Slag Flow Imaging for Precise Refining Vessel Discharge Estimation
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Solution Overview
Problem
Existing methods for estimating slag discharge amounts from refining vessels, such as those described in JP-A No. H7-41813 and 2018-119195, face issues with high costs and low precision due to the use of weighing instruments and geometric calculations, which are affected by variations in converter shapes and slag conditions.
Innovation Solution
A method that uses a single imaging device to capture the slag flow, measure its width, and calculate the volume or mass flow rate to estimate the slag discharge amount, reducing costs and improving accuracy by using image analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a weighing instrument is used to measure slag discharge amount, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical weighing instrument with an optical imaging system. A camera captures images of the slag flow, and image processing algorithms calculate the slag discharge amount based on the visual data. This substitution eliminates the need for complex mechanical weighing devices while achieving accurate measurements through non-contact optical methods.
Solution Approach 2:
The patent creates a visual copy (image) of the slag flow and processes this copy to determine the discharge amount. Instead of directly measuring the physical slag with a weighing instrument, the system captures an image copy of the slag flow and extracts measurement information from this digital representation, simplifying the measurement process.
2Device complexity
If geometric calculation method is used to estimate slag discharge amount, then device complexity is reduced, but measurement precision deteriorates due to variations in converter shapes and slag conditions
Solution Approach 1:
The patent replaces geometric calculation methods with optical image-based measurement. Instead of using theoretical geometric models that assume idealized shapes and conditions, the system captures actual images of the slag flow and processes these images to determine the discharge amount, thereby adapting to real-world variations in converter shapes and slag conditions.
Solution Approach 2:
The patent changes the measurement parameter from theoretical geometric parameters (which assume idealized conditions) to actual visual parameters captured by the imaging device. By measuring the actual slag flow width and other parameters directly from images, the system adapts to variations in real-world conditions while maintaining measurement precision.
3Device complexity
If image analysis method is used to measure slag flow width, then device complexity is reduced and cost is lowered, but measurement precision may be affected by image quality and processing accuracy
Solution Approach 1:
The patent uses optical imaging and digital image processing to replace complex mechanical measurement systems. The imaging device captures the slag flow, and software algorithms automatically process the images to extract precise width measurements, eliminating the need for complex physical measurement apparatus while maintaining accuracy through computational methods.
Data Source
AI summary
In a slag discharge amount estimation method, images of a slag flow flowing out from an outlet of a refining vessel are captured with a single imaging device. An upstream side of the slag flow is wider than a downstream side. Widths of the slag flow are found from the captured images, and a volume flow rate or mass flow rate of the slag flow is found. On the basis of the volume flow rate or the mass flow rate, a slag discharge amount is estimated.