WO2016103196A1 - Système et procédé de collecte et d'analyse de données relatives à un état de fonctionnement dans un système de réacteur à lance d'injection immergée par le haut - Google Patents

Système et procédé de collecte et d'analyse de données relatives à un état de fonctionnement dans un système de réacteur à lance d'injection immergée par le haut Download PDF

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Publication number
WO2016103196A1
WO2016103196A1 PCT/IB2015/059906 IB2015059906W WO2016103196A1 WO 2016103196 A1 WO2016103196 A1 WO 2016103196A1 IB 2015059906 W IB2015059906 W IB 2015059906W WO 2016103196 A1 WO2016103196 A1 WO 2016103196A1
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WO
WIPO (PCT)
Prior art keywords
lance
operating condition
reactor system
injector reactor
submerged lancing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2015/059906
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English (en)
Inventor
Robert Walter Matusewicz
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Outotec Finland Oy
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Outotec Finland Oy
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2014905265A external-priority patent/AU2014905265A0/en
Priority to PL15831160T priority Critical patent/PL3237823T3/pl
Priority to ES15831160T priority patent/ES2769200T3/es
Priority to EP15831160.5A priority patent/EP3237823B1/fr
Priority to JP2017533565A priority patent/JP6503069B2/ja
Priority to AU2015370483A priority patent/AU2015370483B2/en
Application filed by Outotec Finland Oy filed Critical Outotec Finland Oy
Priority to CN201580070556.0A priority patent/CN107110605B/zh
Priority to EA201791302A priority patent/EA033240B1/ru
Priority to KR1020177019394A priority patent/KR102034940B1/ko
Publication of WO2016103196A1 publication Critical patent/WO2016103196A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D19/00—Arrangements of controlling devices
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
    • C21C5/28—Manufacture of steel in the converter
    • C21C5/30—Regulating or controlling the blowing
    • C21C5/35—Blowing from above and through the bath
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D3/00—Charging; Discharging; Manipulation of charge
    • F27D3/16—Introducing a fluid jet or current into the charge
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
    • C21C5/28—Manufacture of steel in the converter
    • C21C5/30—Regulating or controlling the blowing
    • C21C5/34—Blowing through the bath
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
    • C21C5/28—Manufacture of steel in the converter
    • C21C5/42—Constructional features of converters
    • C21C5/46—Details or accessories
    • C21C5/4673—Measuring and sampling devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D99/00—Subject matter not provided for in other groups of this subclass
    • F27D99/0001—Heating elements or systems
    • F27D99/0033—Heating elements or systems using burners
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
    • C21C5/28—Manufacture of steel in the converter
    • C21C5/42—Constructional features of converters
    • C21C5/46—Details or accessories
    • C21C5/4606—Lances or injectors
    • C21C5/4613—Refractory coated lances; Immersion lances
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D3/00—Charging; Discharging; Manipulation of charge
    • F27D3/16—Introducing a fluid jet or current into the charge
    • F27D2003/168—Introducing a fluid jet or current into the charge through a lance
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D99/00—Subject matter not provided for in other groups of this subclass
    • F27D99/0001—Heating elements or systems
    • F27D99/0033—Heating elements or systems using burners
    • F27D2099/0036—Heating elements or systems using burners immersed in the charge

