Vertical Furnace Molten Level Detection Using Void Fraction
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Solution Overview
Problem
Existing methods for detecting the liquid level of molten materials in vertical furnaces, such as blast furnaces, require costly equipment and suffer from inaccuracies due to varying void fractions in the furnace bottom, leading to unstable operation and potential blockages.
Innovation Solution
A method and apparatus that calculate the void fraction of a solid-filled structure in the furnace bottom using the inclination angle of the liquid surface and residual amount of molten material, allowing for precise detection of the liquid level by incorporating a liquid level detection unit that processes these values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a special sensor or camera is introduced to measure liquid level directly, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces direct mechanical/optical sensing (special sensors or cameras) with an indirect calculation method based on material balance. The liquid level is determined by calculating the residual amount of molten material through mass conservation principles, using readily available process data (charge amounts, discharge amounts, production rates) rather than requiring specialized measurement equipment in the harsh furnace environment.
2Device complexity
If the void fraction is assumed to be constant for simplification, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent performs preliminary measurement of the void fraction at the beginning of the detection process. By measuring the void fraction once before the liquid level detection calculation, the system establishes an accurate baseline value that accounts for the actual coke bed conditions. This preliminary action ensures subsequent liquid level calculations are precise without requiring continuous complex adjustments.
3Loss of energy
If the liquid level is not monitored accurately, then operational costs are reduced, but reliability deteriorates due to unstable operation and potential blockages
Solution Approach 1:
The patent implements a feedback mechanism where the calculated liquid level information is continuously monitored and used to adjust furnace operations. When the liquid level approaches critical thresholds, the system provides feedback signals to control tapping operations or adjust charging rates, preventing unstable operation and blockages while optimizing furnace efficiency and reducing unnecessary operational costs.
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 accurate detection of the liquid level, enabling stable operation by preventing high liquid levels and blockages, thus reducing operational costs and maintaining furnace stability.
Implementation Method 1
calculating a void fraction of the solid-filled structure; and detecting the liquid level of the liquid after end of the discharge by using the calculated void fraction and a residual amount of the liquid
Data Source
AI summary
A molten material liquid level detection method that can detect a liquid level of molten material from a residual amount of the molten material with high accuracy and a method for operating a vertical furnace by using the detection method. The molten material liquid level detection method detects a liquid level of molten material remaining in a bottom portion of a vertical furnace after end of discharge of a molten material. The molten material liquid level detection method includes calculating a void fraction of the solid-filled structure, and detecting a liquid level of the molten material after the end of the discharge by using the calculated void fraction and a residual amount of the molten material after the end of the discharge.