Iron Ore Softening Test Device with Dynamic Load and Gas Control
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Solution Overview
Problem
Existing methods for measuring the softening and melting properties of iron ores in blast furnaces are inadequate as they fail to simulate the actual atmosphere, do not dynamically adjust the load, and lack online weighing capabilities, leading to inaccurate test results.
Innovation Solution
A device comprising a high temperature furnace, gas supply system, and weighing system that simulates the blast furnace atmosphere by dynamically controlling the reducing gas composition and flow rate, adjusts the load on the iron ore specimen based on temperature, and enables online weighing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple reducing gas mixture of CO and N2 is used, then the device complexity is reduced, but the measurement precision deteriorates because it cannot simulate the actual blast furnace atmosphere
Solution Approach 1:
The gas supply system is divided into multiple independent gas storage devices, each storing a different reducing gas component (CO, H2, CO2, N2). This segmentation allows precise control of each gas component's flow rate independently, enabling accurate simulation of the complex blast furnace atmosphere while maintaining system manageability
Solution Approach 2:
The system dynamically adjusts the composition and flow rates of reducing gas components based on temperature parameters. The gas mixing device receives multiple gas streams with controllable flow rates, and the mixture composition changes according to the heating temperature to match actual blast furnace conditions at different temperature zones
2Device complexity
If a fixed load is applied to the iron ore, then the device complexity is reduced, but the measurement precision deteriorates because it cannot account for the changing pressure of the stock column during smelting
Solution Approach 1:
The loading system transforms from a static fixed-load mechanism to a dynamic load adjustment system. The loading device receives temperature signals and automatically adjusts the load on the iron ore specimen in real-time, simulating the changing pressure conditions that occur as the stock column descends and transforms during actual blast furnace smelting
Solution Approach 2:
The loading system incorporates temperature feedback control. The temperature acquisition device continuously monitors the heating temperature, and this information feeds back to the loading device, which automatically adjusts the applied load accordingly. This closed-loop feedback ensures the load accurately reflects the actual pressure conditions at each temperature stage
3Measurement precision
If online weighing capability is added to the device, then the measurement precision is improved through real-time weight monitoring, but the device complexity increases
Solution Approach 1:
The weighing device serves multiple functions: it measures the weight of the graphite crucible, monitors the weight change of the iron ore specimen during heating, and detects the weight of dropped molten iron. This multi-functionality justifies the added complexity by providing comprehensive measurement capabilities throughout the entire smelting process
Solution Approach 2:
The weighing device acts as an intermediary measurement tool that indirectly observes the smelting process through weight changes. Rather than directly measuring temperature or chemical composition, it uses weight as a proxy indicator to infer the progression of reduction, softening, melting, and dropping stages, providing valuable data without requiring direct intervention in the high-temperature environment
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 device provides more accurate test results by simulating the actual blast furnace environment, adjusting the load to match the changing pressure, and allowing real-time weight measurement, thereby improving the relevance of the test outcomes.
Implementation Method 1
The gas supply system is used to inject a reducing gas including N2, H2, CO2 and CO into the hearth
Implementation Method 2
The high temperature furnace is provided therein with a hearth; the hearth is provided therein with a cylindrical graphite crucible
Data Source
AI summary
A method for measuring the softening and melting performances of iron ore in blast furnace is disclosed, which is implemented by a device including a high temperature furnace, gas supply system, a loading system and a weighing system. The method includes: step 1: the dried coke and iron ore specimen are placed in the graphite crucible in a specified way; step 2: the graphite crucible is placed in the high temperature furnace, and N2 is continuously fed into the high temperature furnace to reach an airtightness requirement; step 3: a vacuum pump is used to extract mixed gas in a hearth of the high temperature furnace and heating process is started; step 4: both the composition of mixed gas and pressure imposed on the iron ore are controlled according to the designed temperature variation; step 5: data are acquired to calculate.