Definitions

  • Molten bath smelting or other pyrometallurgical operations which require interaction between the bath and a source of oxygen-containing gas utlilize several different arrangements for the supply of the gas.
  • these operations involve direct injection into the molten matte/metal. This maybe by bottom blowing tuyeres as in a Bessemer type furnace or side blowing tuyeres as in a Peirce-Smith type converter.
  • the injection of gas may be by means of a lance to provide either top blowing or submerged injection. Examples of top blowing lance injection are the KALDO and BOP steel making plants in which pure oxygen is blown from above the bath to produce steel from molten iron.
  • top blowing lance injection is the Mitsubishi copper process, in which lances cause jets of oxygen- containing gas such as an oxygen-enriched air, to impinge on and penetrate the top surface of the bath, respectively to produce and to convert copper matte.
  • oxygen-containing gas such as an oxygen-enriched air
  • submerged lance injection the lower end of the lance is submerged so that injection occurs within rather than from above the slag layer of the bath, to provide top submerged lancing (TSL) injection.
  • TSL top submerged lancing
  • the top blowing in the Mitsubishi copper process uses a number of relatively small steel lances which have an inner pipe of about 50 mm diameter and an outer pipe of about 100 mm diameter.
  • the inner pipe terminates at about the level of the furnace roof, well above the reaction zone.
  • the outer pipe which is rotatable to prevent it sticking to a water-cooled collar at the furnace roof, extends down into the gas space of the furnace to position its lower end about 500- 800 mm above the upper surface of the molten bath. Particulate feed entrained in air is blown through the inner pipe, while oxygen enriched air is blown through the annulus between the pipes.
  • the outer pipe burns back by about 400 mm per day.
  • the outer pipe therefore is slowly lowered and, when required, new sections are attached to the top of the outer, consumable pipe.
  • TSL lances employed for TSL injection are much larger than those for top blowing, such as in the Mitsubishi process described above.
  • a TSL lance usually has at least an inner and an outer pipe, as assumed in the following, but may have at least one other pipe concentric with the inner and outer pipes.
  • Typical large scale TSL lances have an outer pipe diameter of 200 to 500 mm, or larger.
  • the lance is much longer and extends down through the roof of a TSL reactor, which may be about 10 to 15 m tall, so that the lower end of the outer pipe is immersed to a depth of about 300 mm or more in a molten slag phase of the bath, but is protected by a coating of solidified slag formed and maintained on the outer surface of the outer pipe by the cooling action of the injected gas flow within.
  • the inner pipe may terminate at about the same level as the outer pipe, or at a higher level of up to about 1000 mm above the lower end of the outer pipe. Thus, it can be the case that the lower end of only the outer pipe is submerged.
  • the inner pipe of a TSL lance may be used to supply feed materials, such as concentrate, fluxes and reductant to be injected into a slag layer of the bath, or it may be used for fuel.
  • An oxygen containing gas such as air or oxygen enriched air, is supplied through the annulus between the pipes.
  • oxygen-containing gas and fuel such as fuel oil, fine coal or hydrocarbon gas
  • a resultant oxygen/fuel mixture is fired to generate a flame jet which impinges into the slag. This causes the slag to slop within the bath resulting in significant bath movement.
  • This bath movement, together with injection of gases or other materials via the lance results in movement of the lance due to induced forces.
  • the range of motion to which a top submerged lance is subjected has the potential to provide important information regarding process operations occurring in the molten bath.
  • a system for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system having a lance, the lower end of which is to be submerged in a molten bath during operation of the top-submerged lancing injector reactor system including:
  • At least two sensors configured to sense an indicator of the operating condition and to generate a sensed data signal, each sensor being of a different sensor type and at least one of the two sensors being a lance-based sensor;
  • a central processing unit for receiving a plurality of sensed data signals and analysing the sensed data signals relating to at least two indicators of the operating condition to determine a current status of the operating condition.
  • sensors including a variety of low cost sensors may be employed to implement the present invention.
  • temperature sensors, pressure sensors, motion sensors, position sensors, sound and/or image sensors may be employed.
  • the at least two sensors are of a different type such that they can be used to sense different but perhaps complimentary indicators of an operating condition.
  • at least one of the sensors is a lance-based sensor.
  • a first sensor is used to sense the motion of the lance and sensor signals indicate that the lance is not moving
  • a second sensor type for example that senses the position of the lance within the reactor
