CN-117327852-B - Intelligent carbon brick and preparation method thereof, and carbon brick residual thickness measuring method and system

CN117327852BCN 117327852 BCN117327852 BCN 117327852BCN-117327852-B

Abstract

The application discloses an intelligent carbon brick, a preparation method thereof and a carbon brick residual thickness measuring method and system, wherein the intelligent carbon brick comprises a carbon brick body and a film type electric sensor fixed on the surface of the carbon brick body, the film type electric sensor is of a multilayer heterogeneous film structure and comprises a first insulating protection layer, a metal functional layer, a second insulating protection layer and a second transitional connection layer in sequence, the metal functional layer is a patterned film resistor, the film resistor extends to the other end along one end of the carbon brick body, the intelligent carbon brick is stacked layer by layer along the periphery of the furnace wall inside a furnace body, in the production process, the film resistor can synchronously corrode along with the carbon brick body, the output resistance value of the film type electric sensor can be changed, and the residual thickness of the carbon brick body can be directly reflected according to the output resistance value and the change condition of the output resistance value, so that the real life of the furnace body can be more accurately and reliably detected online, and the safety of iron making production is ensured.

Inventors

FENG KE
QI RUI
DUAN QINGSONG
ZHANG JIANBO
LI XIULING

Assignees

中冶赛迪工程技术股份有限公司
中冶赛迪技术研究中心有限公司

Dates

Publication Date: 20260508
Application Date: 20230928

Claims (13)

