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' Evaluation Algorithm of the Control Quality of ``Cupola DEVELOPMENT OF “WHOLE” EVALUATION ALGORITHM OF THE CONTROL QUALITY OF “CUPOLA -MIXER” MELTING DUPLEX PROCESS Dmitriy Demin To cite this version: Dmitriy Demin. DEVELOPMENT OF “WHOLE” EVALUATION ALGORITHM OF THE CON- TROL QUALITY OF “CUPOLA -MIXER” MELTING DUPLEX PROCESS. Technology audit and production reserves, PC Technology Center, 2019, 10.15587/2312-8372.2019.174449. hal-03020985 HAL Id: hal-03020985 https://hal.archives-ouvertes.fr/hal-03020985 Submitted on 19 Dec 2020 HAL is a multi-disciplinary open access L’archive ouverte pluridisciplinaire HAL, est archive for the deposit and dissemination of sci- destinée au dépôt et à la diffusion de documents entific research documents, whether they are pub- scientifiques de niveau recherche, publiés ou non, lished or not. The documents may come from émanant des établissements d’enseignement et de teaching and research institutions in France or recherche français ou étrangers, des laboratoires abroad, or from public or private research centers. publics ou privés. METALLURGICAL TECHNOLOGY UDC 681.5:519.24:621.74 DOI: 10.15587/2312-8372.2019.174449 Demin D. DEVELOPMENT OF «WHOLE» EVALUATION ALGORITHM OF THE CONTROL QUALITY OF «CUPOLA – MIXER» MELTING DUPLEX PROCESS Об’єктом дослідження є управління дуплекс-процесом «вагранка – міксер», предметом дослідження – якість системи управління плавкою «в цілому». Під терміном «в цілому» розуміється, що оцінюються не окремі операції управління, а можливість діючої в цеху системи управління забезпечувати задані вимоги щодо якості чавуну. Одним з найбільш проблемних місць є відсутність у керівного персоналу алгоритмів отримання об’єк- тивної інформації про якість управління дуплекс-процесами плавки. Це призводить до того, що не вдається отримати відповідь на питання, в якій саме ділянці або в який саме момент часу реалізації процесу допущені порушення в частині управління плавкою. В ході дослідження використовувалися методи розрахунку вибіркових статистичних функцій, перевірки гіпотези про вид закону розподілу, регресійний аналіз, дисперсійний аналіз, методи теорії ймовірності. Дані методи були інтегровані в загальний алгоритм, названий алгоритмом оцінки «в цілому» якості управління дуплекс-процесом плавки. Запропонований алгоритм дозволяє кількісно оцінити якість управління дуплекс-процесом за таким показником, як ймовірність отримання відхилень за хімічним складом. А також тривалість нестаціо- нарного режиму, яка відповідає часу стабілізації хімічного складу шляхом операцій управління процесом, передбаченого прийнятою в цеху системою управління. Отримані результати апробації алгоритму дозволяють вважати його ефективним інструментом отримання об’єктивної інформації про якість управління дуплекс-процесом плавки «вагранка – міксер». Це пов’язано з тим, що коректність постановки і рішення задачі забезпечила отримання адекватних результатів. На відміну від існуючих емпіричних оцінок, запропонований алгоритм дозволяє розробляти варіанти удосконалення процесів управління. Як обґрунтування цього висновку запропоновано концеп- туальні варіанти технічної реалізації системи регулювання. Зокрема, запропонована проста схема регулятора, що забезпечує можливість підтримання сталості температури чавуну і продуктивності вагранки шляхом регулювання рівня холостої та металевої колош. Управління процесом в цьому випадку здійснюється шляхом подачі керуючих сигналів на виконавчі механізми шиберів бункера з коксом і мета - левою шихтою, що формуються системами ручного або автоматизованого управління. Ключові слова: алгоритм оцінки «в цілому» якості управління, схема регулятора, вагранкова плавка, термочасова обробка, дуплекс-процес плавки «вагранка – міксер». Received date: 10.11.2018 Copyright © 2019, Demin D. Accepted date: 02.12.2018 This is an open access article under the CC BY license Published date: 30.06.2019 (http://creativecommons.org/licenses/by/4.0) 1. Introduction technological processes, since laboratory experiments are of little use, given the specifics of metallurgical processes Metallurgical processes are among the complex ob - and equipment. jects of control. This is due to the fact that there are Despite all these objective difficulties, the requirements uncertainties in assessing their state. The reasons for for the quality of the products should be invariably ob- this are the complexity, and often the impossibility of served, and taking into account their constant tightening. measuring state variables, the multi-alternativeness in All this determines the relevance of research aimed at choosing the final state and quality control criteria, and finding methods of mathematical description and optimal, often the conflict of such criteria. Significant difficul - according to the selected criteria, control of such pro - ties are caused by the mathematical description of these cesses. The task of assessing the quality of management, processes, since obtaining an adequate description is as- in accordance with the process control system adopted at sociated with the need to build