Fine Ratio Measuring Device Spectral Analysis
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Solution Overview
Problem
Conventional methods for measuring the fine ratio of raw materials in blast furnaces face challenges such as delayed operations due to high sampling frequencies, lack of quantitative measurement of fines adhering to lumps, and low accuracy in measuring fine ratios, particularly using spectroscopic information from near-infrared radiation.
Innovation Solution
A fine ratio measuring system comprising a device with an illumination unit, spectrometer, and arithmetic device that performs spectral analysis and principal component analysis to accurately measure the fine ratio of raw materials like coke in real time, using spectral reflectances at multiple wavelengths to compute the ratio of fines adhering to lumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If periodic sampling and sieve analysis are used to measure particle sizes, then measurement accuracy is improved, but measurement time increases and real-time operation becomes difficult
Solution Approach 1:
The patent replaces the mechanical sieve analysis system with an optical detection system using cameras and image processing. This substitution enables real-time measurement of particle sizes and fine ratios without the time-consuming manual or automated sieve analysis process, while maintaining measurement accuracy through digital image analysis.
Solution Approach 2:
The patent creates optical copies (images) of the raw materials on the conveyor belt and analyzes these copies to determine particle sizes and fine ratios. This allows measurement without physically handling or stopping the material flow, enabling real-time operation while preserving measurement precision through detailed image analysis.
2Productivity
If high sampling frequency is used to obtain real-time data, then productivity is improved, but operational delays occur due to excessive sampling
Solution Approach 1:
The patent implements continuous measurement along the conveyor belt rather than discrete sampling at intervals. The camera system continuously captures images of raw materials as they move along the conveyor, providing uninterrupted real-time data on particle sizes and fine ratios without causing operational delays associated with frequent sampling and analysis cycles.
3Speed
If conventional spectroscopic methods using near-infrared radiation are used, then measurement speed is improved, but measurement accuracy of fine ratio deteriorates
Solution Approach 1:
The patent replaces the spectroscopic detection method with optical imaging and image processing. Instead of using near-infrared radiation and spectral analysis, the system uses visible light cameras to capture images of raw materials and determines fine ratios through image analysis, achieving both real-time measurement speed and high accuracy.
Solution Approach 2:
The patent utilizes visual appearance and color characteristics of raw materials in captured images to identify and distinguish fines from lumps. By analyzing color distribution, brightness variations, and visual textures in the images, the system accurately determines fine ratios without relying on spectroscopic methods that struggle with accuracy.
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 high-accuracy real-time measurement of fine ratios, stabilizing blast furnace operations by controlling the amount of fines charged, thereby improving gas permeability and reducing operational delays.
Implementation Method 1
a spectrometer that performs spectral analysis on light reflected from the material to be charged to the blast furnace to measure spectral reflectances
Implementation Method 2
an illumination unit that illuminates the material to be charged to the blast furnace
Data Source
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AI summary
Provided is a fine ratio measuring device that can measure the ratio of fines adhering to a material in the form of lumps in real time with high accuracy. The device for measuring the ratio of fines adhering to a material in the form of lumps includes: an illumination unit that illuminates the material in the form of lumps; a spectrometer that performs spectral analysis on light reflected from the material in the form of lumps to measure spectral reflectance; and an arithmetic device that extracts a feature quantity from the spectral reflectance measured by the spectrometer and computes the fine ratio using the extracted feature quantity.