Cold Iron Source Melting Ratio Estimation in Converter Refining
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Solution Overview
Problem
Existing methods for determining the complete melting of a cold iron source in a converter-type refining furnace are subjective and prone to errors due to variations in gas flow rates and refractory surface temperature changes, while conventional melting models are computationally costly and time-consuming.
Innovation Solution
A cold iron source melting ratio estimation device and method that uses real-time input of molten iron temperature and carbon concentration, coupled with a database of model equations and parameters, to compute the melting ratio of the cold iron source, thereby predicting the occurrence of unmelted cold iron source during refining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional melting models are used to determine complete melting of cold iron source, then measurement accuracy can be achieved, but computation time becomes excessively long and computational costs increase
Solution Approach 1:
The patent extracts only the essential parameters needed for melting determination (molten iron temperature and carbon concentration) from the complex conventional models. By focusing on these key indicators that directly reflect melting state, the system achieves accurate melting determination without requiring computationally intensive complete thermal field simulations.
Solution Approach 2:
The patent employs a simplified estimation model that requires minimal computational resources compared to conventional detailed thermal models. This lightweight approach uses readily available process data (temperature and carbon concentration) to quickly assess melting status, making it suitable for real-time control applications where computation time is critical.
2Measurement precision
If existing methods for determining complete melting are used, then melting status can be assessed, but operator subjectivity and errors due to gas flow rate variations and refractory temperature changes occur
Solution Approach 1:
The patent implements a feedback mechanism that continuously monitors molten iron temperature and carbon concentration, and uses this information to dynamically estimate the cold iron source melting ratio. This closed-loop approach eliminates operator subjectivity by providing objective, data-driven melting status assessment that automatically adjusts to varying process conditions.
Solution Approach 2:
The patent replaces subjective visual assessment and manual determination methods with an automated computational estimation system. By substituting human judgment with algorithm-based calculation using process data, the system eliminates operator subjectivity and provides consistent, reliable melting status determination.
3Object-generated harmful factors
If the molten pig iron ratio is reduced to increase cold iron source usage, then CO2 generation is reduced, but reaction heat becomes insufficient and cold iron source may not be completely melted
Solution Approach 1:
The patent enables the refining process to self-regulate by continuously estimating the cold iron source melting ratio and using this information to automatically adjust process parameters. The system monitors whether the cold iron source is melting at the expected rate and triggers appropriate control actions (such as extending refining time or adjusting oxygen flow) to ensure complete melting, eliminating the need for conservative molten pig iron ratios.
Solution Approach 2:
The patent changes the control parameter from fixed molten pig iron ratio to dynamic cold iron source melting ratio estimation. By continuously calculating the actual melting progress based on temperature and carbon concentration data, the system can optimize the balance between cold iron source usage and melting completeness, allowing higher cold iron source ratios while ensuring complete melting through real-time parameter adjustment.
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
The solution allows for accurate and rapid estimation of the cold iron source melting behavior, reducing computational costs and operator subjectivity, while predicting the occurrence of unmelted cold iron source, thus enhancing refining efficiency.
Implementation Method 1
the heat of reaction between oxygen blown in during refining and carbon and silicon contained as impurity elements in the molten pig iron
Implementation Method 2
it is necessary to compensate for the heat absorption resulting from the heating and melting of the cold iron source
Data Source
AI summary
A cold iron source melting ratio estimation device that estimates a melting ratio of a cold iron source charged into a converter-type refining furnace during refining of molten iron in the converter-type refining furnace. The device includes: an input section to which measured values of in-furnace information or estimated values of the in-furnace information is input, the in-furnace information including a molten iron temperature and a carbon concentration in the molten iron during refining; a database section that stores a model equation and parameters related to a refining reaction of the molten iron in the converter-type refining furnace; a computation section that computes the melting ratio of the cold iron source using the measured values or the estimated values input to the input section; and an output section that displays the melting ratio of the cold iron source computed by the computation section.