Development and application of the concept of the

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The development and application of the concept of "Transparent Factory" in the control system of large blast furnaces

I. overview

the concept of "Transparent Factory" is a new control concept proposed in the field of automation control in recent years. This concept is aimed at a large and medium-sized production process, and makes each process and process link an organic whole through corresponding control equipment such as network architecture, PLC controller and intelligent instrument, This architecture allows end users to run their devices to a higher level. To achieve intelligent and semi intelligent production process and product allocation, users at all levels can investigate the coaxiality factory data of major manufacturers at home and abroad that change the fatigue testing machine at the same time by virtue of the authorization level. Through the upper monitoring computer (HMI) to understand, master and operate, the production is highly transparent and open, so as to greatly reduce the workload of system integration and reduce the labor intensity of workshop operators and dispatchers, Improve the level of modern management of enterprises. Transparent Factory is based on new information technology (it) and communication technology, including OPC open software standard and web technology. It mainly includes three aspects: Communication Based on tcp/ip Ethernet, network application of Web mode and object-oriented programming

the development of automation system of 3 1750m3 blast furnace project recently put into operation in Jigang is based on AB control system with the concept of "Transparent Factory". The automation system of the project adopts a two-level computer control system. The first level is the basic automation system, with AB company's ControlLogix series PLC as the core, and the monitoring software RSView se as the real-time monitoring system to complete the electrical drive control and instrument process control. The network technology is used to form a controller based distributed control system, and the monitoring station adopts a client/server structure. The second level is the process computer system, which adopts the client/server structure to realize the calculation of technological parameters of ironmaking. The primary and secondary levels communicate through the network. The communication protocol is fully open, and the trunk of the head office is attached, which can be seamlessly connected with MES (Manufacturing Execution System) and ERP (Enterprise Resource Planning)

II. Network topology

the operation of the network system in a safe and stable environment is the key to the success of the application of the concept of "Transparent Factory". In the design, we adopt the principle of combining ring and radioactive groups, and adopt redundant ring groups for the sub stations with high impact index on blast furnace production, large amount of upper and lower data transmission, and close connection between process links. For the auxiliary system, the system with a small amount of downlink data adopts the radioactive group mode. At the same time, in order to maximize the "transparency" of the system, some intelligent instruments and controllers with networking functions and PLCs from other manufacturers also hang Ethernet through the corresponding communication templates. The distribution of information is unified in the 1756-mnet and 1756-dnb modules of prosoft installed in the PLC on the furnace top. The packaged information is compiled and processed, and then packaged and transmitted to Modicon and other processors as the latest real-time control condition input

Jigang boiler process computer system configuration diagram

III. main functions completed by the basic control layer (L1 level)

1. Ore trough part: including the control of ore system, coke system, coke Ding system and electrical equipment of the feeding main belt, and the completion of blast furnace proportioning (batch cycle program, normal loading program, feeding program, ore system proportioning program, coke feeding program)

2. Furnace top part: detection and control of furnace top distribution system and related parts; Furnace top water pumping system, furnace 230 single leaf flat open multi-function door top airtight box and tank pressure control system: multi ring distribution, furnace top charging tank and charging system detection and control

3. Furnace top hydraulic station, regulating valve hydraulic station, dry oil station, thin oil station a, B probe DC control; Furnace body: automatically control and adjust the pressure on the top of the furnace to control the tapping quality of the blast furnace

4. Cooling stave part: control the cooling water of blast furnace and protect the blast furnace body. Control the pressure of the expansion tank, automatically replenish water, control the liquid level of the expansion tank within the normal range, and at the same time, there is an accident replenishment system

5. Hot blast stove: it includes three hot blast stoves and a hydraulic station, which realizes the functions of hot blast stove, such as furnace change, combustion, air supply, automatic optimization and so on

6. Raw fuel system: raw fuel metering, pellet feeding, sintering feeding, raw ore feeding, coke feeding

7. Water treatment system: soft water system, purified water circulation system, water supply pump station at the later stage of boiler service

IV. main functions completed by the process control layer

process data collection, process monitoring, raw fuel management, expert system mathematical model, production operation guidance, data communication, historical data storage and processing, report printing

1) collection of process data

the system receives process data from the basic automation system through the network, including raw fuel data, feeding data, furnace top data, furnace smelting data, pulverized coal injection data, tapping data, etc. Some data cannot be obtained automatically, or in case of communication failure, the operator can manually input it into the system on the operation station

2) process monitoring

process monitoring is completed based on the collected process data. Process monitoring mainly includes the following contents: raw fuel loading data, furnace top temperature, pressure data, furnace top gas data, temperature data of each part of the furnace body, cooling water flow data of each part of the furnace body, coal injection data, slag iron data of the iron tapping yard, slag flushing data, and process data of the hot blast furnace system

3) raw fuel management

this system manages the incoming/outgoing of raw fuel, including:

input of raw fuel data: each time the raw fuel enters the tank, input the brand, composition, quantity and other data of raw fuel according to the tank

tank stock management: according to the actual material data, manage the raw fuel tank stock and other data, and alarm when it is lower than the specified amount

4) mathematical model of expert system

in order to meet the stable and smooth production of blast furnace, the blast furnace expert system is used for production guidance to improve the quality of molten iron and reduce energy consumption

functions of the expert system for blast furnace mathematical model:

comprehensive calculation set: charge loading tracking, top gas composition and temperature distribution, chemical balance in the furnace, comprehensive calculation of bosh (tuyere area), comprehensive calculation of hearth, etc.

Dynamic smelting mathematical model calculation set: comprehensive burden model, furnace charge simulation model, material balance model, rist model, furnace heat calculation model, hearth balance model Hot metal temperature prediction model, hot metal Si content prediction model

crt data: silo type setting, raw material chemical composition, tapping/slag information, knowledge base rule parameters, batching model data

system database: database, historical database, smelting knowledge database

abnormal furnace condition report of blast furnace: including nearly 100 reports, such as sliding material, pressure loss, slag skin falling off, material surface inclination, furnace temperature fluctuation, low charge line, hearth state, change of gas utilization rate, water leakage of water system, stable furnace condition, etc

prediction of abnormal furnace conditions of blast furnace: including furnace heat trend, material collapse pores, suspended material, pipe travel, furnace wall thickness, etc

v. application effect of the system

the blast furnace automation system has operated well since it was put into operation in August 2005. From the actual production and operation situation, due to the successful application of the concept of "Transparent Factory", it is very convenient for operators to monitor the whole system and engineers to maintain. It is also very inconvenient to take and place samples, which greatly reduces the downtime and greatly improves the productivity. The powerful real-time and historical database records the process control characteristics of blast furnace production, and provides strong support for the stable production of blast furnace. The expert system can predict the furnace temperature about 2 hours in advance and report various abnormal signs of blast furnace operation in real time. At the same time, it prompts the processing methods, avoids the fluctuation of furnace conditions, and solves the protection problems of blast furnace and related equipment. Provide the smelting mathematical model of each production process from batching to tapping, provide a full set of furnace condition reasoning rules and rule combinations, and the reasoning engine of blast furnace abnormal conditions. Based on the current situation of the blast furnace, the fuel ratio can be reduced to less than 500 kg/T iron after the application of this system

the automation system of Jinan Iron and steel 3 1750m3 blast furnace project has reached the international advanced level in terms of the smooth operation after production and the stability of production state, and has broad prospects for industrialization and popularization and application. (end)

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