A method for reducing consumption based on blast furnace distribution mechanism and model optimization research

Abstract

The present application relates to blast furnace ironmaking technical field, particularly relates to a kind of consumption reduction method based on blast furnace distribution mechanism and its model optimization research.The present application improves the uniformity of burden distribution from the source by analyzing the genetic law of particle size segregation in the process of series tank blast furnace distribution and proposing an effective charging sequence optimization scheme.The established mathematical model considers the coriolis force and coal gas drag force, and combined with intelligent distribution software can accurately predict the distribution effect, providing a reliable tool for fine and intelligent distribution.The proposed coke platform and center coke addition strategy effectively reduces the center coke consumption under the premise of ensuring the reasonable distribution of gas flow, directly reducing the coke ratio and fuel consumption.The present application can significantly improve the blast furnace gas utilization rate, improve the degree of smooth operation of furnace condition, and improve the pig iron yield and quality.Practice shows that the blast furnace fuel ratio can be successfully reduced by more than 10kg / t, generating economic benefits of more than 30 million yuan per year, while meeting the national energy-saving and emission-reducing industrial policy.

Description

Technical Field

[0001] This invention relates to the field of blast furnace ironmaking technology, and in particular to a method for reducing energy consumption based on the research of blast furnace charging mechanism and its model optimization. Background Technology

[0002] Blast furnace ironmaking is a major process in steel production, accounting for a significant portion of energy consumption and CO2 emissions. Reducing the fuel ratio is key to lowering ironmaking costs and energy consumption. Blast furnace operation is mainly divided into upper-level charging and lower-level blast furnace charging systems. Currently, research and practice on lower-level charging are relatively in-depth, but the optimization of the upper-level charging system still lacks systematic and precise theoretical model support. Existing blast furnace charging research and operation have the following problems: First, there is insufficient understanding of the particle size segregation law and its hereditary influence between the charging hopper and weighing hopper in the series-tank system, leading to difficulties in controlling the uniformity of charging. Second, traditional charging models often ignore key forces such as Coriolis force and gas drag, resulting in deviations between the calculated charge landing point, charge flow width, and charge surface shape and the actual operating conditions, making it difficult to achieve precise charging guidance. Third, the angle and amount of central coke addition and the corresponding coke bed platform lack quantitative optimization basis, leading to coke waste or unreasonable gas flow distribution, affecting gas utilization and smooth furnace operation. Fourth, there is a lack of intelligent material distribution software that can comprehensively consider various material distribution parameters, furnace charge characteristics, and stress conditions, making it impossible to quickly respond to changes in raw materials and provide the optimal material distribution strategy.

[0003] Therefore, we need to invent a comprehensive method that can accurately analyze the entire process of material feeding, establish a high-precision prediction model, and guide intelligent optimization and control, so as to achieve low-carbon, high-efficiency, and stable operation of blast furnaces. Summary of the Invention

[0004] To address the technical problems in existing technologies, such as unclear charging mechanism, insufficient model accuracy, crude central coking, and lack of intelligent control, this invention provides a consumption reduction method based on the research of blast furnace charging mechanism and its model optimization.

[0005] Therefore, the present invention provides the following technical solution: A method for reducing energy consumption based on the blast furnace charging mechanism and its model optimization research includes the following steps: S1. Based on the actual equipment geometric parameters of the target blast furnace, a three-dimensional geometric model from the treasury to the throat surface is established; the discrete element method is used in combination with the three-dimensional geometric model to simulate the charging and discharging process of the furnace charge in the treasury; the mass point force analysis method is used in combination with the simulated charging and discharging process to establish a mathematical model of the movement of the furnace charge in the central throat, rotary chute and throat void. S2. Using the established mathematical model, simulate the particle size distribution of the furnace charge in the feeding tank and weighing tank respectively; S3. Based on the established mathematical model, the blast furnace intelligent charging software is used to calculate the material flow trajectory, material flow width, and material surface model; S4. Using the intelligent charging software for blast furnaces, study the influence of different operating parameters on the distribution of furnace charge, and quantitatively establish the correspondence between the charging level and the chute inclination angle; S5. Based on mathematical models and intelligent blast furnace charging software, the effects of different central coking angles, coking amounts and initial coke layer shapes on coke collapse and radial ore-coke ratio distribution are simulated and studied. The obtained influence relationships are used to optimize the central coking and coke platform strategies. S6. Apply the parameters obtained in steps S1-S5 to the target blast furnace, use the blast furnace intelligent charging software to calculate and guide the adjustment of the charging matrix online or offline, continuously monitor the blast furnace operation indicators, and verify and adjust the mathematical model and blast furnace intelligent charging software parameters based on production data feedback.