  • the two independently sensed signals can be combined and analysed to provide an accurate diagnosis of the current operating condition, which is not possible relying on data collected using a single sensor type.
  • both the lance motion sensor and the lance position sensor constitute lance-based sensors, in that the lance motion sensor is mounted on the lance to sense movement thereof and the lance position sensor is configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system.
  • a status of the operating condition can be determined provided that one of the at least two sensors is a lance-based sensor.
  • a lance-based sensor may be configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system in the form of an indicator relating to a lance position, lance submergence or lance wear. Moreover, the lance-based sensor may be configured to sense the mechanical interaction by sensing a direct measure of the mechanical interaction.
  • the central processing unit compares the current status of the operating condition to an optimal operating condition to determine whether one or more process controls require adjustment to shift the current operating condition towards an optimal operating condition.
  • Feedback regarding the current status of the operating condition may be provided to an operator of the top-submerged lancing injector reactor system. That is, the operator may be provided with one or more instructions for manually adjusting the process controls to shift the current operating condition towards the optimal operating condition.
  • feedback regarding the current status of the operating condition may be provided directly to a process control unit associated with the submerged lancing injector reactor system.
  • the process control unit is provided instructions for autonomously adjusting process controls to shift the current operating condition towards the optimal operating condition. For instance, if a combination of sensors determine that the slag condition in the bath is undesirable, i.e. too thick and viscous due to a bath temperature that is too low, then the instruction to the operator or process control unit might be to increase the bath temperature in an attempt to shift the current operating condition towards a more fluid slag.
  • At least three different types of sensors are provided to enable a variety of operational conditions to be detected.
  • the sensors may be selected from a variety of sensor types including pressure, motion, sound, temperature and image sensors.
  • motion sensors may include orientation sensors generally, and more specifically accelerometers, gyroscopes, magnetometers, inertial measurement units, and the like.
  • lance-based sensors sense the orientation of a lance for example, by detecting the magnitude and direction of lance movements, acceleration of the lance in various directions and/or the G-forces to which the lance is subjected.
  • a position sensor may take the form of a position encoder which measures the position of the lance relative to the furnace hearth and may or may not be mounted on the lance. Sound and image sensors, e.g.
  • slag viscosity for example, due to the sound of the molten splash patterns being generated.
  • sensor types such as image and sound sensors, for example, are merely indicative of a particular operating condition
  • other sensor types are capable of providing direct measurement of an operating condition.
  • sensor types include sensors for measuring bath temperature, lance motion, lance position, or lance submergence. At least one of these sensor types is preferably included in the system for collecting data relating to an operating condition.
  • the operating condition indicated by the sensed signals may relate to one or more of the following: bath temperature, slag condition, lance position, lance submergence or lance wear.
  • a method for collecting and analysing data relating to an operating condition in a top- submerged lancing injector reactor system having a lance, the lower end of which is to be submerged in a molten bath during operation of the top-submerged lancing injector reactor system including the following steps:
  • the lance-based sensor may be mounted on the lance and/or configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system.
  • the lance-based sensor may further be configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system in the form of an indicator relating to lance position, lance submergence or lance wear.
  • the mechanical interaction of the lance with the top-submerged lancing injector reactor system may sense an indicator relating to lance position, lance submergence or lance wear.
  • the method may further include the step of comparing the current status of the operating condition to an optimal operating condition; and determining whether one or more process controls require adjustment to shift the current operating condition towards the optimal operating condition.
  • the method further includes the step of providing feedback regarding the current status of the operating condition to an operator of the top-submerged lancing injector reactor system.
  • the method further includes the step of providing feedback regarding the current status of the operating condition to a process control unit associated with the submerged lancing injector reactor system.
  • the at least two sensors are selected from the following sensor types: pressure, motion, sound, temperature and image.
  • the step of providing at least two sensors in the top-submerged lancing injector reactor system involves providing at least three sensors.
