Sintering Process Detection and Automatic Control---Problems and Countermeasures

Although the application of DCS has greatly improved the detection and control level of sintering production in China, compared with the advanced level in foreign countries, the quality of automatic detection and control of the sintering plant process in China is not high. The reasons can be summarized as: three aspects of the research, research and application conditions of hardware equipment, technical means and control methods. (1) The hardware equipment used for detection and control is a high-temperature, high-humidity, high-dust system, which requires high temperature resistance, moisture resistance and anti-interference. At present, the research and production of detection components can not meet the requirements of sintering process detection. There is a common defect that the quality of components is not good, the service life is short, and the measurement is inaccurate. Even many important process parameters such as gas permeability cannot be detected, which will inevitably affect the process. The quality of the test, and the control based on it is also restricted. Therefore, it is urgent to research and develop advanced detection equipment such as gas component analyzer and material layer gas permeability measuring device which can be used for online continuous detection, and at the same time vigorously promote the distributed control system. Application in the sinter plant. (II) Research on advanced technical means and control methods The research on advanced technical means and control methods is far from deep. For a dynamic complex system with many influencing factors and large hysteresis, it is difficult to achieve high by relying on traditional control methods. Quality control. With the development of computer technology and control theory and technology, many advanced research methods and control methods have been introduced into the field of sintering, and a new way to detect and control the sintering process is one of the current research hotspots. Central South University of Technology and Northeastern University have achieved initial success in the research of sintering process detection and control. What these studies have in common is the application of advanced research methods and artificial intelligence techniques to the field of sintering. Years of research and production practices have shown that the sintering process is complex and it is difficult to establish accurate mathematical models. Many aspects rely on the actual experience of operators and domain experts to adjust the operation, which will inevitably bring blindness and uncertainty of control. . Artificial intelligence technologies such as expert systems, fuzzy techniques, and neural networks are powerful tools for solving such problems. At present, the research on the detection and control of the sintering process is mostly directed to a certain part of the production process, and the research on the overall control scheme focusing on the whole process of sintering is less. Dr. Fan Xiaohui from Central South University of Technology proposed an alkali-centered sinter chemical composition control and gas permeability-centered sintering state control overall control scheme suitable for the sintering process. The mathematical model was combined with the knowledge model to establish The expert guidance system of sintering process control, the accuracy of control guidance is above 80%, and for the characteristics of large hysteresis of sintering process, the method of predicting the sinter alkalinity is studied in advance and applied to production practice. In the actual sintering production process in China, there are still some blind spots of control, such as the control of the sintering end point. Since the endpoint cannot be directly detected and there are many factors involved, almost all raw material parameters, operating parameters and status parameters will directly or indirectly affect the end state. Changing the speed of the machine to adjust the end point will bring a series of corresponding changes such as the feeder speed, the ring cooler speed, the speed of the plate feeder and the material level of the bottoming trough, and the change of the material level of the mixing trough. This will result in greater fluctuations in the sintering process. For such difficult-to-control links, manual methods are still used for subjective judgment and adjustment, which brings great instability to the sintering production. However, the close relationship between the sintering end point and the sintering yield, quality and energy consumption makes it impossible to ignore the effect of the end point control. The end point control is suitable and stable, which not only keeps the sintering process stable, but also ensures the effective use of the sintered area. At the same time, grasp the opportunity to increase production and reduce energy consumption. At present, the problems to be solved in the study of sintering endpoint control are accurate judgment, early prediction and design of appropriate control strategies. Central South University of Technology is working to solve this problem and develop an intelligent control system for the sintering end point. According to reports, the ongoing research work also includes neural network-based image compensation of the tail section; sintering fuzzy control of the igniter of the sintering machine; and intelligent control of the thickness of the sintering machine layer. The nuclear radiation is used for the measurement control of the external fuel in the sintering process; the process of the decision-making process is used to control the grade of the sintered ore, and the gray theory is used to predict the chemical composition of the sintered ore. (III) Conditions for research and application At present, one of the more prominent problems is that enterprises pay insufficient attention to process detection and automatic control. Although the importance of automatic sintering control for sintering production is becoming more and more significant, it has not received the attention it deserves in practical applications. Using advanced control methods to serve the sintering industry, it is also necessary for each sintering enterprise to carry forward the spirit of brave practice, change old ideas, increase investment in scientific research, actively cooperate with institutions of higher learning and scientific research units, and accelerate the transformation of scientific research results into actual productivity. The application of the sintering distributed control system has made the sintering production in China a "eye-to-manual" situation. The process detection and automatic control have reached a step, which has reduced production fluctuations, improved productivity and sinter quality, and reduced energy. The effect of labor and labor intensity. However, compared with the level of automatic detection and control of foreign advanced sintering enterprises, there is still a big gap. Developed a new type of instrument for process detection, using artificial intelligence technology and advanced control methods to develop a control system suitable for the actual production of sintering in China, and applied it to practice to improve the overall level of China's sintering industry, and has become a production manager in the field of sintering. The direction of the joint efforts of researchers.

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