A method for real-time quantitative evaluation of application effect of sintering process energy-saving technology

Abstract

The application discloses a kind of sintering process energy-saving technology application effect real-time quantitative evaluation method, comprising the following steps: S1, based on actual production data, set the benchmark condition of sintering process, and use benchmark operating parameter as the input of energy consumption prediction model, obtain the energy consumption under benchmark condition;S2, for the sintering process under benchmark condition, add data-based energy-saving technology parameters on the basis of benchmark operating parameter, as the input data of energy consumption prediction model under technical condition, calculate the energy consumption under technical condition;S3, calculate the energy consumption under benchmark condition and the energy consumption difference under technical condition, obtain the technical energy-saving potential of sintering process;When technical energy-saving potential reaches maximum, then the energy consumption under corresponding technical condition is the technical limit energy consumption of sintering process.The application can online debug different energy-saving technology application states based on multiple types of conditions by constructing sintering process energy consumption analysis system, and the corresponding energy consumption is calculated and analyzed in real time, so as to carry out real-time quantitative evaluation on sintering process, predict the technical limit energy consumption and energy-saving potential of sintering process, and feedback the energy-saving effect of multi-technology coupling.

Description

Technical Field

[0001] This invention relates to the field of energy conservation assessment in metallurgy, and in particular to a method, system, and construction method for real-time quantitative assessment of the application effect of energy-saving technology in sintering processes. Background Technology

[0002] The sintering process plays a crucial role in the entire metallurgical industry, producing sintered ore that accounts for more than 70% of the blast furnace charge and consuming approximately 23% of the energy in the steel production process. Therefore, energy-saving transformation of the sintering process is particularly critical for achieving deep energy conservation in the metallurgical industry.

[0003] For example, patent document No. 201510225409.8 discloses a sintering energy consumption prediction method based on an integrated model, which includes the following steps:

[0004] 1) Feature selection for the model is performed using the feature selection algorithm based on RReliefF;

[0005] 2) Based on historical data of the selected model features, establish an improved Extreme Learning Machine intelligent prediction model and a regression-type Support Vector Machine intelligent prediction model;

[0006] 3) Perform weighted integration of multiple single intelligent prediction models to obtain the integrated sintering energy consumption prediction value.

[0007] The above-mentioned technical solution, based on the integrated prediction model of information entropy, has good prediction accuracy and generalization ability, while also having high time efficiency.

[0008] However, with the increase in applied technologies, the coupling between various technologies has gradually increased. Furthermore, due to the lag, complexity, and uncertainty of the sintering production process, traditional methods for calculating sintering energy consumption and assessing energy-saving potential often fail to decouple various energy-saving technologies in real time and accurately assess the energy-saving effect and potential of applying multiple technologies in the sintering process.

[0009] Therefore, it is necessary to improve the existing technologies to overcome the aforementioned shortcomings. Summary of the Invention

[0010] The purpose of this invention is to provide a real-time quantitative evaluation method for the application effect of energy-saving technology in the sintering process. By combining knowledge of material balance, heat balance and metallurgical reaction mechanism, and through database management system, data-driven and visualization technologies, the method can realize real-time visual monitoring and quantitative evaluation of the coupled application effect of energy-saving technology in the sintering process, so as to solve the problems existing in the prior art.

[0011] The above-mentioned technical objective of the present invention is achieved through the following technical solution:

[0012] A method for real-time quantitative evaluation of the application effect of energy-saving technology in sintering process includes the following steps:

[0013] S1. Based on actual production data, set the baseline operating conditions for the sintering process, and use the baseline operating parameters as input to the energy consumption prediction model to obtain the energy consumption under the baseline operating conditions.

[0014] S2. For the sintering process under the benchmark operating conditions, add data-driven energy-saving technical parameters to the benchmark operating parameters as input data for the energy consumption prediction model under the technical operating conditions, and calculate the energy consumption under the technical operating conditions.

