铁矿石烧结过程热状态模型的研究与应用
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摘要
铁矿石烧结造块是钢铁联合企业重要的一环,随着我国钢铁工业的快速发展,它的各项技术经济指标直接影响整个钢铁工业的效益。而烧结过程热状态是烧结正常进行的重要标志,烧结过程热状态分布合理时能生产出优质的烧结矿。目前国内外有关烧结过程热状态的研究仅能通过烧结终点间接的判断,或者非连续的测量和计算烧结料层的温度和热量。本研究通过连续测量烧结机台车侧板温度,开发烧结过程热状态模型系统软件,对烧结过程热状态进行实时判断与分析,在线指导烧结生产,具有重要的理论意义和实用价值。
深入剖析了烧结过程气-固相热交换和物理化学变化,将烧结过程热状态分解为竖向、纵向和横向三维空间上的热状态分布。在不考虑横向烧结非均匀性的情况下,将烧结过程热状态描述为料层各带厚度的分布和迁移速度的变化。
在冶金传热理论的基础上,根据烧结各带的热交换和化学反应的特点,将烧结过程分成三个阶段分别建立了控制方程,并计算了方程的关键参数。通过编制计算机程序采用隐式差分法求解出理想条件下的料层温度,并计算出各带的厚度和迁移速度,分析了它们的热状态特征。
采用非接触式红外线温度扫描仪测量烧结机台车侧板竖向温度,应用多项式移动平滑算法对采集的原始数据进行滤波处理,利用侧板温度与料层温度对应的变化特性,建立了料层各带的划分模型,采用自动寻优的方法确定模型的带宽系数,通过多次工业试验优化了侧板温度划分的层数。针对料层各带厚度的分布和迁移速度的变化,结合机理模型计算的结果,深入研究了烧结过程热状态特性。并分析了宝钢高配比褐铁矿原料条件下的热状态特性。
针对模型对数据的要求,设计了SQL Sever 2000平台上的数据库系统SinterDb,采用基于OPC技术的软件通讯接口,编制了高效的数据读取、写入代码,实现了数据的实时采集。同时,采用视图机制简化了数据的查询操作,提高了数据的安全性。
采用VC程序设计语言开发了烧结过程热状态模型系统软件,结合多线程技术、Matcom与VC混合编程技术和MCI语音技术,实现了竖向热状态分析、纵向热状态分析、横向热状态分析、数据查询、参数设置、系统帮助6大系统功能。系统投入使用后,通过指导生产,烧结过程趋于合理,产质量得到提高,验证了模型的有效性。统计数据显示,生产率提高1.23 t/m~2·d,成品率提高1.04%,转鼓强度提高0.86%。同时系统带来的经济效益明显,据测算,系统实现的直接经济效益可达1700万元/年。基于侧板测温的热状态模型的开发及系统软件的应用为烧结过程热状态的研究提供了一条新的途径,具有广阔的应用前景。
Iron ore sintering is one of the most important links in integrated steelworks. Along with the rapid development of iron & steel industry in China, technical and economic indexes of iron ore sintering have a direct effect on the economic benefit of steel complex. Thermal state is an important indication of normal sintering process, sintering process in normal thermal state will produce sinter with high grade. At present, thermal state of sintering process is only researched by the indirect judgment of burnt through point or uncontinuous measurement and calculation of sinterbed temperature and quantity of heat. In this paper, side-plate temperature is measured continuously, and software system of thermal state model in sintering process is developed. It has a great theoretical significance and practical use on real-time judgment and analysis of thermal state in sintering process and the guidance of production online.
This paper gives a profound analysis of gas-solid heat transfer and physical and chemical change of sintering process, and then thermal state of sintering process is divided into three-dimensions distribution of vertical thermal state, longitudinal thermal state, and transversal thermal state. Take no account of transversal heterogeneity, thermal state of sintering process is described as the change of the thickness of each zone in bed layer and migration rate.
Sintering process is divided into three stages and control equations of each stage is set up according to the characteristics of the heat-exchange and chemical reaction of each zone base on heat transfer metallurgical theory, and then the key parameters of equations are calculated. Ideal bed temperature is solved out by the program of implicit difference method. The thickness of each zone and migration rate are also figured out and their thermal state characteristics are analyzed,
Non-contact infrared temperature scanner is used in the side-plate vertical temperature measurement of pallet. Filtering process is taken out on raw data using moving-polynomial smoother algorithm. Partition model of each zone is set up by the change characteristics of the curve of side-plate temperature and bed temperature. The bandwidth coefficient of the model is fixed by automatic optimization. The number of side-plate temperature layers is optimized by industrial tests. This research made a deep study of the characteristics of thermal state in sintering process directing at the change of thickness distribution of each zone and migration rate, considering the result of mechanism model. And the thermal state of Bao-Steel under the raw material condition of high limonite proportion is analyzed.
According to the data demand of model, the database system SinterDb on the platform of SQL Sever 2000 is designed. Real-time acquisition of data is realized by software communication interface based on OPC technology. Efficient read and write code of data is programmed. The operation of data query is simplified by the use of view mechanism and the safety of data is increased.
Software system of thermal state model in sintering process is developed using programming language of VC. Six system functions of vertical thermal state analysis, transversal thermal state analysis, longitudinal thermal state analysis, data query, parameter setting, and system help are realized by multi-thread technology, mixed programming technology of Matcom and VC, and MCI voice technology. This system is put to use. By the guidance of this system in production, it tends towards a reasonable sintering process, and improvement is made in yield and quality. Therefore, the validity of the model is verified. The statistical data shows that the productivity increases 1.23 t/m~2·d, pan yield increases 1.04%, and tumbler strength increases 0.86%. Meanwhile, the economic efficiency increases significantly. According to calculation, the direct economic benefit of this system can reach to 17,000,000 RMB/year. The development of thermal state model based on side-plate temperature measurement and the application of this software system provide a new way in the research of thermal state of sintering process. And it has a bright prospect of application.
