Furnace Slag Weight Estimation via Image Processing
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Solution Overview
Problem
Existing methods for estimating furnace slag weight after slag-removal in steel production are inaccurate due to changes in the furnace throat shape and the presence of air bubbles, leading to inefficiencies in auxiliary raw material charging and reduced iron yield.
Innovation Solution
A device and method that calculates slag weight using input data including furnace shape, molten metal and slag components, and slag height, employing a slag bulk density estimation model and volume model to determine the accurate slag weight remaining in the converter post-slag removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual estimation or weighing methods are used to determine furnace slag weight, then the process is simple to operate, but the measurement precision is low due to slag bubbling, bulk density variation, and potential overflow
Solution Approach 1:
The patent replaces mechanical weighing methods with an optical measurement system. A camera captures images of the slag surface, and image processing algorithms calculate the slag volume and weight based on the captured visual data, eliminating the need for physical weighing equipment and operators.
Solution Approach 2:
The patent introduces an intermediary computational model that converts visual information (image data) into quantitative measurements (slag weight). This intermediary processing layer bridges the gap between simple visual observation and precise measurement, achieving both ease of operation and high precision.
2Device complexity
If geometric calculation from tilt angle and calming properties is used to estimate furnace slag volume, then the device complexity is low, but the measurement precision deteriorates when furnace throat shape changes due to wear or skull attachment
Solution Approach 1:
The patent creates a digital copy (image) of the actual slag surface in the furnace. By capturing the real-world slag surface through a camera and processing this digital representation, the system obtains accurate measurements without being affected by changes in furnace geometry, as each measurement is based on direct visual capture rather than geometric assumptions.
3Productivity
If auxiliary raw materials are charged based on inaccurate slag weight estimation, then the charging process is quick, but the productivity decreases due to excessive charging leading to lower cost efficiency and iron yield rate
Solution Approach 1:
The patent implements a feedback mechanism where the precisely measured slag weight (obtained through image processing) is used to determine the exact charging amount of auxiliary raw materials. This closed-loop approach ensures that materials are charged optimally based on actual slag conditions, avoiding both over-charging and under-charging, thereby maximizing productivity and minimizing waste.
Data Source
AI summary
A furnace slag amount estimation device (1) includes: an input unit (11) configured to receive input data including furnace shape data for a converter, data on components and temperatures of molten metal and slag before start of or during blowing treatment, and slag height data in a furnace of the converter; a slag bulk density calculation unit (13) configured to calculate a slag bulk density after the converter is tilted, using the input data and a model; a slag volume calculation unit (14) configured to calculate a slag volume in the furnace after the converter is tilted, using the slag height data after the converter is tilted, the furnace shape data, and a model; and a slag weight calculation unit (15) configured to calculate a slag weight in the furnace after the converter is tilted and slag is discharged, using the calculated slag bulk density and the calculated slag volume.