  • At least one of the at least two sensors is configured to provide direct measurement of at least one of the following indicators of the operating condition: bath temperature, lance motion, lance position, or lance submergence.
  • the operating condition indicated by the method may relate to one or more of the following: bath temperature, slag condition, lance position, lance submergence or lance wear.
  • Figure 1 is a partially cut away schematic of a molten bath smelting furnace including a top submerged lance in accordance with the prior art.
  • Figure 2 is a schematic showing a system for collecting and processing data relating to an operating condition in a top-submerged lancing injector reactor in accordance with an embodiment of the present invention.
  • Figure 3 is a table illustrating the inter relationship between various sensor types as indicators of various operating conditions in accordance with an embodiment of the present invention.
  • Figure 4 is a flowchart showing a method for collecting and processing data relating to an operating condition in a top-submerged lancing injector reactor system in accordance with an embodiment of the present invention.
  • FIG. 1 there is shown an exemplary top-submerged lancing injector reactor system 100.
  • the reactor 102 has a cylindrical shell 104 closed at its top end by a roof 106 from which an off-take flue 108 projects upwardly to an off-gas boiler/heat exchanger 1 10.
  • a section of the shell 104 has been removed to enable the interior of the reactor 102 to be viewed, although the shell 104 is circumferentially continuous at all levels in its height, apart from tap holes.
  • the roof 106 has an inlet 1 12 down through which a top submerged injecting lance 1 14 extends so that a lower end portion of the lance 1 15 is submerged in the molten bath 1 16.
  • the reactor 102 also has a feed port 1 18 opening through roof 106 to enable raw materials for a required pyro-metallurgical operation to be charged into bath 1 16, and a burner port 120 for enabling insertion of a burner 122 if required for heating the reactor.
  • Lance 1 14 has connectors 124 that enable connection of lance 1 14 to separate sources of fuel/reductant and oxygen-containing gas, to enable the separate passage of these materials down through lance 1 14 and to mix at the lower, outlet end of lance to feed a combusting mixture.
  • the combustion of the fuel and oxygen mixture generates a combustion zone in the molten bath 1 16 at the lower, outlet end of lance 1 15, as well as strong turbulence in the molten bath 1 16 that causes the raw materials charged through port 1 18 to be dispersed in the molten bath to give rise to the required pyro-metallurgical reactions therein.
  • a top-submerged lancing injector reactor system 100 as illustrated in Figure 1 is typically operated by an operator who controls the position of the lance 1 14 within the reactor 102 by raising or lowering the lance relative to the bath by means of a lifting apparatus 126 attached to the lance Operators make various manual observations regarding the position of the lance and the movement of the lance, which over time leads the operator to developing an intuitive understanding of the range of motion of the lance that is indicative of optimal operating conditions in the reactor and a range of movement of the lance that is indicative of sub-optimal operating conditions within the reactor.
  • FIG. 2 the system of the present invention provides means for improved guidance of an operator with regard to how particular observations relate to operating conditions within the reactor and how an operator should appropriately respond to those operating conditions where they are sub- optimal.
  • a system 200 for collecting, processing and analysing data relating to an operating condition in a top-submerged lancing injector reactor system 100 is provided.
  • the top-submerged lancing (hereinafter also referred to as "TSL") injector reactor system 100 has a lance 1 14, the lower end 1 15 of which is to be submerged in a molten bath 1 16 during operation of the TSL injector reactor system.
  • TSL top-submerged lancing
  • the system 200 includes at least two sensors 210, each of the at least two sensors being of a different sensor type and at least one of the at least two sensors is a lance-based sensor.
  • Each sensor 210 is configured to sense an indicator of an operating condition and to generate a sensed data signal.
  • a central processing unit 220 receives the sensed data signals. The central processing unit 220 then processes and analyses the sensed data signals to determine a current status of the operating condition.
  • the central processing unit 220 is directly coupled directly to a process control unit 230.
  • feedback regarding the current status of the operating condition is transmitted directly from the central processing unit 220 to the process control unit 230.
  • the direct feedback can be translated into instructions for the process control unit 230 to adjust the reactor's process controls in an effort to adjust the current operating condition towards an optimal operating condition.
  • feedback regarding the current operating conditions may be provided to the operator together with recommendations for adjustments to be made to the reactor's process controls in an effort to improve the operating conditions. In this case, the requisite adjustments are implemented manually by the operator in the usual manner.
