital temperature controller. This module is responsible for automatically judging the preheating status according to the preset temperature threshold and guiding the operator to complete the discharge operation through indicator light signals.

[0103] Specifically, the temperature judgment and discharge module 500 integrates a digital temperature control instrument, which is electrically connected to two K-type thermocouples to continuously receive and process the temperature signals transmitted by the thermocouples.

[0104] The temperature controller has built-in comparison logic and presets three temperature ranges: the temperature range below the lower limit of the preheating target, the temperature range within the target preheating range, and the temperature range exceeding the safety alarm threshold.

[0105] When the average temperature of the two thermocouples is in the first range, the instrument will not light up any indicator lights, the system will continue to preheat, and no operator intervention is required.

[0106] When the average temperature rises and enters the second range, that is, when it reaches the lower limit of the preheating target but does not exceed the safety alarm threshold, the instrument will automatically light up the green indicator light. The green indicator light indicates that the alloy material has been fully preheated to the temperature range that meets the process requirements. At this time, the operator can perform the material discharge operation.

[0107] When the average temperature continues to rise and exceeds the safety alarm threshold, the instrument immediately illuminates a red indicator light and simultaneously triggers the built-in buzzer to emit a continuous alarm sound. The red indicator light and buzzer work in tandem to alert the operator that the material is in a dangerous overheating state, posing a risk of melting and adhesion, and requiring immediate action.

[0108] Operators follow the indicator light signals to execute the corresponding process flow. When the green indicator light illuminates, operators use lifting equipment to smoothly lift the trough from above the slag and iron ditch and transfer it to the pre-set discharge position.

[0109] The tank is located behind the discharge station. The operator manually opens the mechanical switch of the discharge port at the bottom or side wall of the tank. The preheated hot alloy material flows out from the discharge port by its own gravity and falls into the receiving container placed below, thus completing the material delivery.

[0110] After the material is discharged, the operator manually closes the discharge port and returns the empty tank to the loading station to prepare for the next batch of material.

[0111] When the red indicator light illuminates and is accompanied by a buzzer alarm, the operator should immediately execute the emergency response procedure: use lifting equipment to quickly lift the trough from above the slag and iron ditch and transfer it to the discharge station.

[0112] Unlike the normal discharge process, in an emergency, it is required to discharge the material as quickly as possible to reduce the material temperature and prevent it from sticking and agglomerating due to continuous heat accumulation. The operator quickly opens the discharge port to urgently discharge all the material in the tank into the receiving container, and then closes the discharge port.

[0113] After emergency discharge is completed, the operator should check the inside of the tank, especially the upper surface of the baffle, for any material residue or adhesion. If any abnormality is found, it should be cleaned up in time.

[0114] The temperature judgment and discharge module 500 also has a status recording function: the digital display temperature controller automatically records the temperature change curve, the highest temperature value and the trigger time of each status signal during each preheating cycle. These data are stored in the non-volatile memory inside the instrument and can be retrieved for subsequent production analysis or process optimization.

[0115] After the temperature judgment and discharge module 500 completes the discharge operation, it sends a cycle reset signal to the system, indicating that the preheating process of this batch of alloy materials has been completed.

[0116] like Figure 4 , 5 As shown, a second objective of this invention is to provide a device for recovering waste heat from blast furnace slag iron troughs and preheating alloy materials, comprising a trough, a porous metal baffle, a thermocouple, a temperature monitoring and digital display system, a feed inlet, lifting lugs, a discharge outlet, a blast furnace slag iron trough, and the high-temperature liquid slag flowing inside it.

[0117] Specifically, the tank is welded from 15 mm thick 310S heat-resistant stainless steel plate, with a length of 2.5 meters, a width of 1.8 meters, a height of 0.8 meters, and an effective volume of 3.6 cubic meters.

[0118] The upper part of the tank has two feed ports, each measuring 700 mm by 700 mm, for adding alloy materials into the tank.

[0119] Four lifting lugs are symmetrically distributed on both outer walls of the tank for hoisting the entire device to or from the blast furnace slag and iron trough. A discharge port is located at the bottom or lower side wall of the tank, equipped with a mechanical-manual control switch for discharging alloy materials after preheating.

[0120] Inside the tank, a metal perforated plate is horizontally installed 50 mm from the bottom of the tank. The metal perforated plate is made of 310S heat-resistant stainless steel plate with a thickness of 15 mm. The plate has through holes with a diameter of 1 mm evenly opened. The metal perforated plate is welded and fixed to the side wall of the tank.