深入剖析了烧结过程气-固相热交换和物理化学变化,将烧结过程热状态分解为竖向、纵向和横向三维空间上的热状态分布。在不考虑横向烧结非均匀性的情况下,将烧结过程热状态描述为料层各带厚度的分布和迁移速度的变化。
在冶金传热理论的基础上,根据烧结各带的热交换和化学反应的特点,将烧结过程分成三个阶段分别建立了控制方程,并计算了方程的关键参数。通过编制计算机程序采用隐式差分法求解出理想条件下的料层温度,并计算出各带的厚度和迁移速度,分析了它们的热状态特征。
采用非接触式红外线温度扫描仪测量烧结机台车侧板竖向温度,应用多项式移动平滑算法对采集的原始数据进行滤波处理,利用侧板温度与料层温度对应的变化特性,建立了料层各带的划分模型,采用自动寻优的方法确定模型的带宽系数,通过多次工业试验优化了侧板温度划分的层数。针对料层各带厚度的分布和迁移速度的变化,结合机理模型计算的结果,深入研究了烧结过程热状态特性。并分析了宝钢高配比褐铁矿原料条件下的热状态特性。
针对模型对数据的要求,设计了SQL Sever 2000平台上的数据库系统SinterDb,采用基于OPC技术的软件通讯接口,编制了高效的数据读取、写入代码,实现了数据的实时采集。同时,采用视图机制简化了数据的查询操作,提高了数据的安全性。
采用VC程序设计语言开发了烧结过程热状态模型系统软件,结合多线程技术、Matcom与VC混合编程技术和MCI语音技术,实现了竖向热状态分析、纵向热状态分析、横向热状态分析、数据查询、参数设置、系统帮助6大系统功能。系统投入使用后,通过指导生产,烧结过程趋于合理,产质量得到提高,验证了模型的有效性。统计数据显示,生产率提高1.23 t/m~2·d,成品率提高1.04%,转鼓强度提高0.86%。同时系统带来的经济效益明显,据测算,系统实现的直接经济效益可达1700万元/年。基于侧板测温的热状态模型的开发及系统软件的应用为烧结过程热状态的研究提供了一条新的途径,具有广阔的应用前景。
Iron ore sintering is one of the most important links in integrated steelworks. Along with the rapid development of iron & steel industry in China, technical and economic indexes of iron ore sintering have a direct effect on the economic benefit of steel complex. Thermal state is an important indication of normal sintering process, sintering process in normal thermal state will produce sinter with high grade. At present, thermal state of sintering process is only researched by the indirect judgment of burnt through point or uncontinuous measurement and calculation of sinterbed temperature and quantity of heat. In this paper, side-plate temperature is measured continuously, and software system of thermal state model in sintering process is developed. It has a great theoretical significance and practical use on real-time judgment and analysis of thermal state in sintering process and the guidance of production online.
This paper gives a profound analysis of gas-solid heat transfer and physical and chemical change of sintering process, and then thermal state of sintering process is divided into three-dimensions distribution of vertical thermal state, longitudinal thermal state, and transversal thermal state. Take no account of transversal heterogeneity, thermal state of sintering process is described as the change of the thickness of each zone in bed layer and migration rate.
Sintering process is divided into three stages and control equations of each stage is set up according to the characteristics of the heat-exchange and chemical reaction of each zone base on heat transfer metallurgical theory, and then the key parameters of equations are calculated. Ideal bed temperature is solved out by the program of implicit difference method. The thickness of each zone and migration rate are also figured out and their thermal state characteristics are analyzed,
Non-contact infrared temperature scanner is used in the side-plate vertical temperature measurement of pallet. Filtering process is taken out on raw data using moving-polynomial smoother algorithm. Partition model of each zone is set up by the change characteristics of the curve of side-plate temperature and bed temperature. The bandwidth coefficient of the model is fixed by automatic optimization. The number of side-plate temperature layers is optimized by industrial tests. This research made a deep study of the characteristics of thermal state in sintering process directing at the change of thickness distribution of each zone and migration rate, considering the result of mechanism model. And the thermal state of Bao-Steel under the raw material condition of high limonite proportion is analyzed.
According to the data demand of model, the database system SinterDb on the platform of SQL Sever 2000 is designed. Real-time acquisition of data is realized by software communication interface based on OPC technology. Efficient read and write code of data is programmed. The operation of data query is simplified by the use of view mechanism and the safety of data is increased.
Software system of thermal state model in sintering process is developed using programming language of VC. Six system functions of vertical thermal state analysis, transversal thermal state analysis, longitudinal thermal state analysis, data query, parameter setting, and system help are realized by multi-thread technology, mixed programming technology of Matcom and VC, and MCI voice technology. This system is put to use. By the guidance of this system in production, it tends towards a reasonable sintering process, and improvement is made in yield and quality. Therefore, the validity of the model is verified. The statistical data shows that the productivity increases 1.23 t/m~2·d, pan yield increases 1.04%, and tumbler strength increases 0.86%. Meanwhile, the economic efficiency increases significantly. According to calculation, the direct economic benefit of this system can reach to 17,000,000 RMB/year. The development of thermal state model based on side-plate temperature measurement and the application of this software system provide a new way in the research of thermal state of sintering process. And it has a bright prospect of application.
引文
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