This article will give introduce the solution of the online monitoring system for new trends in submerged arc furnace technology in today’s main application fields: ferroalloys, non-ferrous, special application, and recycling.
The submerged arc furnace is an industrial electric furnace with huge power consumption. Mainly composed of a furnace shell, furnace cover, furnace lining, short net, water cooling system, smoke exhaust system, dust removal system, electrode shell, electrode pressing and lifting system, loading and unloading system, controller, burn-through device, hydraulic system, submerged arc furnace Transformers and various electrical equipment.
The submerged arc furnace developed and manufactured by Hani Metallurgy adopts the most advanced tubular water-cooled furnace cover technology, tubular water-cooled furnace wall technology, copper-steel composite plate conductive cross-arm technology, EBT tapping technology, large-section water-cooled cable technology, PLC control technology, high impedance technology, auxiliary energy technologies such as carbon-oxygen lance and oxygen burner, oxygen-enriched operation technology and hot metal charging technology, as well as the solution of the online monitoring system for submerged arc furnaces, have all been applied in electric furnaces. For various types of furnaces, more specialized and precise design and manufacture can be achieved.
Next, we mainly introduce the online monitoring system for new trends in submerged arc furnace technology
The Online Monitoring System for New Trends in Submerged Arc Furnace Technology
Why carry out submerged arc furnace inspection?
The submerged arc furnace body is in a high-temperature state due to long-term work, and the internal furnace lining is made of refractory materials that can resist high temperatures and chemical erosion. The main function of the furnace lining is to form the working space, reduce heat dissipation losses, and protect the metal structural parts from thermal stress and chemical attack. The quality of refractory materials not only determines the efficiency of the production process but also plays a vital role in the safety of submerged arc furnaces and operators. Therefore, in furnace smelting, the temperature monitoring of the furnace body surface has always been a difficult point that needs to be focused on and continuously improved. Because once the refractory material cracks or falls off, the high-temperature molten iron in the furnace will leak directly to the water cooling system, insulation system, and furnace wall along the cracks or falling off parts, which will seriously cause the entire blast furnace ore heat to be scrapped and even personal safety.
Therefore, our company has developed a set of an online monitoring system for submerged arc furnaces, which can detect the temperature in the furnace and furnace wall to ensure the safe production of smelting.
Project Construction Analysis
The online monitoring system of submerged arc furnaces uses digital video technology, computer communication technology, and network technology to realize intelligent temperature monitoring of submerged arc furnaces through real-time dynamic monitoring, record query, network transmission, etc. At the same time, the whole process of real-time monitoring of the furnace and furnace wall is realized, and all temperature changes are comprehensively monitored and recorded.
According to the needs of safety management, the monitoring area can be manually set, and the dynamic status of the monitoring area can be understood and mastered in real-time and intuitively through the integration, sharing, real-time and intuitive operation of alarm and image resources, and timely deployment, command, and disposal can effectively improve the production efficiency of the submerged arc furnace. , to ensure the safety of staff.
According to the needs of safety management, it is urgent to achieve “early detection, early response, and early disposal” for the temperature monitoring of submerged arc furnaces through intelligent means.
Demand analysis of the online monitoring system for new trends in submerged arc furnace technology
(1) System requirements: The monitoring system is installed in the designated area of the submerged arc furnace to achieve all-weather, all-round, real-time, non-contact, and accurate temperature measurement requirements. It can quickly obtain monitoring data for points of interest, and an infrared thermal imager is required. and its full set of components, each component of the system must meet the relevant parameter requirements.
(2) Data requirements: The temperature video data can be viewed and stored in real-time, and the data format meets the parameter requirements.
(3) Monitoring scope: Through the infrared thermal imaging submerged arc furnace monitoring system, the staff can dynamically monitor the specific area of the submerged arc furnace in the monitoring center in real-time.
(4) Alarm requirements: When the temperature of the submerged arc furnace is abnormal, it can alarm in time, including the hidden danger of equipment temperature failure and abnormal temperature caused by equipment failure. The monitoring system needs to ensure the accuracy of the fire alarm and avoid the waste of manpower and material resources.