[0121] The porous metal partition divides the interior of the tank into two zones: the lower zone is an air gap between the porous metal partition and the tank bottom, which acts as a buffer against radiative heat; the upper zone is the space between the porous metal partition and the upper part of the tank, used to accommodate the alloy material, i.e., the preheating zone. This structure prevents the alloy material from directly contacting the hottest part of the tank bottom, while allowing radiative heat from the tank bottom to be evenly transferred upwards through the micropores.

[0122] K-type thermocouples are installed at the center of both sides of the tank. The thermocouples are graded K and have a temperature range of 0 to 1000 degrees Celsius. They are covered with a 310S stainless steel protective sleeve with a temperature resistance of 1200 degrees Celsius. The thermocouples are fixed to the side walls by threaded insertion.

[0123] The thermocouple's measuring end extends into the tank to collect the temperature of the alloy material in real time. The thermocouple is electrically connected to the temperature monitoring and digital display system.

[0124] The temperature monitoring and digital display system includes a digital temperature controller, a red alarm indicator, and a green alarm indicator. The digital temperature controller displays the temperature value measured by the thermocouple in real time and automatically illuminates the corresponding indicator light according to preset thresholds: when the temperature is between 600 and 800 degrees Celsius, the green indicator light automatically illuminates, indicating that preheating is complete; when the temperature exceeds 800 degrees Celsius, the red indicator light automatically illuminates and an audible and visual alarm is issued, indicating that the material is overheating and there is a risk of melting and adhesion.

[0125] Working Principle: During loading, the discharge port is closed, and the alloy material is added to the tank through the inlet. After completion, the device is hoisted to a position directly above the blast furnace slag-iron trough using lifting lugs, ensuring the bottom of the trough faces the radiant surface of the high-temperature liquid slag. Radiant heat passes through the bottom of the trough to the air gap layer below the porous metal baffle, and then evenly heats the alloy material upwards through the micropores on the porous metal baffle. Simultaneously, the temperature of the porous metal baffle itself is controlled below the melting and softening temperature of the alloy material, preventing direct contact between the material and the high-temperature trough bottom, which could lead to melting and adhesion. During preheating, two thermocouples monitor the material temperature in real time and transmit the data to the temperature monitoring and digital display system. When the temperature is between 600 and 800 degrees Celsius, the green indicator light on the temperature monitoring and digital display system illuminates, indicating that preheating is complete, and the device can be hoisted away and the discharge port opened to release the material. When the temperature exceeds 800 degrees Celsius, the red indicator light illuminates and an alarm sounds, requiring immediate hoisting and emergency opening of the discharge port to release the material, preventing overheating and adhesion. The entire preheating process requires no external energy source, relying solely on the radiant heat from the slag-iron trough.

[0126] 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 preferred examples and are not intended to limit 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 system for recovering waste heat from blast furnace slag and iron troughs to preheat alloy materials, comprising a feed control module (100), wherein the feed control module (100) is used to acquire the type identifier of the alloy material and retrieve the minimum particle size, melting and softening temperature, and average temperature of the slag-iron radiant surface of the alloy material, characterized in that, It also includes a partition parameter configuration module (200), a partition fabrication and installation module (300), a preheating station module (400), and a temperature judgment and discharge module (500). The partition parameter configuration module (200) is used to generate parameters including partition aperture and suspension height, including the following steps: The value of the partition pore size is set to be smaller than the minimum particle size; Based on the melting and softening temperature and the average temperature of the slag-iron radiating surface, a steady-state thermal balance equation for the partition is established. The suspension height is obtained by numerical iteration under the constraint that the steady-state temperature of the partition does not exceed the melting and softening temperature minus the safety margin. The partition fabrication and installation module (300) fabricates a perforated metal partition with through holes based on the partition hole diameter and suspension height and installs it inside the tank. It is used to set the distance between the lower surface of the partition and the inner surface of the tank bottom as the suspension height and generate an installation completion signal. The preheating station module (400) receives the installation completion signal, lifts the tank to the top of the slag and iron trough for radiative preheating, and collects the temperature data of the alloy material through thermocouples; The temperature judgment and discharge module (500) receives temperature data. When the temperature is within the preset range, it lights up a green light and allows discharge. When the temperature exceeds the safety threshold, it lights up a red light and forces emergency discharge.

2. The system for recovering waste heat from blast furnace slag and iron trough and preheating alloy materials according to claim 1, characterized in that: The feeding control module (100) automatically obtains the type identifier of the alloy material by reading the material batch barcode, and retrieves the minimum particle size, melting and softening temperature and the average temperature of the slag-iron radiation surface under the current working conditions from the pre-stored alloy property database based on the type identifier, and packages the above parameters into a loading preparation data package.