[0006] Furthermore, the mathematical model in step S1 contains Coriolis force parameters and gas traction parameters.

[0007] Furthermore, in step S2, during the simulation of the particle size distribution of the furnace charge in the feeding tank and the weighing tank, it is necessary to clearly define that the degree of furnace charge segregation in the feeding tank is greater than that in the weighing tank, and that the segregation in the feeding tank will exacerbate the hereditary pattern of segregation in the weighing tank.

[0008] Furthermore, in step S2, during the process of simulating the particle size distribution of the furnace charge in the feeding tank and weighing tank respectively, a charging mode is adopted in which the sintering ore feeding sequence is advanced and / or the coke and sintering ore feeding sequence is delayed, so as to reduce the overall particle size segregation of the furnace charge in the tank and during the discharge process.

[0009] Further, in step S3, the calculation of the material flow trajectory is based on the main landing point of the furnace charge under different chute inclination angles, lengths, shapes, rotation speeds, material line heights, furnace charge types, and whether Coriolis force and gas resistance are considered; the calculation of the material flow width is the influence of parameter changes involved in the calculation of the material flow trajectory on the material surface spreading width; the calculation of the material surface model is based on the prediction of the material surface shape and platform width according to the material distribution matrix. The parameters of the material distribution matrix include the number of gears, the number of rings, and the batch size, supporting two gear angle division systems: the equal cross-sectional area method and the equal diameter method.

[0010] Furthermore, step S5 optimizes the center coking and coking platform strategy by closing the throttle valve when coking reaches the secondary center position, and then coking the center coking when the chute tilts to the center position.

[0011] Furthermore, step S5 optimizes the center coking and coke platform strategy, which can reduce the center coking amount to about half of the original design value while forming an effective coke platform.

[0012] Furthermore, the blast furnace operating indicators in step S6 include fuel ratio, gas utilization rate, and air volume.

[0013] Advantages and positive effects of the present invention: This invention is the first to systematically analyze the inheritance law of particle size segregation during the charging process of a blast furnace and proposes an effective scheme to optimize the charging sequence, thereby improving the uniformity of the furnace charge distribution from the source.

[0014] By establishing a mathematical model that considers Coriolis force and gas drag, and combining it with intelligent fabric laying software, the fabric laying effect can be predicted with high accuracy, providing a reliable tool for refined and intelligent fabric laying.

[0015] The proposed coke platform and center coking strategy effectively reduce the amount of coke used in the center while ensuring a reasonable distribution of gas flow, thereby directly reducing the coke ratio and fuel consumption.

[0016] The implementation of this entire method can significantly improve blast furnace gas utilization, enhance furnace operation, and increase pig iron production and quality. Practice has shown that it can successfully reduce the blast furnace fuel ratio by more than 10 kg / t, generating annual economic benefits exceeding 30 million yuan, while also complying with national energy conservation and emission reduction policies. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a particle size distribution diagram along the height of the feeding tank.

[0019] Figure 2 This is a diagram showing the height of the weighing tank and the radial particle size distribution.

[0020] Figure 3 The diagram shows the particle size distribution patterns of two pre-concentrated calomel models at the height and radial direction of the weighing tank.

[0021] Figure 4 This is a graph showing the change in particle size of the furnace charge inside the hopper during the discharge process.

[0022] Figure 5 This is a diagram showing the parameters for calculating the material flow trajectory in the fabric software.

[0023] Figure 6 This is a diagram illustrating the main landing point of the furnace charge.

[0024] Figure 7 This diagram illustrates the influence of Coriolis force and gas resistance on the main landing point of the furnace charge.

