Blast Furnace Air Flow Detection Using Cross-Shaped Temperature Gun
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Solution Overview
Problem
Current methods for detecting gas flow distribution in blast furnaces are inaccurate and inconvenient, relying on expensive infrared devices and gas sampling, which can interfere with operations and provide limited information, and do not account for variations in burden layer thickness and heat conduction.
Innovation Solution
A method using a cross-shaped temperature-measuring gun to divide the blast furnace throat into regions, calculating the solid-gas heat flow ratio, and adjusting for burden material thickness and pressure drop to accurately determine gas flow distribution, incorporating a verification process to ensure errors are within acceptable limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If gas sampling equipment is installed in the radial direction of the throat to analyze compositional distribution, then measurement precision is improved, but device complexity increases and safety issues arise due to gas leakage risks
Solution Approach 1:
The patent extracts the measurement function from complex gas sampling equipment and implements it through a simplified temperature measurement system. By measuring temperature distribution at the furnace throat and using thermal field analysis to infer gas flow composition and distribution, the system eliminates the need for physical gas sampling devices, thereby reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The patent introduces temperature as an intermediary parameter to indirectly measure gas flow composition and distribution. Instead of directly sampling and analyzing gas composition, the system uses temperature measurements as a mediator to infer flow characteristics, avoiding the safety issues and complexity associated with direct gas sampling while achieving accurate measurement.
2Measurement precision
If infrared imaging is used to observe flame size and thermocouple temperature to determine gas flow changes, then measurement capability is improved, but information completeness deteriorates due to limited detection scope
Solution Approach 1:
The patent divides the furnace throat cross-section into multiple measurement regions and positions temperature measuring guns at different locations to capture temperature distribution across the entire cross-section. This segmented measurement approach comprehensively captures gas flow distribution information, overcoming the limited detection scope of single-point measurements while maintaining high measurement precision.
Solution Approach 2:
The patent transitions from single-point temperature measurement to two-dimensional temperature field measurement by arranging multiple temperature measuring guns in a cross-shaped configuration across the furnace throat cross-section. This dimensional expansion enables comprehensive capture of gas flow distribution patterns, preventing information loss while preserving measurement accuracy.
3Ease of operation
If cross-shaped temperature-measuring gun is mounted at the furnace top for on-line monitoring, then ease of operation is improved, but measurement precision deteriorates because temperature distribution alone cannot comprehensively reflect gas flow distribution
Solution Approach 1:
The patent transforms the measurement approach by changing from direct temperature measurement to thermal field analysis. Instead of simply measuring temperature values, the system analyzes the thermal field distribution pattern and uses thermal field theory to infer gas flow composition, velocity, and distribution characteristics. This parameter transformation enables comprehensive gas flow detection using temperature measuring guns, maintaining ease of operation while significantly improving measurement precision.
Solution Approach 2:
The patent replaces direct mechanical gas sampling and composition analysis with a thermal field-based measurement system. By using temperature distribution patterns as a substitute for direct gas composition measurement, the system achieves comprehensive gas flow detection through non-intrusive thermal field analysis, maintaining operational simplicity while enhancing measurement accuracy.
4Measurement precision
If gas sampling device is inserted inside the burden, then measurement capability is improved, but productivity deteriorates due to interference with burden unloading and accelerated lining abrasion
Solution Approach 1:
The patent extracts the measurement function from the burden interior to the furnace throat exterior. By measuring temperature distribution at the furnace throat and using thermal field analysis to infer gas flow characteristics, the system eliminates the need to insert sampling devices into the burden, thereby removing interference with burden unloading operations and preventing accelerated lining abrasion while maintaining measurement capability.
Solution Approach 2:
The patent uses temperature distribution at the furnace throat as an intermediary to indirectly measure gas flow composition and distribution that would otherwise require direct burden interior sampling. This intermediary measurement approach provides the same information as burden interior sampling without the harmful effects, preserving productivity while maintaining measurement precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables timely and accurate adjustment of material distribution systems, maintaining stable blast furnace operation, extending equipment life, and reducing fuel consumption without the need for expensive instruments.
Implementation Method 1
a cross-shaped temperature-measuring gun mounted at the furnace top for on-line monitoring the distribution of the gas flow temperature
Implementation Method 2
obtaining a solid-gas heat flow ratio of each of the temperature-measuring device regions according to temperature values from each of the temperature-measuring devices and a balance equation between a heat flow rate of gas and a heat flow rate of solid
Implementation Method 3
the distribution of the gas flow cannot be comprehensively reflected solely by the temperature distribution... the burden layer thickness and heat conduction vary significantly in the radial direction
Data Source
Figure 1~2C
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Figure 5~6
AI summary
A method for detecting an air flow distribution in a blast furnace, taking into account a heat exchange between an air flow and a solid material bed and the effect of a distribution of a material layer structure in a radial direction of a blast furnace on the radial air permeability of blast furnace, which affects a mode of air flow distribution, wherein the distribution of the air flow and the radial material layer structure of the blast furnace can be calculated by combining a cross-shaped temperature-measuring gun and other main blast furnace operating parameters. According to the detection method, a blast furnace operator can timely and accurately infer, from a change in a current radial air flow temperature distribution, the direction of change of the distribution of the air flow and the radial material layer structure at a furnace throat portion, thus providing a direction for the adjustment of a material distribution system, ensuring the blast furnace to run stably and smoothly, extending a service life and reducing a fuel ratio without other expensive detecting instruments.