JP2002121556A - Furnace casing diagnosis system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a furnace casing diagnosis system for coke ovens which can predict and prevent future pitting of furnace wall bricks. SOLUTION: A database 10 comprising operation data, blend coal data, coke data, repair data and damage data produced for each carbonization chamber is analyzed to construct an extrusion force-generation model 11 wherein the extrusion force generated in each carbonization chamber under a certain condition is mathematized. The extrusion force generated in the future is predicted for each carbonization chamber based on the extrusion force- generation model 11 (16), and the risk of pitting of furnace wall bricks is predicted based on the future extrusion force predicted for each carbonization chamber (17). This system may previously predict the future risk of pitting of furnace wall bricks for each carbonization chamber, e.g. the risk of pitting of furnace wall bricks for a carbonization chamber after X years, and therefore prevents pitting of furnace wall bricks and extends the life of the oven.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a furnace body diagnosis system capable of diagnosing damage to a furnace wall brick of a coke oven and extending the life of the furnace.

[0002]

2. Description of the Related Art In a coke oven in which coal is carbonized to form coke, a combustion chamber and a carbonization chamber are alternately arranged, and the combustion chamber and the carbonization chamber are separated by a refractory brick partition (furnace wall brick). . Coal loaded in the hopper of the charging vehicle is charged into the carbonization chamber from above. Coal is carbonized by the heat of the combustion chambers arranged on both sides of the carbonization chamber to form coke. The carbonized coke is pushed from the side by the extrusion ram of the extruder and discharged from the carbonization chamber.

[0003] The furnace wall brick of a coke oven is aged and damaged due to the past operation history. Since the coke oven is a continuous operation facility, it cannot be stopped after operation to repair the furnace wall brick. Therefore, at present, measures such as thermal spray repair of damaged portions of the furnace wall bricks are taken to extend the life of the furnace.

[0004] In recent years, various furnace body diagnostic systems for qualitatively or quantitatively diagnosing the damage state of the furnace wall brick of a coke oven have been proposed. For example, Japanese Patent Application Laid-Open No. H11-131069 discloses that damage to a furnace wall of a coke oven is estimated based on a deviation between an estimated pushing force calculated assuming that no furnace wall damage has occurred and an actually measured actual pushing force. However, there is described a method for estimating the damage condition of a coke oven for determining the necessity of furnace wall repair. According to the method for estimating the damage state of a coke oven, the damage state of the furnace wall of the coke oven can be estimated as accurately as possible while eliminating unstable factors such as the operator's intuition.

[0005]

If the furnace wall brick in the coking chamber is significantly damaged and the pushing force in the coke oven becomes abnormally large, a part of the furnace wall brick is removed during extrusion or a hole is formed in a part of the furnace wall brick. Or open. Coal, coke, brick pieces, and the like may damage or block the combustion chamber or the heat storage chamber due to the removal or perforation (hereinafter referred to as a perforation) of the furnace wall brick in the coking chamber. As a result, the combustion temperature cannot be maintained normally, and the production of the coke oven is greatly hindered. Also,
Since the combustion chamber and the heat storage chamber are actually inaccessible places and difficult to repair, if the combustion chamber and the heat storage chamber are damaged once, production of the coke oven will be reduced and production will be greatly impeded. It is necessary to repair the combustion chamber and the heat storage chamber. That is, it can be said that the life of the coke oven is determined by the damage of the combustion chamber and the heat storage chamber. In order to extend the life of the coke oven and to continue the operation of the coke oven, it is important to prevent a hole in the furnace wall brick of the coking chamber and not to damage the combustion chamber and the heat storage chamber.

However, the conventional Japanese Patent Application Laid-Open No. H11-131
According to the method for estimating the damage condition of a coke oven described in Japanese Patent No. 069, even if the current damage condition of the furnace wall brick can be estimated to some extent, the future damage condition of the furnace wall brick cannot be predicted. It is not possible to predict in advance the hole in the wall brick.

Accordingly, an object of the present invention is to provide a coke oven furnace body diagnostic system capable of predicting a future opening of a furnace wall brick and preventing the opening of the furnace wall brick. .

