Digital and intelligent solutions for electric arc furnace melting workshop production
Electric arc furnace (EAF) digital steelmaking first uses automation technology to process and prepare scrap steel, and then an industrial TV system and automatic measurement equipment guide the fully automated metal production process. The new intelligent equipment used in the production of electric arc furnace steelmaking can minimize the situation of human operations, safely and reliably perform dangerous or difficult work processes, and with the help of process analysis and powerful tools of intelligent production systems, in-depth understanding Steel craft production process.-electric arc furnace melting workshop
The digital control of EAF steelmaking is mainly based on the following four aspects:
- The data collection and analysis of the electric arc furnace production process and production equipment are mainly the basis of the primary and secondary data;
- Data collection of other resources, so-called smart sensors;
- Automatic functions such as manipulators and robots;
- Equipment condition monitoring.
The above aspects have made considerable innovations in the past few years, where they are integrated, integrated and seamlessly interacted to achieve a fully optimized electric arc furnace process flow with the highest possible degree of automation.
A metallurgical plant uses an encrypted cloud service system to collect and store all data of the primary and secondary automation systems, and it is located in the same location as the software licensing system, thereby providing customers with dynamic trends and various related reports, including in the simple dashboard The operational intelligence technology shown on Operators and managers can use any browser anywhere in the world to view the required information and select important information in the large database for analysis and research.
The interactive report shows the most important key values, and the outliers are clearly highlighted, and the values of the last few furnaces can be easily compared. Reports can be customized according to the needs of each user, and users can also create their own screens, meter displays, and reports.
Statistical analysis of the correlation between different parameters to determine the optimized operating parameters of the electric arc furnace and its auxiliary equipment. Analyze and study the data report, clarify the next step, monitor the status through the large database of the first-level automation system, and then select the predictive maintenance method according to the monitoring situation.-electric arc furnace melting workshop
One of the least automated links in the electric arc furnace steelmaking workshop is adding scrap steel to the electric arc furnace. This work is very challenging. It is necessary to maintain safe and reliable production operations, and there must be no failures, damage, or downtime. A fully automated system is used to add scrap steel raw materials to the electric arc furnace, which can accurately reproduce the feeding state and action. The operation of the crane is synchronized with the operation of the dust removal sealing system and the top of the electric arc furnace. Its advantages are shorter power-off time and higher safety factor of the equipment, which means that there is very little damage in the entire scrap feeding process. Moreover, it is very convenient and simple to add the automatic filling system to the existing electric arc furnace steel plant.
First, it is necessary to install measuring devices and sensors in order to locate the scrap steel basket. In addition, the crane body is moved in a fully automated manner. Figure 1 is a schematic diagram of an electric arc furnace adding scrap steel raw materials and a dust removal sealing system.
The next step is to use a similar position sensor system in the scrapyard to automatically load the scrap basket and measure the scrap pile. The crane uses the secondary system budget ratio to grab scrap from different piles for batching and loading.- electric arc furnace melting workshop
The filling operation of the arc outlet of the electric arc furnace is one of the most dangerous operating areas of the electric arc furnace and its surroundings. Steel mouth packing. Today, people use the intelligent automatic sand filling device (as shown in Figure 2) to complete this work, the operator only needs to monitor through the camera system.
The sand box ① is filled with sand by the material conveying system through pipes or chutes. Once the tapping is completed, the sand box and camera ② move to the inspection hole of the tap hole. If the tap hole is empty and clean, the operator will fill the sand through the console. The camera also monitors whether the tap hole is filled properly. If more sand is needed, the operator can easily fill the sand by pressing the button. After accurately filling the steel outlet with sand, the sand box will move back to the robot arm and the camera will return to a safe position. Then, close the inspection hole with the flap valve ④. This automatic sand filling device brings more safety to the daily work of the operator and helps reduce the power-off time of the electric arc furnace.
Sometimes, when opening the water outlet of the steel outlet, the steel outlet cannot be opened normally. Generally, the furnace outlet is directly burned with an oxygen lance at the bottom of the furnace. This process is very dangerous. Here, automated tools are needed to help deal with this problem. There is no need for maintenance personnel to enter the hazardous area, and the steel outlet is opened by the manipulator with an oxygen lance (Figure 3), which is basically the same process as the operator.
The manipulator is controlled remotely through the arc furnace operation room or through the tapping console. The oxygen lance is a consumable item and needs to be replaced every time it is used. The oxygen lance must also be replaced in a safe area, that is, when the manipulator is turned back to the parking space Gun replacement operation.
The slag door auxiliary device (shown in Figure 4) has two functions. One is to close the channel of the slag door so that no scrap will fall into it because the scrap is difficult to melt here; second, the flow of slag can be accurately controlled, You can even clean the slag door area. The use of slag door auxiliary devices can minimize dangerous operations in front of the furnace door, improve operation safety, help reduce downtime, and run closed operations to reduce energy consumption. The system operates at the same time as the cylinder driving the slag door. The thickness of the slag door must ensure that the slag channel can be blocked and no scrap can fall into it.
In the predictive repair and maintenance of the steelmaking workshop, it requires constant exploration and research by people in the industry. It is believed that through efforts, the efficiency, safety, and reliability of steelmaking in digital electric arc furnaces and other related equipment can be greatly improved.