Characteristics of the online monitoring system for new trends in submerged arc furnace technology
The online monitoring system for new trends in submerged arc furnaces includes an infrared thermal imager, an air-cooled protective cover, and other parts. This system adopts a special air-cooled protective cover to cool the equipment to ensure that the infrared thermal imager can be used in a high-temperature environment and ensure its service life.
Air-cooled protective cover
The appearance of the air-cooled protective cover
Submerged Arc Furnace Online Monitoring System Solution
Made of double-layer stainless steel material, it has good corrosion resistance and is suitable for high temperature, high dust environments or environments with large temperature differences; to achieve protection. Therefore, it is widely used in metallurgy, electric power, glass, building materials, and other industries to achieve the purpose of improving production efficiency, improving the working environment, and reducing labor intensity. Dimensions of air-cooled protective cover (unit: mm)
Technical parameters of air-cooled protective cover:
Ambient temperature: ≤200℃ Relative humidity: ≤80% (40℃)
Atmospheric pressure: 86～106Kpa Dust concentration: ≤200mg/ m3
Compressed air temperature at the inlet: ≤35℃ Pressure: 0.3～0.6Mpa
Air volume: 0.3～0.6L/S
The monitoring center is mainly composed of software and is an organization on system functions and management. Since the video signal and control signal have all been connected to the Ethernet, any computer in the Ethernet can be monitored by means of permission control.
1. Real-time Monitoring
The actual bandwidth of real-time transmission of remote infrared images between the regional monitoring center and the front-end monitoring system is low. On the premise of ensuring real-time performance and image quality, the system adopts new technologies to reduce the occupation of bandwidth resources.
In the monitoring center, all image information, temperature analysis, and real-time temperature monitoring information of each monitoring point can be monitored in real-time, and the functions of real-time display, monitoring, storage, analysis, and processing reports of remote infrared images can be completed.
In the monitoring center, multi-channel infrared image information can be monitored in real time, and one machine and one screen can be monitored at the same time; the monitoring center and multiple terminals can monitor any monitoring point at the same time.
2. Remote Monitoring
Remote control infrared monitoring equipment.
Remotely set infrared alarm parameters, such as monitoring position, alarm temperature, alarm target, temperature difference alarm, etc.
When the temperature is alarming, the sound and alarm signal can be issued through the sound and light alarm device.
Receive the alarm information of the monitoring system, and designate the corresponding infrared thermal imaging instrument to record the video for accident investigation.
All alarm information is automatically saved and can be printed out when necessary.
The monitoring center can display and store the real-time image of the infrared thermal imager of each monitoring point.
The monitoring center can remotely play back the historical images of any infrared thermal imager at the station (the time can be set).
The system has strong fault tolerance, and will not cause system errors and crashes due to misoperation and other reasons.
The system has the ability of remote configuration, remote maintenance, and remote start of the station equipment.
The system can use an online office computer as a sub-control workstation (with appropriate software).
Submerged Arc Furnace Monitoring:
Equipped with special thermal imager for blast furnace, pinhole lens with a large field of view, refrigeration shield, and other professional imaging equipment to adapt to various special business scenarios;
Multi-area, multi-angle observation, wide coverage area, large detection range;
The equipment is equipped with protective devices and intelligent protection measures are set to effectively reduce the probability of damage to the lens caused by material tossing;
It can be equipped with a professional cloud platform for data storage, and the required detection data can be obtained remotely in real-time;
Submerged arc furnace thermal imaging monitoring alarm software:
The software integrates a unique DDE image detail enhancement algorithm to reduce image noise, solve the interference of smoke and dust airflow, and provide clear imaging and accurate temperature measurement;
Supports various functions such as regional temperature distribution setting, pseudo-color, time temperature change, trend analysis, color scale calling, pixel percentage content, isothermal analysis, temperature replication, etc.;
The software uses a lossless compression algorithm to ensure the security and reliability of data transmission;
Support the on-site staff and the remote mobile terminal to observe the furnace conditions at the same time, and can conduct a detailed analysis of the furnace conditions in real time;
Intelligently send the abnormal state of the current monitoring object, and send early warning information in real-time;
Real-time display of regional temperature distribution, and intelligent abnormal alerts based on distribution trends;
Customized blast furnace material level monitoring software supports personalized cross-star temperature measurement and mouse temperature measurement, as well as temperature distribution statistics;