[0008]

Hereinafter, the present invention will be described. In order to solve the above-mentioned problem, the present inventor has created an extrusion force generation model in which the extrusion force is formulated for each carbonization chamber, and estimates a future extrusion force for each carbonization chamber based on the extrusion force generation model. Then, based on the estimated future pushing force for each carbonization chamber, the possibility that the wall brick of the coke oven was punctured was predicted in advance. That is, the present invention relates to a furnace body diagnostic system for diagnosing damage to a furnace wall brick in a coke oven for coking and coking to produce coke, and includes operation data, blended coal data, coke data, and repair data created for each coking chamber. And at least one of the damage data is analyzed, and an extruding force generation model in which the extruding force generated under a certain condition is mathematically formulated for each carbonization chamber is created. The present invention is characterized in that the extruding force of the furnace wall brick is estimated, and the possibility of blasting of the furnace wall brick is predicted based on the estimated future extruding force of each carbonization chamber. Here, the pushing force generation model is created by statistically processing numerical values in a database for each carbonization chamber.

According to the present invention, it is possible to predict in advance the possibility that the furnace wall brick will be pierced in the future for each coking room, for example, to predict the possibility that the furnace wall brick of the coking room will be punctured after X years. be able to. This prevents the furnace wall brick from breaking,
Furnace life can be extended.

Further, the present invention analyzes the damage data, creates a brick damage propagation model in which the temporal change of damage to the furnace wall brick is modeled for each carbonization chamber, and forms a carbonization model based on the brick damage propagation model. Estimate the future damage to the furnace wall bricks for each room, and at least the estimated damage data for the furnace wall bricks and the expected future operation data, blended coal data, coke data and repair data for each coking room. One set of data is substituted for the pushing force generation model, and the future pushing force for each carbonization chamber is estimated.

The pushing force is greatly affected by the state of damage to the brick. According to the present invention, the chronological change of the damage data of the furnace wall brick is substituted into the extruding force generation model, so that it is possible to more accurately predict a future hole in the furnace wall brick.

Further, the present invention creates a furnace wall puncture model for obtaining conditions for rupture of a furnace wall brick, and adds damage data for each future carbonization chamber and future data for each carbonization chamber to this furnace wall rupture model. The method is characterized in that the extruding force of the furnace wall is collated to predict the possibility of blasting of the furnace wall brick. Here, the furnace wall puncture model is created from past puncture results, off-line tests, and numerical simulations. In addition, for the extrusion force, the extrusion force obtained from the extrusion force generation model may be directly used,
From the extruding force obtained from the extruding force generation model, determine the local load or local pressure locally applied to a part of the furnace wall brick divided into multiple instead of the entire furnace wall brick, using this local load or local pressure Is also good.

According to the present invention, it is possible to quantitatively predict the possibility that the furnace wall brick will break.

Further, according to the present invention, if there is a possibility that the bricks of the coke oven are ruptured, the bricks which are predicted to be punctured are repaired in advance and the bricks of the coke oven are punctured. It is characterized by preventing.

When the furnace wall brick is repaired, the pushing force is reduced. ADVANTAGE OF THE INVENTION According to this invention, it can prevent that the furnace wall brick of a carbonization chamber ruptures, and can extend the life of a furnace.

Further, the present invention prevents the blast furnace wall brick from being punctured by operating under the condition of maintaining the extruding force without piercing when the blast furnace wall brick of the coke oven may be punctured. It is characterized by the following.

According to the present invention, by operating with an extruding force under such a condition that the furnace wall brick does not break, the furnace wall brick in the carbonization chamber can be prevented from breaking and the life of the furnace can be extended. .