[0015] S3. Calculate the energy consumption difference between the baseline operating condition and the technical operating condition to obtain the technical energy-saving potential of the sintering process; when the technical energy-saving potential reaches its maximum, the energy consumption under the corresponding technical operating condition is the technical limit energy consumption of the sintering process.

[0016] Furthermore, the specific process of step S1 is as follows:

[0017] S11. Input data preparation: Collect and organize actual production data, including field parameters, component parameters, operating parameters and equipment parameters, and establish an initial database of baseline operating conditions;

[0018] S12. Baseline Operating Condition Setting: Use baseline operating parameters to set baseline operating conditions as a benchmark point for subsequent technical evaluation;

[0019] S13. Baseline Energy Consumption Calculation: The baseline energy consumption is calculated using formula (1):

[0020]

[0021] Among them, E base The baseline energy consumption is the total energy consumption of the sintering process without the application of any energy-saving technologies; i represents the use of different energy-consuming items or materials in the sintering process; m represents the total number of energy-consuming items, that is, the total number of different energy-consuming items involved in the sintering process; C i E is the reduction factor; i,base This indicates the contribution or importance of each energy consumption item i to the total energy consumption in the sintering process.

[0022] Furthermore, in steps S2 and S3, when applying a single energy-saving technology based on the baseline operating condition, the energy consumption under the single technology operating condition is calculated using formula (2).

[0023]

[0024] Among them, E tecSingle-technology energy consumption refers to the total energy consumption of the sintering process when applying a single energy-saving technology; m represents the total number of energy consumption items, that is, the total number of different energy consumption items involved in the sintering process; C i E is the reduction factor; i,tec For each energy consumption item i, the actual energy consumption after applying a single energy-saving technology;

[0025] The energy-saving potential of applying a single energy-saving technology is calculated using formula (3);

[0026] P tec =E base -E tec (3)

[0027] Among them, P tec Energy saving potential refers to the reduction in energy consumption during the sintering process after applying a single energy-saving technology, i.e., the energy saved; E base E is the baseline energy consumption. tec Energy consumption per technology.

[0028] Furthermore, in steps S2 and S3, when multiple energy-saving technologies are applied based on the baseline operating conditions, the energy consumption of the multi-technology coupling is calculated using formula (4).

[0029]

[0030] Among them, E tec_multi Multi-technology coupled energy consumption refers to the total energy consumption of the sintering process when multiple energy-saving technologies are applied simultaneously; m represents the total number of energy consumption items, i.e., the total number of different energy consumption items involved in the sintering process; i represents the energy consumption item, C i E is the reduction factor; i,tec_multi For each energy consumption item i, the actual energy consumption after applying multiple energy-saving technologies;

[0031] The energy-saving potential of applying multiple energy-saving technologies in combination is calculated using formula (5):

[0032] P tec_multi =E base -E tec_multi (5)

[0033] Among them, P tec_multi The energy-saving potential of multi-technology coupling represents the reduction in energy consumption in the sintering process after applying multiple energy-saving technologies, i.e., the energy saved; E base E is the baseline energy consumption. tec_multi Energy consumption due to multi-technology coupling;

[0034] The energy-saving contribution of applying multiple energy-saving technologies in combination is calculated using formula (6);

[0035]

[0036] Among them, C tec_multi The contribution of multi-technology coupling to energy saving represents the percentage of overall energy consumption reduction achieved after the application of multiple energy-saving technologies; P i The energy-saving potential of a single technology in coupled applications; P total This is the sum of the energy-saving potential of each technology in the coupled application;

[0037] When the coupling energy-saving potential reaches its maximum, the technical limit energy consumption is determined by formula (7):

[0038] E limit =min(E tec_multi (7)

[0039] Among them, E limit E represents the minimum energy consumption achieved when multiple energy-saving technologies are applied in the sintering process, indicating the lowest energy consumption value that can be achieved when multiple energy-saving technologies are applied. tec_multi Energy consumption due to multi-technology coupling.