mathematical models of a particular industrial enterprise, also falls into the scope of the control object from a small data sample. Moreover, such a search. Among these processes is the duplex process such data should be obtained directly in the course of «cupola – mixer». Despite the fact that this process is 4 TECHNOLOGY AUDIT AND PRODUCTION RESERVES — № 3/1(47), 2019 ISSN 2226-3780 INDUSTRIAL AND TECHNOLOGY SYSTEMS: METALLURGICAL TECHNOLOGY not among the widespread, its study is of interest from 2.2. Technological audit of the cupola melting control the point of view of solving a number of management process. Melting is carried out on a site equipped with two problems. This is because the control of metallurgical cupolas with a capacity of 5 t/h each, working alternately. processes in each of these furnaces requires the correct The technical characteristics of the cupola are given formulation and solution of problems at each stage of in Table 1. the search for optimal control. This also applies to as - Table 1 sessing the initial state, and constructing a mathematical Technical characteristics of the cupola model, and the stage of describing the final state, and the No. Name Dimension Characteristic choice of control in the conditions that occur in these 1 Performance t/h 5 types of furnaces: – uncertainty in the estimation of heat and mass transfer 2 Download method – skip lift parameters, heat and energy characteristics and physi- 3 Diameter in the light mm 900 cochemical processes occurring in furnaces; 4 Cross-sectional area mm2 0.636 – presence of a drift of process characteristics; Useful height (from the axis of the – impossibility of measuring some state variables in 5 lower row of tuyeres to the level of mm 4234 the filling window) real time; 6 The number of the I row tuyeres – 6 – significant inertia of metallurgical furnaces as control 7 The number of the II row tuyeres – 6 objects. Therefore, conducting research to overcome these listed 8 The number of the III row tuyeres – 6 difficulties in any part of them should be considered relevant. 9 I row tuyere size mm × mm 200 × 125 10 II row tuyere size mm × mm 70 × 50 2. The object of research 11 III row tuyere size mm × mm 70 × 50 and its technological audit 12 Receiver diameter mm 820 13 Working capacity of a receiver m3 0.283 Height from the hearth to the slag tap 2.1. The object of research and the scheme of the «cupola – 14 mm 450 mixer» melting duplex process. The object of research is the hole of the receiver Height from the hearth to the axis of control of the «cupola – mixer» duplex process, the subject 15 mm 400 of research is the quality of the «whole» melting control the I row tuyeres system. The term «whole» will further be understood to 16 Diameter of the slag tap hole mm 50 mean that it is not individual control operations that are 17 Diameter of metal tap holes mm 25 evaluated, but the ability of the control system operating 18 Number of metal tap holes – 2 in the workshop to provide specified requirements for the 19 Transition window section mm × mm 120 × 90 quality of cast iron. 20 The mass of the loaded metal charges kg 500 The duplex process diagram is shown in Fig. 1. 21 The mass of idle charges kg 900–930 The height of the idle charge above the The adopted control system includes a set of measures 22 mm 550–600 for the management of cupola melting and thermal treat- upper edge of the III row of tuyeres ment carried out in the mixer. 23 Air pressure in the tuyere box mm wc 600–650 А-72-2 The site is equipped with two identical cupolas with 24 Fan type – a capacity of 5 t/h each, working alternately taking into No. 725766 account the regulations for repair work. 25 Fan aperture diameter mm 220 Melting is carried out after prepa- ration of the cupola for work and ignition of the idle ears. The igni- tion process is carried out within 2–3 hours. The height of the idle charges is measured with a measur- ing rod. After ignition of coke, the idle charge is purged for 2–3 min, having previously closed the working window. After purging, the level of the idle charge is checked, and if it is below a predetermined component of 1250 mm, coke is added. Coke is loaded with a skip hoist. The cupola loading is carried out by skip lift. Limestone in the amount of 12 kg is poured onto an idle charge to slag the first portions of coke ash. Then, layer-by-layer loading of mate- rials is carried out in the following Fig. 1. «Cupola – mixer» duplex process scheme: 1 – transfer system of charge loading; 2 – skip hoist; sequence: metal spike (500 kg), coke 3 – cupola; 4 – mixer; 5 – transfer bucket; 6 – casting buckets; 7 – casting conveyor; 8 – filling area; spike (53–58 kg), flux (16–17 kg). 9 – casting molds, ready for filling; 10 – filling forms The flux is loaded into the hopper TECHNOLOGY AUDIT AND PRODUCTION RESERVES — № 3/1(47), 2019 5 INDUSTRIAL AND TECHNOLOGY SYSTEMS: ISSN 2226-3780 METALLURGICAL TECHNOLOGY of the weighing cart directly to the fuel spike, which is charge leads to the burnout of the blank spike, therefore, considered working.
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