[0018]

FIG. 1 shows a coke oven to which a furnace body diagnostic system according to an embodiment of the present invention is applied.
As is well known, the coke oven has a carbonization chamber 1 at the top of the heat storage chamber.
And the combustion chamber 2 are alternately arranged to form a furnace group. The carbonization chamber 1 has a length of 12 to 16 m, a height of 4 to 7 m, and a width of 400 m.
m-450 mm, the coal charge amount is about 12-40 t, and in order to facilitate the extruding of coke, the CS side with the coke guide wheel is 40-400 more than the PS side with the extruder.
The width is 75mm wide. The coke oven includes a carbonization chamber 1 for carbonizing coal, a combustion chamber 2 for burning fuel gas, a heat storage chamber for utilizing residual heat of combustion waste gas, and a horizontal flue below the heat storage chamber. The combustion chamber 2 is subdivided into a number of flue.

The coke oven is provided with ancillary equipment such as a charging car, an extruder, a coke guide car, and a fire extinguishing car. The charging vehicle receives coal from the gate at the bottom of the charging coal tank, travels to a predetermined coking chamber 1 and charges the coal into the coking chamber 1. When the carbonization of the coal is completed in the coking chamber 1 and coking is completed, the extruder opens the furnace lid of the coking chamber 1 and extrudes the red hot coke and closes the furnace lid. The extruder has a furnace lid removing device that lifts and opens the furnace lid of the carbonization chamber 1, and an extrusion ram that extrudes red hot coke. The coke guide vehicle is located on the opposite side of the extruder across the carbonization chamber 1. When extruding red hot coke in the coking chamber, the coke guide vehicle opens the furnace lid of the coking chamber on the coke guide vehicle side and guides the extruded red hot coke onto the fire extinguishing vehicle. The fire extinguishing car receives red hot coke that is extruded through the guide grid of the coke guide car, and is driven by the train to run. The fire extinguishing vehicle that has received red hot coke travels to the fire tower where red hot coke is sprinkled and extinguished.

[0020] The furnace wall brick of the coke oven is aged and damaged due to the past operation history. 2 to 4 show coke oven damage. FIG. 2 shows the defect of the furnace wall brick in the carbonization chamber 1. As shown in FIG. 2, the surface 3 of the furnace wall brick of the carbonization chamber 1 may be broken with a certain extent due to frictional resistance or the like. Due to the loss of the surface 3 of the furnace wall brick, for example, the original original thickness W of 100 mm is reduced to about 60 mm. If the surface 3 of the furnace wall brick in the coking chamber 1 is lost and the furnace wall brick becomes uneven, the extrusion resistance increases, and as a result, phenomena such as compaction occur.

FIG. 3 shows cracks in the furnace wall brick. As shown in this figure, cracks 4 occur in the furnace wall brick of the coking chamber 1 due to thermal stress. When carbon invades and grows into the crack 4, the crack 4 and the joint are connected, and the crack 4 expands.

FIG. 4 shows a hole in the furnace wall brick. When an abnormal lateral pressure during extrusion is applied to a part where the surface 3 of the furnace wall brick is missing or a part where the crack 4 is formed, the furnace wall brick comes off,
A hole is opened in the furnace wall brick. The carbonization chamber 1 and the combustion chamber 2 penetrate through the hole 5 of the furnace wall brick, and not only the carbonization chamber 1 but also the combustion chamber 2 and the heat storage chamber are damaged or closed. As described above, since the combustion chamber 2 and the heat storage chamber are actually inaccessible places and difficult to repair, the combustion chamber 2 and the heat storage
In addition, if the heat storage chamber is damaged, it is necessary to repair the coke oven while reducing the production of the coke oven while greatly inhibiting the production. In order to extend the life of the coke oven and continue the operation of the coke oven, it is important not to puncture the furnace wall brick.

FIG. 5 shows an example of a configuration diagram for implementing the present invention using a computer. The coke oven calculator 6
The coke oven 7 is remotely monitored and controlled. Various data from the coke oven 7 are collected by the coke oven computer 6. Data for each carbonization chamber 1 necessary for predicting the hole 5 in the furnace wall brick is transmitted to the diagnostic analysis computer 8. A part of the data may be directly transmitted to the diagnostic analysis computer 8 without passing through the coke oven computer 6, or may be manually input by the computer terminal 8a.