[0040] A real-time quantitative evaluation system for the application effect of energy-saving technology in sintering processes, including

[0041] The sintering database module uses a database management system to store historical data, manual experience data, real-time data, and quantified energy-saving technology data of the sintering process. It uses Python's database connection library to read and write data and connect with other modules.

[0042] The energy consumption prediction module calls on existing data from the sintering database module, designs data analysis algorithms based on knowledge of material balance, heat balance and metallurgical reaction mechanism, constructs an energy consumption prediction model, and uses Python's data analysis library to calculate the energy consumption of the sintering process under benchmark and technical conditions. After comparison, it gives the energy-saving potential and energy-saving effect under different technical application scenarios.

[0043] The Limit Energy Consumption Analysis section is used to conduct in-depth analysis of the preliminary results given by the Energy Consumption Prediction section. By quantitatively comparing and analyzing the changes in sintering process parameters, sintering process energy consumption and energy-saving potential under single-technology application and multi-technology application, it further explores the coupled energy-saving potential of applying multiple energy-saving technologies in the sintering process, and finally derives the technical limit energy consumption of the sintering process.

[0044] In summary, the present invention has the following beneficial effects:

[0045] By constructing an energy consumption analysis system for the sintering process, the application status of different energy-saving technologies can be debugged online based on multiple types of working conditions, and the corresponding energy consumption can be calculated and analyzed in real time. This allows for real-time quantitative evaluation of the sintering process, prediction of the technological limit energy consumption and energy-saving potential of the sintering process, and feedback on the energy-saving effect of multi-technology coupling. Attached Figure Description

[0046] Figure 1 This is a flowchart of the method for quantitatively evaluating the energy-saving effect of the sintering process described in this invention.

[0047] Figure 2 This is a structural block diagram of the energy-saving technology quantitative evaluation system for the sintering process described in this invention.

[0048] Figure 3 This is a schematic diagram of the implementation module of the energy consumption prediction system described in this invention. Detailed Implementation

[0049] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below with reference to the figures and specific embodiments.

[0050] The method proposed in this patent quantifies the impact of sintering energy-saving technology on process energy consumption as its impact on production process operating parameters, thereby realizing the data processing of sintering energy-saving technology. At the same time, it combines metallurgical mechanism and actual production data to jointly construct a sintering process energy consumption analysis and prediction model, calculates the baseline energy consumption and technical limit energy consumption of the sintering process, and conducts comparative analysis, thereby realizing real-time visual monitoring and quantitative evaluation of the application effect of sintering energy-saving technology in the sintering process.

[0051] The overall calculation process of this evaluation method is as follows: Figure 1 As shown, based on the data analysis of the sintering process and its energy-saving technologies, a hierarchical calculation approach is adopted.

[0052] S1. Based on actual production data (including on-site parameters, component parameters, operating parameters, equipment parameters, etc.), set the baseline operating conditions for the sintering process, and use the baseline operating parameters (including ore ratio, air-fuel ratio, desulfurization rate, etc.) as input for the energy consumption prediction model to calculate the energy consumption under the baseline operating conditions.

[0053] S2. For the sintering process under the benchmark conditions, energy-saving technologies are added, and the quantified technical parameters are brought into the model as input data for the technical conditions to calculate the energy consumption under the technical conditions.

[0054] S3. The difference between the baseline energy consumption and the technical energy consumption is the technical energy-saving potential of the sintering process. When the energy-saving potential reaches its maximum, the technical energy consumption under this condition is the technical limit energy consumption of the sintering process.