  • the system employs at least two sensors, each being of a different sensor type.
  • At least one of the sensors is a lance-based sensor which is either mounted on the lance, for example in the form of a lance motion sensor, or configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system, for example in the form of a lance position sensor which need not necessarily be mounted on the lance per se, but senses the position of the lance with respect to the reactor.
  • These sensors are selected from a wide variety of low cost sensors.
  • An example of a suitable temperature sensor, which is also a lance-based sensor, is described in International PCT Application
  • Such a sensor is capable of direct measurement of bath temperature which can be indicative of a number of operating conditions occurring within the reactor, including the condition of the slag, i.e. fluid or viscous.
  • Pressure sensors are used, for example, to measure any restriction or blockage of fluids being injected via the lance.
  • a pressure sensor or transmitter may be mounted in a suitable location on any of the fluid delivery lines, or could be a lance-based sensor mounted in proximity to the lance discharge point, i.e. the lance tip. That is, the pressure within any line feeding oxygen, air or fuel to the lance can be measured at any particular point. A change in the pressure reading at that particular point will typically indicate that a restriction or blockage has occurred.
  • One obvious restriction or blockage occurs when the lance moves from above the bath to a submerged position due to the static pressure head which develops when the discharge point is below the molten slag surface.
  • a difference in the pressure head or back pressure reading, taken at the same point in the fluid flow line can be an indicator of lance submergence as well as other potential blockages or restrictions that may occur during operation of the lance. Whether an increase in back pressure is due to lance submergence or some other restriction in the fluid flow line, is more readily determined with accuracy, when combined with reading from at least one other sensor, such as, for example, a lance position sensor, or a lance motion sensor which is also an indicator of whether the lance tip is submerged in the molten slag bath.
  • motion sensors which may take the form of an orientation sensor, a magnetometer, a gyroscope, and accelerometer or an inertial measurement unit as disclosed in the copending application entitled "A Sensing Device for Determining an Operational Condition in a Molten Bath of a Top-Submerged Lance Injector Reactor System".
  • lance position and lance submergence Other operational conditions that can be measured in relation to the lance are lance position and lance submergence.
  • Lance position is an assumed measure of the lane tip position relative to the top surface of the furnace hearth and lance submergence is an actual measurement of the lance tip position relative to the molten bath surface.
  • Lance position can be measured by way of a position sensor which is attached to the lance hoist mechanism (for raising and lowering the lance within the reactor), or to the lance guide or trolley.
  • a position sensor can be provided in the form of a position encoder. It should be noted that the actual position of the lance within the reactor can only be inferred from this measurement since it must be calibrated to each new lance and infers a lance tip position relative to the top of the furnace hearth. Accordingly, if the length of the lance changes, for example, by wearing of the lance tip through use, then the actual position of the lance tip with respect to the furnace hearth will also change.
  • a measure of lance submergence can be determined by computation, using for example the lance position measurement together with a manual bath height measurement.
  • An inferred measure of submergence can be discerned using a sound sensor, wherein a shift in the measured sound frequency is observed between an above bath and a submerged operation positon of the lance, to allow determination of the point where the lance becomes submerged. From this point on, the lance can be lowered a defined distance and hence the extent of submergence is known.
  • a measure of back pressure as earlier described, can be used to determine the point where the lance becomes submerged.
  • Measurement of sound arising from TSL operation can also be an effective measure. Due to the low injection velocity of a typical TSL lance, a "bubble" frequency of approximately 3 Hz is considered characteristic. In simple terms, this means that injected fluids form bubbles and break away at the lance discharge end about three times per second. These result in characteristic bubbling sounds which can be measured. In its simplest form, if no bubbling sound is detected at all, then it can be inferred that the lance is not submerged in the bath. The characteristic and frequency of the sound will vary with slag condition. Moreover, splash patterns generated within the reactor can be captured on still or video image.
  • volume and size of a normal splash indicative of optimal operating conditions is known, variations in the volume and size of the splashes can be used as an indicator of a change in conditions. For example, in the case of no splash to be seen, the lance is neither in the bath nor proximal to a surface of the bath. When the lance tip is barely submerged, the splash will be very fine. If the slag is very viscous, then the splashed slag tends to form plate-like, string-like or stream-like splashes. These variations in splash form are readily recognised through image analysis.