Table 1 shows a database for each coking chamber 1 created by the furnace body diagnostic system of the present invention. The database is not the average value of the entire coking chamber of the coke oven, but, for example, the data of the first coking chamber 1 for each coking chamber 1 and the second coking chamber 1
Is organized into data. The database includes operation data, blended coal data, coke data, repair data, and damage data.

[Table 1]

The operation data further includes the data shown in Table 1 such as the carbonization time, generated gas, combustion chamber temperature, and coke extrusion force. The coke extrusion force is a current value of an extrusion motor when extruding with a pusher, a torque applied to a shaft of the extrusion motor, a value actually measured using a load cell, or the like.

The blended coal data further includes blended composition, moisture,
Each data shown in Table 1 such as volatile content is included. This blended coal data is mainly managed on a furnace group basis.

The coke data further includes intensity, reaction rate,
And data such as the granularity configuration. This coke data is also managed for each furnace group. By combining the operation data, the blended coal data and the coke data, it is possible to understand what kind of coke was produced when what kind of coal was put into what kind of carbonization room.

The repair data is chart-like data described for each carbonization chamber, and includes data on repair methods such as thermal spraying, semi-dry wet spraying, brick replacement, and the repair position of the repaired brick. Brick transshipment includes brick materials and the like.

The damage data is a content when a health check is performed on the furnace wall brick, and includes data on a damage state of the brick such as a position, a defect depth, a crack width and the like, and a furnace body expansion amount. The damage data is obtained by, for example, analyzing an image captured by a video camera or the like using an image analysis device and quantifying the depth of the defect, the crack width, and the like.

FIG. 6 is a block diagram showing a furnace body diagnostic system according to the present invention. First, the furnace body diagnosis system of the present invention is operated data, blended coal data created for each coking chamber,
Analyzing the database 10 consisting of coke data, repair data and damage data, creating an extrusion force generation model 11 in which the extrusion force generated under a certain condition is formulated for each carbonization chamber 1, analyzing the damage data, A brick damage progression model 12 is created by modeling the change over time of damage to wall bricks for each carbonization chamber, and a furnace wall for obtaining conditions for blasting furnace wall bricks from the repair data, past puncture results or numerical simulations A hole model 13 is created.

The extruding force generation model 11 is obtained by statistically processing the numerical values of the database 10 and performing multiple regression analysis as multiple variables, and formulating the coke extruding force generated under certain conditions for each carbonization chamber. In other words, this extrusion force generation model is a calculation formula for determining under what conditions and how much coke extrusion force is required.

[0032]

(Equation 1)

Since the degree of damage is different for each carbonization chamber 1, even if the same coal is charged under the same conditions, the required pushing force is different if the carbonization chamber 1 is different. Therefore, for example, the coefficient of the dry distillation time is a1 for each carbonization chamber 1, and the blended coal has little effect on the first carbonization chamber, but the large coefficient a2 on the second carbonization chamber.
And the like are expressed as mathematical expressions. The extrusion force increases as the carbonization time is shorter, the charging amount is larger, and the damage to the brick is larger.

The brick damage propagation model 12 is a model in which a database is analyzed and a temporal change (time-series change) of brick damage is modeled for each carbonization chamber. In other words, the brick damage propagation model 12 is a model of how damage progresses by observing the damage situation and taking into account the transition of damage as a result of the observation. The damage data is regularly measured by analyzing an image taken by a video camera or the like. By observing the transition of the damage data, a brick damage progress model 12 is created. According to the brick damage propagation model 12, it was found that under what conditions a load was applied to the coke oven, how long and how much the oven wall brick was damaged,
It is possible to predict the damage of the furnace wall brick in the future. In addition,
In the brick damage propagation model 12, although the operating conditions are also taken into account, since the operating conditions actually change, a time-series change of the damage based on the changed performance is observed. Also,
Although it is desirable that the brick damage propagation model 12 is expressed by a mathematical expression, the mathematical expression need not always be expressed by a mathematical expression. In addition, it is known that the range of damage increases with the progress of the furnace order, and the defect depth and crack width increase.