[0055] The specific process of step S1 is as follows:

[0056] S11. Input data preparation: Collect and organize actual production data, including field parameters, component parameters, operating parameters and equipment parameters, and establish an initial database of baseline operating conditions;

[0057] S12. Baseline Operating Condition Setting: Use baseline operating parameters to set baseline operating conditions as a benchmark point for subsequent technical evaluation;

[0058] S13. Baseline Energy Consumption Calculation: The baseline energy consumption is calculated using formula (1):

[0059]

[0060] Among them, E base The baseline energy consumption is the total energy consumption of the sintering process without the application of any energy-saving technologies; i represents the use of different energy-consuming items or materials in the sintering process; m represents the total number of energy-consuming items, that is, the total number of different energy-consuming items involved in the sintering process; C i E is the reduction factor; i,base This indicates the contribution or importance of each energy consumption item i to the total energy consumption in the sintering process.

[0061] In steps S2 and S3, when applying a single energy-saving technology based on the baseline operating condition, the energy consumption under the single technology operating condition is calculated using formula (2).

[0062]

[0063] Among them, E tec Single-technology energy consumption refers to the total energy consumption of the sintering process when applying a single energy-saving technology; m represents the total number of energy consumption items, that is, the total number of different energy consumption items involved in the sintering process; C i E is the reduction factor; i,tec For each energy consumption item i, the actual energy consumption after applying a single energy-saving technology;

[0064] The energy-saving potential of applying a single energy-saving technology is calculated using formula (3);

[0065] P tec =E base -E tec (3)

[0066] Among them, P tec Energy saving potential refers to the reduction in energy consumption during the sintering process after applying a single energy-saving technology, i.e., the energy saved; E base E is the baseline energy consumption. tec Energy consumption per technology.

[0067] In steps S2 and S3, when multiple energy-saving technologies are applied based on the baseline operating conditions, the energy consumption of the multi-technology coupling is calculated using formula (4).

[0068]

[0069] Among them, Etec_multi Multi-technology coupled energy consumption refers to the total energy consumption of the sintering process when multiple energy-saving technologies are applied simultaneously; m represents the total number of energy consumption items, i.e., the total number of different energy consumption items involved in the sintering process; i represents the energy consumption item, C i E is the reduction factor; i,tec_multi For each energy consumption item i, the actual energy consumption after applying multiple energy-saving technologies;

[0070] The energy-saving potential of applying multiple energy-saving technologies in combination is calculated using formula (5):

[0071] P tec_multi =E base -E tec_multi (5)

[0072] Among them, P tec_multi The energy-saving potential of multi-technology coupling represents the reduction in energy consumption in the sintering process after applying multiple energy-saving technologies, i.e., the energy saved; E base E is the baseline energy consumption. tec_multi Energy consumption due to multi-technology coupling;

[0073] The energy-saving contribution of applying multiple energy-saving technologies in combination is calculated using formula (6);

[0074]

[0075] Among them, C tec_multi The contribution of multi-technology coupling to energy saving represents the percentage of overall energy consumption reduction achieved after the application of multiple energy-saving technologies; P i The energy-saving potential of a single technology in coupled applications; P total This is the sum of the energy-saving potential of each technology in the coupled application;

[0076] When the coupling energy-saving potential reaches its maximum, the technical limit energy consumption is determined by formula (7):

[0077] E limit =min(E tec_multi (7)

[0078] Among them, E limit E represents the minimum energy consumption achieved when multiple energy-saving technologies are applied in the sintering process, indicating the lowest energy consumption value that can be achieved when multiple energy-saving technologies are applied. tec_multi Energy consumption due to multi-technology coupling.