3. The system for recovering waste heat from blast furnace slag and iron trough and preheating alloy materials according to claim 1, characterized in that: The feeding control module (100) detects the material height by a capacitive level switch installed on the upper side wall of the tank. When the material touches the switch, the level switch outputs a high-level signal. After receiving the signal, the feeding control module sets the loading completion flag to true. Otherwise, it keeps it as false and continues to wait for feeding.

4. The system for recovering waste heat from blast furnace slag and iron trough and preheating alloy materials according to claim 1, characterized in that: The partition parameter configuration module (200) calculates the penetration enhancement factor based on the ratio of pore size to minimum particle size through a pre-stored mapping relationship. The factor is multiplied by the Stefan-Boltzmann constant and emissivity and then substituted into the radiation term of the heat balance equation to correct the effective radiative heat flux density that actually passes through the micropores of the partition.

5. The system for recovering waste heat from blast furnace slag and iron trough and preheating alloy materials according to claim 1, characterized in that: The partition parameter configuration module (200) acquires historical data of the average temperature of the slag and iron radiant surface and calculates its standard deviation. The weighted sum of the standard deviation and the preset basic margin is used as the dynamic safety margin. The safety margin increases when the temperature fluctuation is greater and decreases when the temperature fluctuation is smaller.

6. The system for recovering waste heat from blast furnace slag and iron trough and preheating alloy materials according to claim 1, characterized in that: After obtaining the suspension height, the partition parameter configuration module (200) adds a small disturbance value to the height value, substitutes the disturbed height back into the heat balance equation to solve for the corresponding partition temperature, calculates the ratio of temperature change to height change as a sensitivity coefficient, and generates a suggested level for suspension height machining tolerance based on the coefficient.

7. The system for recovering waste heat from blast furnace slag and iron trough and preheating alloy materials according to claim 1, characterized in that: The partition fabrication and installation module (300) is made of heat-resistant stainless steel plate. Through holes are processed according to the partition hole diameter, and the hole spacing is evenly distributed. The processed partition is placed horizontally inside the tank. The partition is welded and fixed to the side wall of the tank around its perimeter. After installation, the actual distance between the lower surface of the partition and the inner surface of the tank bottom is measured to confirm that the deviation of this distance from the suspension height is within the tolerance range recommended by the sensitivity coefficient.

8. The system for recovering waste heat from blast furnace slag and iron trough and preheating alloy materials according to claim 1, characterized in that: The thermocouples in the preheating station module (400) are two K-type thermocouples. The two thermocouples are installed at the center of both sides of the tank. Each thermocouple is covered with a heat-resistant stainless steel protective sleeve and is fixed to the side wall of the tank by threaded insertion. The measuring end of the thermocouple extends into the tank and contacts the alloy material. The two thermocouples independently collect temperature signals and take their arithmetic average as the current temperature value of the material.

9. The system for recovering waste heat from blast furnace slag and iron trough and preheating alloy materials according to claim 1, characterized in that: The lower limit of the preset target range in the temperature judgment and discharge module is the preheating target starting temperature, and the upper limit is the safety alarm temperature; when the average temperature is within this range, the green indicator light is lit, allowing the operator to open the discharge port to discharge material normally; When the average temperature exceeds the safety alarm temperature, the red indicator light will illuminate and the audible and visual alarm will be triggered simultaneously, forcing the operator to immediately open the discharge port for emergency material release. After the material release is completed, the temperature judgment and discharge module will send a cyclic reset signal to the system, indicating that the preheating process for this batch has been completed.

10. A device for recovering waste heat from blast furnace slag and iron trough to preheat alloy materials, used to constitute the system for recovering waste heat from blast furnace slag and iron trough to preheat alloy materials as described in any one of claims 1-9, characterized in that, It includes a tank body made of multiple heat-resistant stainless steel plates welded together. The upper part of the tank body has a feed inlet, the bottom of the tank body has a discharge outlet, and the two outer walls of the tank body are symmetrically distributed with lifting lugs. The tank is equipped with a horizontally arranged porous metal partition. The porous metal partition is suspended at a certain height from the bottom of the tank. The porous metal partition is uniformly provided with through holes, and the diameter of the through holes is smaller than the minimum particle size of the alloy material. Thermocouples are installed on both side walls of the tank to collect the temperature of the alloy material inside the tank; It also includes a temperature monitoring and digital display system electrically connected to the thermocouple, used to display the temperature value and illuminate an indicator light according to a preset threshold.

Images