[0025] Figure 8 The influence of Coriolis force and gas resistance on the width of the material flow.

[0026] Figure 9 This is a simplified diagram illustrating the material flow trajectory and its width.

[0027] Figure 10 The diagrams show the equal cross-sectional area division method and the equal diameter division method (left: equal cross-sectional area division; right: equal diameter division).

[0028] Figure 11 This is a diagram showing the distribution of burden on the throat surface of the new No. 2 furnace under the current charging parameters.

[0029] Figure 12 A diagram showing the effect of different center coking angles on coke collapse.

[0030] Figure 13 A graph showing the effect of different coking amounts on the ore-to-coke ratio.

[0031] Figure 14 This diagram illustrates the impact of the coke layer platform on the collapse and the ore-coke ratio. Detailed Implementation

[0032] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. 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 should fall within the scope of protection of the present invention.

[0033] This invention provides a method for reducing energy consumption based on the blast furnace charging mechanism and its model optimization research, comprising the following steps: S1. Based on the actual equipment geometric parameters of the target blast furnace, a three-dimensional geometric model from the charging hopper to the throat surface is established; the discrete element method is used in combination with the three-dimensional geometric model to simulate the charging and discharging process of the furnace charge in the charging hopper; the mass point force analysis method is used in combination with the simulated charging and discharging process to establish a mathematical model of the movement of the furnace charge in the central throat, rotary chute and throat void; the mathematical model contains Coriolis force parameters and gas drag force parameters.

[0034] S2. Using the established mathematical model, simulate the particle size distribution of the furnace charge in the charging tank and the weighing tank respectively. In the process of simulating the particle size distribution of the furnace charge in the charging tank and the weighing tank respectively, it is necessary to clarify that the degree of furnace charge segregation in the charging tank is greater than that in the weighing tank, and that the segregation in the charging tank will aggravate the hereditary pattern of segregation in the weighing tank.

[0035] In simulating the particle size distribution of furnace charge in the charging hopper and weighing hopper respectively, a charging mode is adopted that advances the sintering ore feeding sequence and / or delays the coke and sintering ore feeding sequence to reduce the overall particle size segregation of the furnace charge in the hopper and during the discharge process.

[0036] S3. Based on the established mathematical model, the blast furnace intelligent charging software is used to calculate the charge flow trajectory, charge flow width, and charge surface model; such as... Figure 5-7 As shown, the calculation of the material flow trajectory is based on the main landing point of the furnace charge under different chute inclination angles, lengths, shapes, rotation speeds, material line heights, furnace charge types, and whether or not Coriolis force and gas resistance are considered; the calculation of the material flow width is the effect of the parameter changes involved in the calculation of the material flow trajectory on the material surface spreading width; the calculation of the material surface model is based on the prediction of the material surface shape and platform width according to the material distribution matrix. The parameters of the material distribution matrix include the number of gears, the number of rings, and the batch size, and it supports two gear angle division systems: the equal cross-sectional area method and the equal diameter method.

[0037] S4. Using the intelligent charging software for blast furnaces, study the influence of different operating parameters on the distribution of furnace charge, and quantitatively establish the correspondence between the charging level and the chute inclination angle; S5. Based on mathematical models and intelligent blast furnace charging software, the effects of different central coking angles, coking amounts, and initial coke layer shapes on coke collapse and radial ore-to-coke ratio distribution were simulated and studied. The obtained influence relationships were used to optimize the central coking and coke platform strategy. The optimized central coking and coke platform strategy involves closing the throttle valve when coke is placed to the secondary center position, and then placing the central coke when the chute tilts to the center position. Under the premise of forming an effective coke platform, the central coke amount can be reduced to about half of the original design value.

[0038] S6. Apply the parameters obtained in steps S1-S5 to the target blast furnace, use the intelligent blast furnace charging software to calculate and guide the adjustment of the charging matrix online or offline, continuously monitor the blast furnace operating indicators, and verify and adjust the mathematical model and the parameters of the intelligent blast furnace charging software based on production data feedback. Blast furnace operating indicators include fuel ratio, gas utilization rate, and blast volume.