The furnace wall puncture model 13 is an equation for obtaining conditions for puncturing the furnace wall brick, and is calculated from past puncture results, off-line tests, numerical simulations 14 and the like. The past puncture results refer to the results of actual holes being opened, for example, the coke oven was punctured about three times. From such drilling results, offline tests, and numerical simulations,
The following formula is created to determine the conditions under which a hole is opened in the furnace wall brick.

[0036]

(Equation 2)

Here, as the pushing force, the pushing force calculated from the above-described pushing force generating model may be directly used, or the pushing force obtained from the pushing force generating model may be used instead of the entire furnace wall brick. A local load or a local pressure applied locally to a plurality of sections of the furnace wall brick may be obtained, and the local load or the local pressure may be used.

FIG. 7 shows the extrusion of coke in the extruder 22. When extruding coke, coke spreads and lateral pressure is applied to the furnace wall brick. At this time, the pushing force of the coke is not uniformly applied to the entire furnace wall, but is applied locally as a large local load or local pressure.

FIG. 8 is a graph showing the relationship between the pushing force and the local load. This graph is created using a compression test apparatus that can measure a local load or a local pressure acting on a side wall provided along the compression direction when the test coke is compressed in the extrusion direction. In this compression test apparatus, test coke generated under conditions corresponding to operating conditions in a real furnace is used. When a local load or pressure is used, the conditions for puncture of the furnace wall brick can be more reliably obtained. For example,
According to this furnace wall puncture model, a healthy brick is several hundred kg.
The brick does not break even when a local load of f is applied, but 50 m
It can be seen that bricks with m-deletion may break when a local load having a load index of 0.6 is applied.

Next, as shown in FIG. 6, a future damage of the furnace wall brick for each carbonization chamber 1 is estimated based on the brick damage propagation model 12 (15). Here, for example, the damage status of the brick after X years is estimated.

Next, the estimated damage to the furnace wall brick (1)
5) and the expected future operation data, blended coal data, coke data and repair data for each coking room are substituted into the extrusion force generation model 11 to estimate the future extrusion force for each coking room (16). ). Here, the brick damage state after X years, the estimated total evaluation data after X years, the blended coal data, and the like are input to the extrusion force generation model 11, and the coke extrusion force after X years is estimated. For example, if the current carbonization chamber extrusion force is At, it is predicted that the extrusion force will be Bt based on the expected carbonization chamber damage 10 years later. In addition, since the transition of the actual extrusion force is taken as data for several years, one term of time can be formed in the extrusion force generation model 11, so that the future extrusion force can be estimated without estimating damage to the furnace wall brick. Is also good.

Next, the damage (15) for each future coking chamber and the future pushing force (16) for each coking chamber obtained by the pushing force generation model 11 are compared with the furnace wall puncture model 13, and the furnace wall is examined. Predict the possibility of brick puncture (17). Here, it is predicted that, for example, if the furnace wall brick is added to the damage state of the furnace wall brick 10 years later with the pushing force of Bt, the furnace wall brick will be punctured.

If there is a possibility that the furnace wall brick of the coke oven will break, the furnace wall brick in which the hole is predicted is repaired in advance to prevent the furnace wall brick from breaking (18). , 2
0). Furnace wall bricks that are supposed to be broken are repaired by, for example, replacing with new bricks, well-known thermal spraying, semi-dry wet spraying, or the like. FIG. 9 shows the transition of the pushing force of the actual furnace. When the furnace wall brick is repaired, it can be seen that the extrusion force decreases.

Further, as shown in FIG. 6, when there is a possibility that the bricks of the coke oven are punctured, the furnace wall bricks are ruptured by operating under the condition of maintaining the pushing force so as not to puncture. May be prevented (19, 20). For example, if the furnace wall brick breaks because it is pushed by the pushing force of Bt, the operating conditions are changed so that no load is applied, and the pushing is performed by the pushing force of At. Extrusion force increases as the time required for carbonization increases. Extrusion force can be reduced by elongating the time for carbonization and reducing extrusion force. As described above, according to the furnace body diagnostic system of the present invention, when there is a possibility that a puncture may occur, the puncture location is repaired in advance, or the condition in which the coke oven maintains the pushing force that does not puncture. Operated in. When the furnace wall brick is punctured, the combustion chamber or the heat storage chamber where the brick is inaccessible is damaged, so that the furnace wall brick must be punctured, but according to the furnace body diagnostic system of the present invention, the furnace wall brick Can be prevented, and the life of the furnace can be extended while maintaining healthy combustion conditions.