  • a lance motion sensor is used to indicate whether a lance is moving in a normal or abnormal manner
  • the lance is most likely not submerged and being operated out of the molten slag bath.
  • This diagnosis can be verified using a lance position or lance submergence measurement.
  • a lance operator will typically recognise and correct the problem from the lack of lance movement alone.
  • both the lance motion sensor and the lance position sensor constitute lance-based sensors.
  • data signals generated by three different types of sensor can be used to determine an adverse operating condition: A lance motion sensor, a lance position sensor and a temperature sensor.
  • the lance motion sensor measures excessive movement indicating an abnormal operating condition.
  • this data could indicate one of a number of issues relating to process factors or problems with mechanical interaction within the reactor. So the following analysis is employed using data collected using all three sensor types to arrive at a comprehensive diagnosis:
  • the lance motion sensor detects an abnormal movement condition indicating a higher degree of movement than is normal
  • the lance position indicator shows the lance is in the correct position
  • the bath temperature indicates a low temperature condition.
  • both the lance motion sensor and the lance position sensor constitute lance-based sensors.
  • the temperature sensor may be, but need not be, a lance-based sensor.
  • the suggested course of action would be to increase the energy input to the system, for example by increasing the fuel addition rate via the lance.
  • the bath temperature indication alone could provide a solution.
  • the third example uses the same three sensors in a circumstance where the bath temperature is also low. In this example the following indicators occur:
  • the bath temperature is indicated as being low
  • the lance is indicated as being at the correct position relative to the furnace.
  • the lance motion sensor indicates that the lance is not moving.
  • the combined sensor information indicates that the lance tip has worn back to the point where the lance is not submerged in the molten bath, but rather in a position above it.
  • the course of action would be to remove the lance from service for repair of the lance tip and a path of adding more fuel would not rectify the problem and restore optimal operating conditions.
  • sensors for sound measurement, lance position, lance backpressure and bath temperature are utilised.
  • the indicators for these sensors show:
  • Bath temperature is in the correct range
  • the lance position sensor and the lance backpressure sensor constitute lance-based sensors.
  • the diagnosis is that the slag chemistry is not in the correct range and that an adjustment through slag chemistry modification is required.
  • FIG. 3 there are shown some examples of possible interactions between various sensor types.
  • the sensors can be grouped together depending on the application.
  • analysis of a minimum number of low cost sensors is combined to enable low cost operation and more stable plant operation.
  • the method 400 includes the step of providing at least two sensors, in the top-submerged lancing injector reactor system, each sensor being of a different sensor type and at least one of the two sensors being a lance-based sensor, each sensor configured to sense at least one operating condition indicator during operation of the top-submerged lancing injector reactor system.
  • the method includes the step of transmitting the sensed data signals generated by the at least two sensors to a central processing unit.
  • the sensed data signals relating to at least two operating condition indicators are analysed to determine a current status of the operating condition.
  • the method may further include the step of comparing the current status of the operating condition to an optimal operating condition; and determining whether one or more process controls require adjustment to shift the current operating condition towards the optimal operating condition.
  • the system of the present invention provides lower cost and more consistent operation of a top-submerged lance injection reactor using relatively low- cost sensors.
  • the transmission of sensed signals determining a variety of operating factors to a central processing unit for processing and analysis enables the sensed signals to be analysed by an expert system module using proprietary algorithms to provide an improved diagnosis which can be used to guide operator action or directly instruct the plant control unit to make appropriate adjustments. This enables more consistent and stable plant operation between shifts and more efficient operation of the reactor.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Manufacturing & Machinery (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
  • Furnace Charging Or Discharging (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Treatment Of Steel In Its Molten State (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)
  • Monitoring And Testing Of Nuclear Reactors (AREA)
  • Investigating And Analyzing Materials By Characteristic Methods (AREA)