[0039] This invention aims to solve the problem of blast furnace energy consumption reduction through a systematic approach involving mechanistic research, model building, and intelligent control. Unlike traditional energy consumption reduction methods that rely on experience and focus on adjusting local parameters, this invention analyzes the entire material distribution process from its root cause, achieving accurate prediction and optimization.

[0040] Traditional blast furnace energy consumption reduction methods mainly rely on lower-level adjustments, such as adjusting blast volume, tuyeres area, and tuyeres length to improve the initial gas flow distribution in the hearth. This method directly impacts furnace conditions, but has limited optimization potential and does not completely solve problems caused by uneven upper-level charging. Traditional experience-based upper-level charging operations rely on fixed angle correspondences and a crude method of center coking. Operators adjust the charging matrix based on their perception of furnace conditions, lacking precise understanding of the movement patterns of the charge within the flask, chute, and empty space, leading to inaccurate control and delayed response.

[0041] Example The present invention relates to the analysis of the genetic law of particle size segregation at the top of a bellless furnace in a series of tanks, revealing a bottleneck in energy saving that traditional methods have failed to recognize, namely the heritability of particle size segregation in the furnace charge.

[0042] like Figure 1 The above indicates that under different charging sequences, the particle size exhibits regular segregation in the height direction, which can be improved by methods such as pre-loading sinter.

[0043] like Figure 2 As shown, the segregation pattern persists in the weighing tank and is affected by the feeding tank.

[0044] like Figure 3 As shown, the particle size distribution of the furnace charge generated by the Jiao Ding-1 belt conveyor and the furnace charge generated by the Jiao Ding-2 feeding tank in the weighing tank directly proves that the segregation in the feeding tank will be "inherited" and aggravate the degree of segregation in the weighing tank.

[0045] like Figure 4 As shown, the concentration of small particles at the end of the discharge phase affects the central airflow. This invention, by analyzing this pattern, proposes an optimized loading sequence to control segregation, laying the foundation for uniform material distribution and smooth airflow from the source.

[0046] like Figure 7 As shown, unlike traditional models that ignore key forces, the model of this invention takes into account both Coriolis force and gas drag force for the first time, which significantly improves the accuracy of landing point prediction.

[0047] like Figure 8 The diagram shown illustrates the influence of Coriolis force and gas resistance on the width of the material flow, demonstrating that these forces have a significant impact on the spread of the material flow. The model of this invention can accurately capture these details.

[0048] Figure 9 , 10 As shown, this invention establishes a precise fabric grade-angle correspondence system through software quantitative research, replacing the traditional experience-based correspondence.

[0049] Figure 11 As shown, the model of this invention can visualize the coke collapse process and the distribution of ore-coke ratio, which is impossible to achieve with traditional methods.

[0050] Table of the effects of different central coking amounts on coke slump

[0051] Figure 12 , 13 As shown in Table 3, unlike the traditional concept of adding more coke to the center based on intuition or simply adding it by feel, this invention clearly states that, under the premise of forming an edge coke platform, the amount of coke added to the center can be significantly reduced, such as from 3 rings to 1.5 rings, without affecting the effect.

[0052] Figure 14 As shown, this invention innovatively proposes and verifies a strategy for constructing an edge coke platform. This strategy can effectively suppress collapse and optimize the ore-coke ratio distribution, thereby achieving an ideal airflow pattern of a stable center and a loose edge, which is the core of energy consumption reduction.

[0053] The following is a comparison table of energy saving effects before and after the implementation of the method of the present invention. This table intuitively shows the actual energy saving effect brought about by applying the method of the present invention.

[0054] Comparison table of energy saving effects

[0055] Benxi Beiying Iron and Steel (Group) Co., Ltd. No. 2 3200m 3 Taking a blast furnace as an example, after applying the optimized charging matrix, the blast furnace gradually forms a stable center and a loose edge dual-channel gas flow, improving furnace stability and increasing gas utilization. Even with fluctuating raw material conditions, the monthly fuel ratio is significantly reduced, reaching the advanced level of similar blast furnaces in China. For example, the fuel ratio of the new No. 2 blast furnace in December was 493.5 kg / t, saving over 30 million yuan in fuel costs annually. This invention achieves the effect of increasing production and reducing consumption under long-term stable furnace operation.