[0079] The operation flow of the sintering process energy consumption prediction system is as follows: Figure 2As shown, the overall system is constructed using Python programming, and the main body is divided into three modules. The first section is the sintering database module. This module uses a database management system (SQLite, MySQL) to store historical data, manual experience data, real-time data, and quantified energy-saving technology data for the sintering process. It utilizes Python's database connection libraries (SQLite3, MySQL Connector) to read and write data and connect with other modules. The second section is the energy consumption prediction module. This module uses existing data from the sintering database module and, based on knowledge of material balance, heat balance, and metallurgical reaction mechanisms, designs data analysis algorithms to build an energy consumption prediction model. It uses Python's data analysis libraries (Pandas, NumPy, etc.) to calculate the energy consumption of the sintering process under baseline and technical operating conditions. After comparison, it provides the energy-saving potential and its energy-saving effect under different technology application scenarios. The third section is the ultimate energy consumption analysis module. This module conducts in-depth analysis of the preliminary results given by the energy consumption prediction module. By quantitatively comparing and analyzing the changes in sintering process parameters, sintering process energy consumption, and energy-saving potential under single-technology and multi-technology application scenarios, it further explores the coupled energy-saving potential of applying multiple energy-saving technologies in the sintering process and finally derives the ultimate energy consumption of the sintering process.

[0080] The implementation method of building the system is as follows Figure 3 As shown, it mainly consists of four implementation modules. The first is the baseline energy consumption module, the foundational module for calculating the energy consumption of the sintering process. Its main body is an energy consumption prediction model driven by mechanism and data collaboration, used to calculate the baseline energy consumption and related data for the sintering process. The second is the technology application module, the main part connecting to the quantified sintering energy-saving technology database. It can be used for the management, allocation, and maintenance of sintering energy-saving technologies, and to calculate the technology's energy consumption and related data. The third is the energy-saving potential module, which analyzes the calculation results of the first two modules. It is used for data analysis, quantitative evaluation, and effect feedback of the calculation results of the first two modules, thereby providing the technology's energy-saving potential and technological limit energy consumption. The fourth is the interface implementation module, which mainly uses Python visualization libraries (Matplotlib, Seaborn, etc.) to achieve data visualization, displaying key indicators of the sintering process and the application effects of energy-saving technologies through a visual interface (including line graphs, heat maps, etc.). This allows users to clearly understand the real-time changes in the application effects of energy-saving technologies.

[0081] In this document, the terms "upper," "lower," "front," "back," "left," "right," "top," "bottom," "inner," "outer," "vertical," and "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used for the clarity of expressing the technical solution and for the convenience of description, and therefore should not be construed as limiting the present invention.

[0082] In this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, which includes not only the elements listed but also other elements not expressly listed.

[0083] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A method for real-time quantitative evaluation of the application effect of energy-saving technology in sintering processes, characterized in that, The steps include the following: S1. Based on actual production data, set the baseline operating conditions for the sintering process, and use the baseline operating parameters as input to the energy consumption prediction model to obtain the energy consumption under the baseline operating conditions. S2. For the sintering process under the benchmark operating conditions, add data-driven energy-saving technical parameters to the benchmark operating parameters as input data for the energy consumption prediction model under the technical operating conditions, and calculate the energy consumption under the technical operating conditions. S3. Calculate the energy consumption difference between the baseline operating condition and the technical operating condition to obtain the technical energy-saving potential of the sintering process; when the technical energy-saving potential reaches its maximum, the energy consumption under the corresponding technical operating condition is the technical limit energy consumption of the sintering process.

2. The method for real-time quantitative evaluation of the application effect of energy-saving technology in the sintering process according to claim 1, characterized in that, The specific process of step S1 is as follows: S11. Input data preparation: Collect and organize actual production data, including field parameters, component parameters, operating parameters and equipment parameters, and establish an initial database of baseline operating conditions; S12. Baseline Operating Condition Setting: Use baseline operating parameters to set baseline operating conditions as a benchmark point for subsequent technical evaluation; S13. Baseline Energy Consumption Calculation: The baseline energy consumption is calculated using formula (1): Among them, E base The baseline energy consumption is the total energy consumption of the sintering process without the application of any energy-saving technologies; i represents the use of different energy-consuming items or materials in the sintering process; m represents the total number of energy-consuming items, that is, the total number of different energy-consuming items involved in the sintering process; C i E is the reduction factor; i,base This indicates the contribution or importance of each energy consumption item i to the total energy consumption in the sintering process.