1. The utility model provides an intelligent carbon brick, its characterized in that includes the carbon brick body and fixes the film type electricity sensor on carbon brick body surface, film type electricity sensor is multilayer heterogeneous film structure, including first insulating protection layer, metal functional layer, second insulating protection layer and second transitional coupling layer, first insulating protection layer is inorganic insulating material deposition formed film, the metal functional layer is the deposit the graphical thin film resistor on the first insulating protection layer, graphical thin film resistor extends to the other end along carbon brick body one end, the second insulating protection layer is inorganic insulating material deposit the film that forms on first insulating protection layer and the metal functional layer, the second transitional coupling layer is for attaching on the second insulating protection layer and by organic insulating material preparation film, the another side of second transitional coupling layer is attached to carbon brick body surface.
2. The intelligent carbon brick according to claim 1, wherein the inorganic insulating material is at least one selected from the group consisting of silicon dioxide, silicon nitride, aluminum oxide, aluminum nitride, and boron nitride; and/or the raw material for preparing the metal functional layer is at least one selected from chromium, platinum and chromium-platinum alloy; And/or the organic insulating material is at least one selected from polyimide, polyethylene, polyvinylidene fluoride and polytetrafluoroethylene; and/or, the first insulating protection layer and the second insulating protection layer are formed through a physical vapor deposition process or a chemical vapor deposition process; and/or the patterned thin film resistor is manufactured by combining a physical vapor deposition process or a chemical vapor deposition process with a hard mask etching process; and/or the second transition connecting layer is prepared by spin coating process.
3. The intelligent carbon brick of claim 1, wherein the patterned thin film resistor comprises a plurality of first thin film resistors and a plurality of second thin film resistors, the first thin film resistors are arranged at intervals along one end of the carbon brick body to the other end of the carbon brick body and are connected in parallel, one second thin film resistor is arranged between two adjacent first thin film resistors, and the second thin film resistor is connected in series with the adjacent first thin film resistors.
4. The intelligent carbon brick of claim 3, wherein if the resistance value of the first thin film resistor is far greater than the resistance value of the second thin film resistor, i.e. the ratio of the resistance value of the first thin film resistor to the resistance value of the second thin film resistor is not less than 100, the equivalent resistance of the patterned thin film resistor satisfies the following condition: in the formula, For the equivalent resistance of the patterned thin film resistor, For the resistance value of the first sheet resistance, Is the number of the first film resistors.
5. The intelligent carbon brick as set forth in claim 1, wherein the second transitional connecting layer is attached to the surface of the carbon brick body by means of hot rolling and curing by using an adhesive, so that the thin film type electrical sensor is fixed on the surface of the carbon brick body.
6. The intelligent carbon brick according to claim 5, wherein the method for fixing the film type electrical sensor on the surface of the carbon brick body comprises the following steps: Preparing a layer of film on a substrate by adopting an organic insulating material, and taking the film as a first transition connecting layer; sequentially preparing the first insulating protection layer, the metal functional layer, the second insulating protection layer and the second transitional connection layer on the first transitional connection layer; Adhering the second transition connecting layer to the surface of the carbon brick body by adopting an adhesive through a hot rolling solidification mode; and separating the substrate from the first transitional connecting layer, and removing the first transitional connecting layer to fix the film type electric sensor on the surface of the carbon brick body.
7. The intelligent carbon brick according to claim 6, wherein the substrate is any one selected from the group consisting of a glass substrate, a glazed ceramic substrate, a sapphire substrate and a monocrystalline silicon substrate; And/or removing the first transitional connection layer through a plasma etching process.
8. The intelligent carbon brick according to claim 7, wherein the way of separating the substrate from the first transitional connecting layer comprises immersing the substrate and the first transitional connecting layer in warm water, and then peeling the first transitional connecting layer from the substrate.
9. The method for preparing the intelligent carbon brick according to any one of claims 1 to 8, which is characterized by comprising the following steps: Preparing a layer of film on a substrate by adopting an organic insulating material, and taking the film as a first transition connecting layer; Depositing an inorganic insulating material on the first transition connecting layer to form a film serving as the first insulating protective layer; depositing a patterned thin film resistor on the first insulating protection layer to serve as the metal functional layer; Depositing an inorganic insulating material on the first insulating protective layer and the metal functional layer to form a film serving as the second insulating protective layer; Coating adhesive on the surface of the second transition connecting layer and/or the carbon brick body, and connecting the second transition connecting layer with the surface of the carbon brick body in a hot rolling solidification mode; and separating the substrate from the first transitional connecting layer, and removing the first transitional connecting layer to obtain the intelligent carbon brick.
10. A method for measuring residual thickness of a carbon brick is characterized by comprising the following steps of stacking the intelligent carbon bricks according to any one of claims 1-8 layer by layer along the periphery of a furnace wall in a furnace body, monitoring output resistance values of patterned thin film resistors on all the intelligent carbon bricks, determining erosion conditions of the intelligent carbon bricks according to the output resistance values and the change conditions of the output resistance values, and determining residual thickness of a carbon brick body according to the erosion conditions of the intelligent carbon bricks.
11. The method for measuring the residual carbon brick thickness according to claim 10, wherein the erosion condition comprises an erosion position, the erosion position is a position of an eroded intelligent carbon brick in a furnace body, and the erosion position is determined by numbering and positioning the intelligent carbon bricks stacked in the furnace body one by one, determining the eroded intelligent carbon brick according to the change condition of an output resistance value, and determining the position of the eroded intelligent carbon brick according to the numbering.
12. The method for measuring residual carbon brick thickness according to claim 10, wherein the erosion condition further comprises an erosion severity degree, the erosion severity degree is an erosion severity degree of a carbon brick body of an eroded intelligent carbon brick, the erosion severity degree is determined in such a manner that after the intelligent carbon brick is piled up, an extending direction of a patterned thin film resistor on the intelligent carbon brick is kept consistent with a horizontal direction, a residual effective length of the patterned thin film resistor is determined according to an output resistance value, the residual thickness of the carbon brick body is determined according to the residual effective length, the residual effective length is positively correlated with the residual thickness of the carbon brick body, and the residual thickness of the carbon brick body is negatively correlated with the erosion severity degree.
13. The carbon brick residual thickness measuring system is characterized by comprising a plurality of intelligent carbon bricks according to any one of claims 1-8, wherein the intelligent carbon bricks are piled up layer by layer along the periphery of the furnace wall in the furnace body; The intelligent carbon brick monitoring device comprises a plurality of intelligent carbon bricks, and is characterized by further comprising a monitoring module, wherein the monitoring module is used for monitoring the output resistance values of the patterned thin film resistors on all the intelligent carbon bricks, determining the erosion condition of the intelligent carbon bricks according to the output resistance values and the change conditions thereof, and determining the residual thickness of the carbon brick body according to the erosion condition of the intelligent carbon bricks.

