Development of Blast Furnace Burden Distribution Process Modeling and Control

Yang, Yongliang; Yin, Yixin; Wunsch, Donald C.; Zhang, Sen; Chen, Xianzhong; Li, Xiaoli; Cheng, Shusen; Wu, Min; Liu, Kang‐Zhi

doi:10.2355/isijinternational.isijint-2017-002

Cited by 31 publications

(15 citation statements)

References 51 publications

(65 reference statements)

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“…Consequently, BF condition and detection of material layer distribution information are key factors for saving energy and reducing emissions. A good burden surface shape can improve gas flow distribution, reduce coke rations, and increase ironmaking efficiency [2][3][4]. However, a BF is a large-scale enclosed reactor, and its operating conditions are characterized by high temperatures, high pressures, and high dust levels.…”

Section: Introductionmentioning

confidence: 99%

A Real-Time 3D Measurement System for the Blast Furnace Burden Surface Using High-Temperature Industrial Endoscope

Chen

Jiang

et al. 2020

Sensors

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Capturing the three-dimensional (3D) shape of the burden surface of a blast furnace (BF) in real-time with high accuracy is crucial for improving gas flow distribution, optimizing coke operation, and stabilizing BF operation. However, it is difficult to perform 3D shape measurement of the burden surface in real-time during the ironmaking process because of the high-temperature, high-dust, and lightless enclosed environment inside the BF. To solve this problem, a real-time 3D measurement system is developed in this study by combining an industrial endoscope with a virtual multi-head camera array 3D reconstruction method. First, images of the original burden surface are captured using a purpose-built industrial endoscope. Second, a novel micro-pixel luminance polarization method is proposed and applied to compensate for the heavy noise in the backlit images due to high dust levels and poor light in the enclosed environment. Third, to extract depth information, a multifeature-based depth key frame classifier is designed to filter out images with high levels of clarity and displacement. Finally, a 3D shape burden surface reconstruction method based on a virtual multi-head camera array is proposed for capturing the real-time 3D shape of the burden surface in an operational BF. The results of an industrial experiment illustrate that the proposed method can measure the 3D shape of the entire burden surface and provide reliable burden surface shape information for BF control.

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Section: Introductionmentioning

confidence: 99%

A Real-Time 3D Measurement System for the Blast Furnace Burden Surface Using High-Temperature Industrial Endoscope

Chen

Jiang

et al. 2020

Sensors

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“…As a consequence, most of the studies on the conditions of the burden in the lumpy zone have been based on laboratory-scale experiments or mathematical modeling. Such studies have, e.g., [3][4][5], presented correlations between the charging pattern and the burden structure in the lumpy zone. However, since direct measurements of the layers in the shaft are lacking, the modeling results have usually only been verified for the top layers in the throat or indirectly through gas temperature and composition measurements in the throat.…”

Section: Introductionmentioning

confidence: 99%

“…Compared with physical experiments, mathematical modeling [3] has gained popularity due to its lower cost and higher flexibility. The mathematical modeling approaches [4,5] regarding the BF burden distribution (corresponding to the bell-less charging system) can basically be categorized as volume-based simplified models or classical (continuum) force models [6][7][8][9][10][11][12][13][14], data-driven models [15,16], or hybrid models [17,18], as well as the more computationally expensive models based of the discrete element method (DEM) [19][20][21][22][23]. Among these models, the classical force model has advantages in terms of its simple model formulation and fast computation, which are readily suitable for online implementation.…”

Section: Introductionmentioning

confidence: 99%

Model-Based Analysis of Factors Affecting the Burden Layer Structure in the Blast Furnace Shaft

Saxén

Liu

et al. 2019

Metals

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The distribution of burden layers in an ironmaking blast furnace strongly influences the conditions in the upper part of the process. The bed permeability largely depends on the distribution of ore and coke in the lumpy zone, which affects the radial gas flow distribution in the shaft. Along with the continuous advancement of technology, more information about the internal conditions of the blast furnace can be obtained through advanced measurement equipment, including 2D profiles and 3D surface maps of the top burden surface. However, the change of layer structure along with the burden descent cannot be directly measured. A mathematical model predicting the burden distribution and the internal layer structure during the descending process is established in this paper. The accuracy of the burden distribution model is verified by a comparison with experimental results. A sensitivity study was undertaken to clarify the role of some factors on the arising layer distribution, including the descent-rate distribution, the initial burden surface profile, and the charging direction through the charging matrix. The findings can be used as a theoretical basis to guide plant operations for optimizing the charging.

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“…Burden layer distribution plays an important role in the internal state of a blast furnace (BF) because different layer distributions lead to different permeabilities, which in turn affect the temperature distribution and the height and shape of the cohesive zone [1,2]. For the charging mechanism of a rotating chute in bell-less charging, the shape of the burden surface can be regarded as symmetric; therefore, the radial profile of the burden surface (BSRP) can be studied.…”

Section: Introductionmentioning

confidence: 99%

Radar Detection-Based Modeling in a Blast Furnace: A Prediction Model of Burden Surface Descent Speed

Tian

Hou

Chen

2019

Metals

Self Cite

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The distribution of burden layers is a vital factor that affects the production of a blast furnace. Radars are advanced instruments that can provide the detection results of the burden surface shape inside a blast furnace in real time. To better estimate the burden layer thicknesses through improving the prediction accuracy of the burden descent during charging periods, an innovative data-driven model for predicting the distribution of the burden surface descent speed is proposed. The data adopted were from the detection results of an operating blast furnace, collected using a mechanical swing radar system. Under a kinematic continuum modeling mechanism, the proposed model adopts a linear combination of Gaussian radial basis functions to approximate the equivalent field of burden descent speed along the burden surface radius. A proof of the existence and uniqueness of the prediction solution is given to guarantee that the predicted radial profile of the burden surface can always be calculated numerically. Compared with the plain data-driven descriptive model, the proposed model has the ability to better characterize the variability in the radial distribution of burden descent speed. In addition, the proposed model provides prediction results of higher accuracy for both the future surface shape and descent speed distribution.

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Development of Blast Furnace Burden Distribution Process Modeling and Control

Cited by 31 publications

References 51 publications

A Real-Time 3D Measurement System for the Blast Furnace Burden Surface Using High-Temperature Industrial Endoscope

A Real-Time 3D Measurement System for the Blast Furnace Burden Surface Using High-Temperature Industrial Endoscope

Model-Based Analysis of Factors Affecting the Burden Layer Structure in the Blast Furnace Shaft

Radar Detection-Based Modeling in a Blast Furnace: A Prediction Model of Burden Surface Descent Speed

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