CN-122015489-A - Intelligent OPR continuous curtain type accurate control method and system for full molten pool smelting

CN122015489ACN 122015489 ACN122015489 ACN 122015489ACN-122015489-A

Abstract

The invention discloses an intelligent OPR continuous curtain type accurate control method and system for full molten pool smelting, which belong to the technical field of smelting furnace kilns, and comprise a furnace top bin, wherein a weighing sensor is arranged on the furnace top bin, a feed inlet of a controllable continuous blanking machine is connected to a feed outlet of the furnace top bin, a blanking pipe system comprises a feed pipe and a water cooling nozzle arranged at the tail end of the feed pipe, the feed end of the feed pipe is connected to the feed outlet of the controllable continuous blanking machine, the water cooling nozzle extends into a furnace cavity through a furnace cover of the submerged arc furnace and is used for distributing raw materials in an umbrella-shaped bulk material mode, the lower part of an electrode is vertically inserted into and fixed in the furnace cavity through the furnace cover of the submerged arc furnace, a closed-loop control system is respectively connected with the weighing sensor, the controllable continuous blanking machine and electrode signals, and outputs control instructions to the controllable continuous blanking machine based on weighing data, blanking rate and electrode electrical parameters, so that closed-loop linkage control of blanking and electric energy is realized. The invention can solve the problems that the fine granules cannot be directly connected into the furnace, the matching property between the blanking and the electric energy is poor, the automation degree is low and the like.

Inventors

CHEN LEI
JIANG ZHENGYUAN
LIU ZHENDONG
ZHANG YUANYUAN

Assignees

锦州天晟重工有限公司
辽宁天晟工程技术有限公司
昆明理工大学
新疆湘和新材料科技有限公司

Dates

Publication Date: 20260512
Application Date: 20260330

Claims (10)

1. The intelligent OPR continuous curtain type accurate control method for the full molten pool smelting is characterized by comprising the following steps of: S1, storing smelting raw materials in a furnace top bin, conveying the smelting raw materials in a non-full pipe state through a blanking pipe system by a controllable continuous blanking machine, and continuously scattering the smelting raw materials into a hearth in an umbrella-shaped bulk material form through a water cooling material nozzle arranged on a furnace cover of an ore smelting furnace to form a continuous dynamic material curtain which passes through a high-temperature furnace gas zone from top to bottom; s2, enabling the continuous dynamic material curtain to pass through a material curtain heating area at the upper part of the hearth and be preheated by high-temperature furnace gas, then, enabling the material curtain to fall into a material curtain reaction area surrounding an electrode, carrying out partial reduction reaction under the action of electrode arc plasma, generating molten material and dripping; S3, dropping materials after the reaction in the step S2 fall into and maintain a full molten pool reaction zone at the lower part of the hearth, and finishing the residual reduction reaction, melting and slag iron melting in the zone to form a full molten pool state with no solid material pile on the upper surface; And S4, acquiring the electrical parameters of the electrode and the real-time weighing data of the furnace top bin in real time, and dynamically adjusting the blanking rate of the controllable continuous blanking machine and/or the electric energy input parameters of the electrode through a closed-loop control system based on a preset ore-to-electricity ratio OPR theoretical model so as to realize the matching and linkage control of the blanking rate and the electric energy input in a minute level.
2. The intelligent OPR continuous curtain type accurate control method for full molten pool smelting according to claim 1, wherein in step S1, the scattering radius and the falling point height of the umbrella-shaped bulk material are controlled by adjusting the depth of the water-cooled material nozzle inserted below the furnace cover of the submerged arc furnace.
3. The intelligent OPR continuous curtain type accurate control method for full molten pool smelting according to claim 1, wherein in step S4, the closed loop control system executes adjustment, which comprises the steps of reversely adjusting the blanking rate and/or the blanking position according to the real-time change of the electrode impedance, so that the electrode working point tends to be controlled by constant impedance.
4. The intelligent OPR continuous curtain type accurate control method for full molten pool smelting according to claim 1, wherein in step S4, the real-time weighing data is obtained through a weighing sensor arranged at a support of a furnace top bin, and soft connection is arranged between the controllable continuous blanking machine and the blanking pipeline to isolate the influence of mechanical vibration of the blanking pipeline on weighing precision.
5. The intelligent OPR continuous curtain type accurate control method for full molten pool smelting, according to claim 1, is characterized in that a metal condensation protection area is arranged at the bottom of a furnace in a hearth, a furnace wall condensation protection area is arranged on the side wall of the furnace in the hearth, and smelting raw materials comprise fine ore or low-grade ore, and the granularity of the fine ore or the low-grade ore is smaller than 10mm.
6. A full-bath smelting intelligent OPR continuous curtain type accurate control system, which is characterized by being used for realizing the full-bath smelting intelligent OPR continuous curtain type accurate control method according to any one of claims 1 to 5, comprising: The furnace top bin is used for storing smelting raw materials and is provided with a weighing sensor; The feeding port of the controllable continuous blanking machine is connected with the discharging port of the furnace top bin and is used for receiving raw materials and providing continuous and speed-adjustable blanking; the blanking pipeline comprises a feeding pipe and a water-cooling material nozzle arranged at the tail end of the feeding pipe, the feeding end of the feeding pipe is connected with a discharge port of the controllable continuous blanking machine, and the water-cooling material nozzle extends into a hearth through a furnace cover of the submerged arc furnace and is used for scattering raw materials in an umbrella-shaped bulk material form; The lower part of the electrode is vertically inserted into and fixed in the hearth through the furnace cover of the submerged arc furnace and is used for inputting electric energy into the hearth and generating an electric arc; the closed-loop control system is used for being respectively connected with the weighing sensor, the controllable continuous blanking machine and the electrode in a signal mode, and is configured to operate according to a preset mining-to-electricity ratio OPR theoretical model based on weighing data, blanking rate and electrode electrical parameters, and output control instructions to the controllable continuous blanking machine and/or the electrode to realize closed-loop linkage control of blanking and electric energy.
7. The intelligent OPR continuous curtain type accurate control system for full molten pool smelting is characterized in that the furnace top bin comprises a bin body, a bin support supporting the bin body and a weighing sensor arranged on the bin support, the bin body comprises a straight bin and an inclined cone short bin, the weighing sensor is rigidly connected with the bin support, and the bin support is rigidly connected with the bin body to form an integral triangular weighing structure.
8. The intelligent OPR continuous curtain type accurate control system for full molten pool smelting, according to claim 6, is characterized in that a maintenance valve is arranged between the furnace top bin and the controllable continuous blanking machine, and a soft connection is arranged between the controllable continuous blanking machine and the blanking pipeline.
9. The intelligent OPR continuous curtain type accurate control system for full molten pool smelting according to claim 6, wherein the water cooling nozzle is of a water cooling structure, the water cooling nozzle is driven by a hydraulic cylinder to change the depth of the water cooling nozzle inserted into a hearth, the hydraulic cylinder is connected with a closed-loop control system, and the action of the hydraulic cylinder is controlled by the closed-loop control system.
10. The intelligent OPR continuous curtain type accurate control system for full molten pool smelting, according to claim 6, is characterized in that a metal condensation protection area is arranged at the bottom in the hearth, a furnace wall condensation protection area is arranged on the inner side wall of the hearth, and the raw material filling rate in the feeding pipe is controlled to be 20-40% so as to keep a non-full pipe conveying state.