[0045]

As described above, according to the present invention,
An extrusion force generation model in which the extrusion force is formulated for each carbonization chamber is created, a future extrusion force for each carbonization chamber is estimated based on the extrusion force generation model, and the estimated future extrusion force for each carbonization chamber is calculated. Since the possibility of puncture of the furnace wall brick of the coke oven is predicted in advance, the blast of the furnace wall brick can be prevented, and the life of the furnace can be extended.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a coke oven to which a furnace body diagnostic system according to an embodiment of the present invention is applied.

FIG. 2 shows a defect of a furnace wall brick in a carbonization chamber.

FIG. 3 shows cracks in the furnace wall brick of the coking chamber.

FIG. 4 shows a hole in a furnace wall brick in a carbonization chamber.

FIG. 5 shows an example of a configuration diagram for implementing a furnace body diagnosis system of the present invention using a computer.

FIG. 6 shows a block diagram of a furnace body diagnosis system of the present invention.

FIG. 7 shows the extrusion of coke in an extruder.

FIG. 8 is a graph showing the relationship between the pushing force and the local load.

FIG. 9 is a graph showing the water level of the extrusion force of the actual furnace.

[Explanation of symbols]

 DESCRIPTION OF REFERENCE NUMERALS 1 Carbonization room 10 Database 11 Pushing force generation model 12 Brick damage propagation model 13 Furnace wall puncture model 15 Future brick damage estimation 16 Future pushing force estimation 17 Prediction of puncture occurrence 18 Preliminary repair 19 Operation condition change 20 Prevention of puncture occurrence

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Mitsuru Ogawa 1-2-2 Marunouchi, Chiyoda-ku, Tokyo F-term (in reference) in Nippon Kokan Co., Ltd. 4H012 EA00

Claims (5)

[Claims] 1. A furnace body diagnostic system for diagnosing damage to a furnace wall brick in a coke oven for coking and coking coal, comprising: operation data, blended coal data, coke data, repair data, and repair data created for each coking chamber. Analyze at least one of the damage data, create an extrusion force generation model that formulates the extrusion force generated under certain conditions for each carbonization chamber, and based on this extrusion force generation model, calculate the future A furnace body diagnostic system, which estimates an extrusion force and predicts a possibility of blasting of a furnace wall brick based on the estimated future extrusion force for each carbonization chamber. 2. Analyzing the damage data, creating a brick damage propagation model in which the temporal change of the damage of the furnace wall brick is modeled for each carbonization chamber, and based on the brick damage propagation model, a future model for each carbonization chamber is prepared. Estimate the damage of the furnace wall brick, and estimate the damage data of the furnace wall brick and at least one of the expected future operation data for each coking room, blended coal data, coke data and repair data. The furnace body diagnostic system according to claim 1, wherein is substituted into the pushing force generation model to estimate the future pushing force for each carbonization chamber. 3. A furnace wall puncture model for obtaining conditions for rupture of a furnace wall brick is created, and damage data for each future carbonization chamber and future pushing force for each carbonization chamber are created in the furnace wall puncture model. 3. The furnace body diagnostic system according to claim 1, wherein a possibility of puncturing of the furnace wall brick is predicted. 4. When there is a possibility that the bricks of the coke oven may break, the bricks which are predicted to be broken are repaired in advance to prevent the bricks from being broken. The furnace body diagnostic system according to any one of claims 1 to 3, wherein: 5. When the furnace wall brick of the coke oven has a possibility of puncture, the furnace wall brick is operated under the condition of maintaining an extruding force that does not puncture to prevent the furnace wall brick from puncturing. The furnace body diagnostic system according to any one of claims 1 to 3.