Abstract

La présente invention concerne un système de collecte et d'analyse des données relatives à un état de fonctionnement dans un système de réacteur à lance d'injection immergée par le haut qui comporte une lance dont l'extrémité inférieure est destinée à être immergée dans un bain fondu pendant le fonctionnement du système de réacteur à lance d'injection immergée par le haut. Ledit système comprend (a) au moins deux capteurs conçus pour détecter un indicateur de l'état de fonctionnement et pour générer un signal de données détecté, chaque capteur étant d'un type différent et au moins l'un des au moins deux capteurs étant un capteur fixé sur la lance, et (b) une unité centrale de traitement destinée à recevoir une pluralité de signaux de données détectés et à analyser lesdits signaux relatifs à au moins deux indicateurs de l'état de fonctionnement pour déterminer un état en cours de l'état de fonctionnement.
PCT/IB2015/059906 2014-12-24 2015-12-23 Système et procédé de collecte et d'analyse de données relatives à un état de fonctionnement dans un système de réacteur à lance d'injection immergée par le haut Ceased WO2016103196A1 (fr)

Priority Applications (8)

Application Number Priority Date Filing Date Title
KR1020177019394A KR102034940B1 (ko) 2014-12-24 2015-12-23 상부-침지식 랜싱 주입기 반응로 시스템에서의 동작 상태에 관련된 데이터를 수집하고 분석하기 위한 시스템 및 방법
ES15831160T ES2769200T3 (es) 2014-12-24 2015-12-23 Un sistema y método para recopilar y analizar datos relacionados con una condición de funcionamiento en un sistema reactor de inyector de punción sumergido superior
EP15831160.5A EP3237823B1 (fr) 2014-12-24 2015-12-23 Système et procédé de collecte et d'analyse de données relatives à un état de fonctionnement dans un système de réacteur à lance d'injection immergée par le haut
JP2017533565A JP6503069B2 (ja) 2014-12-24 2015-12-23 トップサブマージランシング注入反応炉システムにおける運転状態に関するデータの収集および解析システムならびに方法
AU2015370483A AU2015370483B2 (en) 2014-12-24 2015-12-23 A system and method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system
PL15831160T PL3237823T3 (pl) 2014-12-24 2015-12-23 System i sposób zbierania i analizowania danych odnoszących się do stanu roboczego w systemie reaktorowym z wdmuchującą lancą zanurzaną od góry
CN201580070556.0A CN107110605B (zh) 2014-12-24 2015-12-23 收集和分析与顶部浸没式喷射注射器反应器系统操作状况有关的数据的系统和方法
EA201791302A EA033240B1 (ru) 2014-12-24 2015-12-23 Система и способ сбора и анализа данных, касающихся режима работы в реакторе с продувкой методом погружения сверху

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
AU2014905265A AU2014905265A0 (en) 2014-12-24 A sensing device for determining an operational condition in a molten bath of a top-submerged lancing injector reactor system
AU2014905265 2014-12-24
AU2015901166A AU2015901166A0 (en) 2015-03-31 A system and method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system
AU2015901166 2015-03-31

Publications (1)

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WO2016103196A1 true WO2016103196A1 (fr) 2016-06-30

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EP (1) EP3237823B1 (fr)
JP (1) JP6503069B2 (fr)
KR (1) KR102034940B1 (fr)
CN (1) CN107110605B (fr)
AU (1) AU2015370483B2 (fr)
EA (1) EA033240B1 (fr)
ES (1) ES2769200T3 (fr)
PE (1) PE20171301A1 (fr)
PL (1) PL3237823T3 (fr)
WO (1) WO2016103196A1 (fr)

Cited By (3)

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EP3687666A4 (fr) * 2018-08-17 2020-08-26 Berry Metal Company Commande du fonctionnement et de la position d'un ensemble lance et buse dans un bain de métal fondu dans un réservoir
EP3766598A1 (fr) * 2019-07-17 2021-01-20 Air Products And Chemicals, Inc. Tuyère pour un four à oxygène
WO2023205911A1 (fr) * 2022-04-27 2023-11-02 Trefimet S.A. Système intelligent d'ouverture de passages avec une lance thermique

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CN113048794A (zh) * 2021-03-22 2021-06-29 中国恩菲工程技术有限公司 智能诊断喷枪

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US5557631A (en) * 1994-05-06 1996-09-17 Dynex Engineering Inc. Sonic furnace monitoring apparatus
US6923843B1 (en) * 2001-11-13 2005-08-02 Nupro Corporation Method for oxygen injection in metallurgical process requiring variable oxygen feed rate
WO2011106023A1 (fr) * 2010-02-26 2011-09-01 Nupro Corporation Système de prédiction de débordement d'un four et d'optimisation d'une lance
WO2011136729A1 (fr) * 2010-04-30 2011-11-03 Agellis Group Ab Mesures dans des cuves métallurgiques
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EP3687666A4 (fr) * 2018-08-17 2020-08-26 Berry Metal Company Commande du fonctionnement et de la position d'un ensemble lance et buse dans un bain de métal fondu dans un réservoir
EP3766598A1 (fr) * 2019-07-17 2021-01-20 Air Products And Chemicals, Inc. Tuyère pour un four à oxygène
WO2023205911A1 (fr) * 2022-04-27 2023-11-02 Trefimet S.A. Système intelligent d'ouverture de passages avec une lance thermique

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JP2018508731A (ja) 2018-03-29
CN107110605B (zh) 2020-03-27
AU2015370483A1 (en) 2017-08-03
EP3237823A1 (fr) 2017-11-01
PL3237823T3 (pl) 2020-04-30
EA033240B1 (ru) 2019-09-30
EP3237823B1 (fr) 2019-10-30
KR102034940B1 (ko) 2019-10-21
KR20170096138A (ko) 2017-08-23
EA201791302A1 (ru) 2017-12-29
ES2769200T3 (es) 2020-06-25
AU2015370483B2 (en) 2019-05-02
PE20171301A1 (es) 2017-08-31
CN107110605A (zh) 2017-08-29
JP6503069B2 (ja) 2019-04-17

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