Description

Intelligent OPR continuous curtain type accurate control method and system for full molten pool smelting Technical Field The invention belongs to the technical field of metallurgical submerged arc furnaces and kilns, and particularly relates to an intelligent OPR continuous curtain type precise control method and system for full molten pool smelting of a submerged arc furnace. Background The submerged arc furnace is an important smelting device for producing iron alloy, calcium carbide, yellow phosphorus and other products. The blanking process of the traditional submerged arc furnace mainly adopts lump ore or pellet ore to enter the furnace, and a stacking material layer is formed in the furnace to cover a molten pool. The blanking mode is generally two modes, namely one mode of feeding through a material pipe at one time, then emptying the material pipe and accumulating the raw materials around the electrode, and the other mode of blanking through a full material pipe, wherein a continuous raw material accumulation area is formed between the material pipe and a molten pool, and the accumulation material layer changes up and down along with the condition of the molten pool. The two modes are passive control, discharge is carried out below an electrode embedded material layer, material is melted by means of furnace charge resistance, and the process flow comprises a furnace top bin, a charging pipe, a material pile, a heating layer, a reaction layer and a molten pool layer. Along with the increasing depletion of mineral resources, the granularity of the minerals is smaller and smaller, the complex low-grade ores are more and more, the traditional blanking process exposes a plurality of problems that 1) the material layer is poor in air permeability, serious material collapse is easy to cause, potential safety hazards exist, 2) the position of an electrode is poor in controllability, temperature gradient is uncontrollable, 3) the stability of heat energy is poor, the periodical temperature change in a furnace is large, 4) the matching of the material rate and electric energy is poor, the energy consumption is high, 5) a large amount of auxiliary flux is required to be added, the waste of resources and energy sources is caused, 6) the material proportion is difficult, the response is delayed, 7) effective linkage control cannot be formed between the electrode and blanking, 8) the intelligent control level is difficult to realize, the position of the electrode cannot be directly observed, and 9) the control precision of the material matching can only reach the secondary stage of the furnace (8-12 hours), and the fine regulation cannot be realized. Therefore, the ore smelting furnace smelting process which can adapt to fine grains and low-grade ores, realize accurate matching of blanking and electric energy and has high automation level is developed, namely the intelligent OPR continuous curtain type accurate control method and system for smelting in a full molten pool are the technical problems to be solved in the field. Disclosure of Invention Aiming at the problems, the invention overcomes the defects of the prior art, and provides an intelligent OPR continuous curtain type accurate control method and system for smelting in a full molten pool, which are used for solving the problems that fine grains cannot be directly fed into a furnace, the matching between the discharging and the electric energy is poor, the degree of automation is low and the like. In order to achieve the above purpose, the present invention adopts the following technical scheme. In a first aspect, a full molten pool smelting intelligent OPR continuous material curtain type accurate control method comprises the following steps: S1, storing smelting raw materials in a furnace top bin, conveying the smelting raw materials in a non-full pipe state through a blanking pipe system by a controllable continuous blanking machine, and continuously scattering the smelting raw materials into a hearth in an umbrella-shaped bulk material form through a water cooling material nozzle arranged on a furnace cover of an ore smelting furnace to form a continuous dynamic material curtain which passes through a high-temperature furnace gas zone from top to bottom; s2, enabling the continuous dynamic material curtain to pass through a material curtain heating area at the upper part of the hearth and be preheated by high-temperature furnace gas, then, enabling the material curtain to fall into a material curtain reaction area surrounding an electrode, carrying out partial reduction reaction under the action of electrode arc plasma, generating molten material and dripping; S3, dropping materials after the reaction in the step S2 fall into and maintain a full molten pool reaction zone at the lower part of the hearth, and finishing the residual reduction reaction, melting and slag iron melting in the zone to form a full molten pool state with no solid material pile