3. The method for real-time quantitative evaluation of the energy-saving technology application effect in the sintering process according to claim 1, characterized in that, In steps S2 and S3, when applying a single energy-saving technology based on the baseline operating condition, the energy consumption under the single technology operating condition is calculated using formula (2). Among them, E tec Single-technology energy consumption refers to the total energy consumption of the sintering process when applying a single energy-saving technology; m represents the total number of energy consumption items, that is, the total number of different energy consumption items involved in the sintering process; C i E is the reduction factor; i,tec For each energy consumption item i, the actual energy consumption after applying a single energy-saving technology; The energy-saving potential of applying a single energy-saving technology is calculated using formula (3); P tec =And base -AND tec (3) Among them, P tec Energy saving potential refers to the reduction in energy consumption during the sintering process after applying a single energy-saving technology, i.e., the energy saved; E base E is the baseline energy consumption. tec Energy consumption per technology.

4. The method for real-time quantitative evaluation of the energy-saving technology application effect in the sintering process according to claim 1, characterized in that, In steps S2 and S3, when multiple energy-saving technologies are applied based on the baseline operating conditions, the energy consumption of the multi-technology coupling is calculated using formula (4). Among them, E tec_multi Multi-technology coupled energy consumption refers to the total energy consumption of the sintering process when multiple energy-saving technologies are applied simultaneously; m represents the total number of energy consumption items, i.e., the total number of different energy consumption items involved in the sintering process; i represents the energy consumption item, C i E is the reduction factor; i,tec_multi For each energy consumption item i, the actual energy consumption after applying multiple energy-saving technologies; The energy-saving potential of applying multiple energy-saving technologies in combination is calculated using formula (5): P tec_multi =And base -AND tec_multi (5) Among them, P tec_multi The energy-saving potential of multi-technology coupling represents the reduction in energy consumption in the sintering process after applying multiple energy-saving technologies, i.e., the energy saved; E base E is the baseline energy consumption. tec_multi Energy consumption due to multi-technology coupling; The energy-saving contribution of applying multiple energy-saving technologies in combination is calculated using formula (6); Among them, C tec_multi The contribution of multi-technology coupling to energy saving represents the percentage of overall energy consumption reduction achieved after the application of multiple energy-saving technologies; P i The energy-saving potential of a single technology in coupled applications; P total This is the sum of the energy-saving potential of each technology in the coupled application; When the coupling energy-saving potential reaches its maximum, the technical limit energy consumption is determined by formula (7): The limit =min(E tec_multi ) (7) Among them, E limit E represents the minimum energy consumption achieved when multiple energy-saving technologies are applied in the sintering process, indicating the lowest energy consumption value that can be achieved when multiple energy-saving technologies are applied. tec_multi Energy consumption due to multi-technology coupling.

5. A real-time quantitative evaluation system for the application effect of energy-saving technology in sintering processes, characterized in that, include The sintering database module uses a database management system to store historical data, manual experience data, real-time data, and quantified energy-saving technology data of the sintering process. It uses Python's database connection library to read and write data and connect with other modules. The energy consumption prediction module calls on existing data from the sintering database module, designs data analysis algorithms based on knowledge of material balance, heat balance and metallurgical reaction mechanism, constructs an energy consumption prediction model, and uses Python's data analysis library to calculate the energy consumption of the sintering process under benchmark and technical conditions. After comparison, it gives the energy-saving potential and energy-saving effect under different technical application scenarios. The Limit Energy Consumption Analysis section is used to conduct in-depth analysis of the preliminary results given by the Energy Consumption Prediction section. By quantitatively comparing and analyzing the changes in sintering process parameters, sintering process energy consumption and energy-saving potential under single-technology application and multi-technology application, it further explores the coupled energy-saving potential of applying multiple energy-saving technologies in the sintering process, and finally derives the technical limit energy consumption of the sintering process.

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