大型高炉布料过程料面输出形状的建模与控制

Burden distribution is one of the most important operation systems in blast furnace iron-making process. It is critical to hot iron production, safety, smooth-running, high-efficient and energy-saving of the whole blast furnace iron-making process. Due to the complex distributed parameter characteristics in BF burden distribution process, the optimization and adjustment of burden distribution matrix are still carried out by experienced foremen, which brings a lot of negative effects to blast furnace stable production. Focusing on the most concerned issue in large blast furnace operation field, this project aims to study the modeling and control of burden surface output shape with distributed parameter characteristic. The main works include: ① study mechanism modeling of burden surface output shape under sparse data and multi-rate sampling; ② study dynamic model description and controller design of burden surface output shape with multi-field coupling; ③ study hybrid control of burden surface output shape with operating variables in different number field; ④ establish a new burden surface output shape modeling and control framework subject to conservation of mass, on the basis of burden distribution law, blast furnace foreman formulating and adjusting burden distribution matrix expert knowledge, moreover, through comprehensive use of metallurgy, mathematics, control science and other disciplines of knowledge and theory. The achievements of this proposed project will be used to provide theoretical basis for burden distribution operation optimization. It is also significant for the energy consumption reducing, energy conservation and emission reduction and performance optimization.

高炉布料是高炉操作中一个重要操作制度，是高炉稳定顺行、高炉稳产、降低事故率和减少燃料消耗的关键环节。由于复杂的分布参数特征的影响，高炉布料制度的制定和调整仍由经验丰富的工长执行，给高炉稳定生产带来较多负面影响。针对高炉现场操作中的实际问题，本课题以分布参数为特征的布料过程料面输出形状的建模和控制为主要研究内容。具体工作包括：①多采样率和稀疏数据下料面输出形状的机理建模研究；②多场耦合因素下料面动态输出形状的模型描述与控制器设计；③多数域操作变量下料面输出形状的混合控制研究；④在布料规律，炉长和工长对布料矩阵的制定和调整的专家知识基础上，综合运用冶金、数学、控制科学等多学科知识及理论，构建一种基于质量守恒规则的高炉布料过程料面输出形状的建模与控制技术架构。本课题将形成的建模与控制成果将为布料矩阵的操作优化提供理论依据，对于实现高炉冶炼过程的节能、减排以及性能指标优化具有十分重要的意义。

高炉冶炼过程中，铁矿石和焦炭作为炉料从炉顶装入，每一批装入的炉料会在炉喉形成一层炉料分布，而60-70层交替装入的矿石和焦炭料形成向下移动的料柱，在下行料柱与上升煤气流的耦合交互下铁矿石、焦炭与煤气流发生缓慢的物理化学反应，最终将铁元素从铁矿石中还原出来并从高炉底部的出铁口排出。由此，炉喉炉料分布是构成下行料柱矿焦比分布、孔隙度分布、上升气流阻力分布的关键，也是影响高炉稳定顺行、高炉稳产、降低事故率和减少燃料消耗的关键环节。针对高炉现场操作中的实际问题，本项目以炉顶装料过程炉喉炉料空间分布的建模与控制为研究内容。提出了基于等体积原则的布料空间分布模型，将高炉布料模型研究中的常规二维料流轨迹模型延伸至三维空间分布模型，给出了布料矩阵与炉喉炉料空间分布的描述关系。研究了调节炉料在炉喉中心与边缘占比的分布计算问题，给出了期望料层厚度分布的设定方法，提出了期望料层厚度分布下布料矩阵逆计算的算法，为布料矩阵参数的制定与调整提供了理论依据。本项目发表期刊论文7篇，其中布料模型和操作参数优化发表在国内top期刊自动化学报(英文版)上，论文被引用17次，授权国家发明专利4项，自制冷态下布料、下料模拟装置一套。本项目的研究成果一旦转化应用，可以推广至在役的绝大多数高炉，更有利于推进高炉装料过程自动化，对于实现高炉冶炼过程的节能、减排以及性能指标优化具有十分重要的意义。.