[0056] Comparison table of the present invention and traditional furnace temperature control methods

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for reducing energy consumption based on the research of blast furnace charging mechanism and its model optimization, characterized in that, Includes the following steps: S1. Based on the actual equipment geometric parameters of the target blast furnace, a three-dimensional geometric model from the treasury to the throat surface is established; the discrete element method is used in combination with the three-dimensional geometric model to simulate the charging and discharging process of the furnace charge in the treasury; the mass point force analysis method is used in combination with the simulated charging and discharging process to establish a mathematical model of the movement of the furnace charge in the central throat, rotary chute and throat void. S2. Using the established mathematical model, simulate the particle size distribution of the furnace charge in the feeding tank and weighing tank respectively; S3. Based on the established mathematical model, the blast furnace intelligent charging software is used to calculate the material flow trajectory, material flow width, and material surface model; S4. Using the intelligent charging software for blast furnaces, study the influence of different operating parameters on the distribution of furnace charge, and quantitatively establish the correspondence between the charging level and the chute inclination angle; S5. Based on mathematical models and intelligent blast furnace charging software, the effects of different central coking angles, coking amounts and initial coke layer shapes on coke collapse and radial ore-coke ratio distribution are simulated and studied. The obtained influence relationships are used to optimize the central coking and coke platform strategies. S6. Apply the parameters obtained in steps S1-S5 to the target blast furnace, use the blast furnace intelligent charging software to calculate and guide the adjustment of the charging matrix online or offline, continuously monitor the blast furnace operation indicators, and verify and adjust the mathematical model and blast furnace intelligent charging software parameters based on production data feedback.

2. The energy consumption reduction method based on the blast furnace charging mechanism and its model optimization research as described in claim 1, characterized in that, The mathematical model in step S1 contains Coriolis force parameters and gas traction parameters.

3. The energy consumption reduction method based on the blast furnace charging mechanism and its model optimization research as described in claim 1, characterized in that, In step S2, during the simulation of the particle size distribution of the furnace charge in the feeding tank and the weighing tank, it is necessary to clearly define that the degree of furnace charge segregation in the feeding tank is greater than that in the weighing tank, and that the segregation in the feeding tank will exacerbate the hereditary pattern of segregation in the weighing tank.

4. The energy consumption reduction method based on the blast furnace charging mechanism and its model optimization research as described in claim 1, characterized in that, In step S2, during the process of simulating the particle size distribution of the furnace charge in the charging tank and weighing tank respectively, a charging mode is adopted in which the sintering ore feeding sequence is advanced and / or the coke and sintering ore feeding sequence is delayed, so as to reduce the overall particle size segregation of the furnace charge in the tank and during the discharge process.

5. The energy consumption reduction method based on the blast furnace charging mechanism and its model optimization research as described in claim 1, characterized in that, In step S3, the material flow trajectory is calculated based on the main landing point of the furnace charge under different chute inclination angles, lengths, shapes, rotation speeds, material line heights, furnace charge types, and whether Coriolis force and gas resistance are considered; the material flow width is calculated based on the influence of parameter changes involved in the material flow trajectory calculation on the material surface spreading width; the material surface model is calculated by predicting the material surface shape and platform width based on the material distribution matrix. The parameters of the material distribution matrix include the grade, number of circles, and material batches, supporting two grade angle division systems: the equal cross-sectional area method and the equal diameter method.

6. The energy consumption reduction method based on the blast furnace charging mechanism and its model optimization research as described in claim 1, characterized in that, The optimization strategy for center coking and coking platform in step S5 is to close the throttle valve when coking reaches the secondary center position, and then place the center coking when the chute tilts to the center position.

7. The energy consumption reduction method based on the blast furnace charging mechanism and its model optimization research as described in claim 1, characterized in that, Step S5 optimizes the center coking and coke platform strategy. Under the premise of forming an effective coke platform, the center coking amount can be reduced to about half of the original design value.

8. The energy consumption reduction method based on the blast furnace charging mechanism and its model optimization research as described in claim 1, characterized in that, The blast furnace operating parameters in step S6 include fuel ratio, gas utilization rate, and air volume.

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