Description

Intelligent carbon brick and preparation method thereof, and carbon brick residual thickness measuring method and system Technical Field The application relates to the technical field of metallurgy, in particular to monitoring of lining erosion in iron-making production, and particularly relates to an intelligent carbon brick, a preparation method thereof, and a method and a system for measuring residual carbon brick thickness by adopting the intelligent carbon brick. Background The carbon brick is a high-temperature resistant neutral refractory material product which is prepared from coke, anthracite and graphite serving as main raw materials and organic materials such as asphalt, tar, anthracene oil and the like serving as binding agents. The carbon brick has high refractoriness, high heat conductivity and electric conductivity, good slag resistance, good heat stability, low thermal expansion coefficient, high-temperature strength, high temperature resistance, good wear resistance and corrosion resistance of various acids, alkalis, salts and organic solvents. Carbon bricks are widely used in the metallurgical industry, and the bottom, hearth and waist of many blast furnaces are built from carbon bricks. Inside the blast furnace lining, one end of the carbon brick is contacted with an iron-making reaction area in the blast furnace, and the other end is connected with the furnace shell through a very thin ramming material. The carbon bricks form a container for restraining the reaction in the blast furnace, and play an important role in maintaining the production of the blast furnace and ensuring the safety of the blast furnace. In the blast furnace production process, as the iron-making reaction raw materials and products are continuously washed, the blast furnace carbon bricks are gradually thinned, and the thickness of the blast furnace carbon bricks is regarded as an important basis for blast furnace maintenance and safety production assurance. Therefore, the thickness monitoring of the blast furnace carbon bricks is a core problem of blast furnace production and safety assurance. Because the internal temperature of the blast furnace hearth is very high, the environment is quite severe, the thickness of the carbon brick is monitored in most of the current modes by drilling blind holes with different depths on the carbon brick, inserting temperature sensors such as armoured thermocouples and the like, measuring the temperature at the depth, and then indirectly deducing the thickness of the carbon brick through a heat transfer simulation model. In this process, it is necessary to drill blind holes in the carbon bricks through the furnace shell and insert temperature sensors. Because of errors generated by temperature measurement and boundary conditions of a heat transfer model, the obtained carbon brick thickness and actual conditions have larger errors, and false alarm and missing alarm of the residual carbon brick thickness can bring great loss to the safety production of the blast furnace. Therefore, a direct, accurate and reliable carbon brick residual thickness measuring mode is urgently needed in blast furnace production. Disclosure of Invention In view of the above-mentioned shortcomings of the prior art, the present application aims to provide an intelligent carbon brick and a preparation method thereof, and a method and a system for measuring residual carbon brick thickness by adopting the intelligent carbon brick, wherein a thin film type electric sensor is integrated on the surface of the carbon brick in situ, and the corresponding output resistance change is utilized to directly reflect the corrosion condition of the inner furnace lining in the furnace body when synchronous corrosion occurs, so as to provide a direct, accurate and reliable carbon brick residual thickness measuring mode for the production processes of blast furnace ironmaking, etc., assist in correcting the prediction precision of a mathematical model of hearth corrosion, comprehensively and truly know the life state in the furnace body, and ensure the safe and reliable ironmaking production. To achieve the above and other related objects, a first aspect of the present application provides an intelligent carbon brick, including a carbon brick body and a thin film type electrical sensor fixed on the surface of the carbon brick body, where the thin film type electrical sensor is a multi-layer heterogeneous thin film structure, and includes a first insulating protection layer, a metal functional layer, a second insulating protection layer and a second transitional connection layer, where the first insulating protection layer is a thin film formed by depositing an inorganic insulating material, the metal functional layer is a patterned thin film resistor deposited on the first insulating protection layer, the patterned thin film resistor extends from one end to the other end of the carbon brick body, the second insulating protectio