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Blast Furnace Cooling Water Monitoring and Control System

Paper Keywords: blast furnace cooling water temperature difference between flow temperature sensor monitoring system for digital automatic control Abstract: Using digital temperature sensors, electromagnetic flow meters for blast furnace cooling water system for monitoring the temperature and flow parameters, while the basis of these data and historical records and artificial setting parameters for analysis and comparison to confirm the cooling water system of blast furnace operation status, poor state and the necessary adjustments. Introduction In the blast furnace production process, as reflected in the furnace produces a lot of heat, no lining materials are difficult to sustain such a high temperature, they must be reasonable furnace cooling, while the effective control of the cooling medium in order to achieve effective cooling so that neither endanger the life of refractories, but also will not be affected by leakage of the cooling element BF operation. Therefore, the cooling medium on the blast furnace necessary monitoring and control is particularly important. This paper presented the blast furnace water-cooled parts of a system to monitor and control the composition and working principle. Blast furnace cooling water system of the more important of several parameters: The role of Blast Furnace Cooling: 1. Lower lining temperature, so that lining to maintain a certain intensity, to maintain a reasonable operating furnace, blast furnace to extend the life and safety in production. 2. The formation of a protective slag skin, steel and graphite layer, to protect the work of lining and replaced the lining 3. Protection of furnace shell, the pillars and other metal structures, from the effect of heat stress, and some equipment, such as draft, slag mouth, hot-air valve such as water cooled to prolong their life. 4. Some of the cooling equipment can play a supportive part of the brick lining effect. Its role, and the relative importance of reducing the temperature, the heat away to form a protective slag skin, to maintain a rational furnace. Therefore, the cooling system in different locations in the amount of heat taken away is very important, there are cooler heat balance analysis shows that the cooling water taken away by the heat and water, and out of the water temperature, water is proportional to the specific heat capacity, while the specific heat capacity of water is a constant, Therefore, cooling water, an important parameter that we need to monitor the water flow into and out of the water temperature.

Through our branch pipe cooler inlet or outlet flow meter is installed to obtain the flow value, through the inlet and outlet temperature sensors were installed to get out of the water temperature, obtained by calculating the difference in temperature. The cooling water system of blast furnace control and regulation of water flow is mainly to adjust, adjust the cooling water flow is the primary means of regulating water control valve opening and start-pressure pumps to increase water pressure in two ways. So we have to do is to monitor the blast furnace of the cooling water out of the water temperature and flow rate, through the heat flux intensity is calculated, and then under the heat flux intensity on the blast furnace wall thickness of the current position to diagnose the situation, and partial or total volume of water to make the appropriate adjustment. System Introduction System from the temperature monitoring function is divided into subsystems, flow monitoring subsystem, control the implementation of subsystems, operation analysis control storage subsystem and the query subsystem five parts (Figure 1). Figure 1 Schematic diagram of blast furnace cooling system control Temperature Monitoring Temperature Monitoring Subsystem subsystem constitutes a Temperature monitoring subsystem devices including: digital temperature sensor, bus connector, the temperature collector, data converters and so on. System structure (figure 2): Figure 2: Schematic diagram of temperature monitoring subsystem Temperature Sensor Temperature sensors used in the United States imported digital temperature sensing element, its high precision, anti-interference ability, and wide temperature range of features makes the lowtemperature measurement systems use very large. Its shell is made of stainless steel, waterproof, corrosion-resistant, can be in poor conditions and temperature environments. The probe easy to install, replace them convenient and good maintainability. The internal digital temperature sensor has a separate address number, the system based on sub-technical parameters

Operating voltage: DC5V 10% Measurement Accuracy: 0.1 Temperature range: -55 ~ 125 Communication lines: RVVP 3x0.3 (ambient temperature 70 ) Or AFP 3x0.3 (ambient temperature 220 ) Dimensions: probe length 50mm, male thread M16 Figure 3 Digital Temperature Sensor Principles of Digital Temperature Sensor temperature Figure 4 Principle of Digital Temperature Sensor temperature Measuring principle of temperature sensor shown in Figure (Figure 4) as shown in Figure medium and low temperature coefficient of the crystal oscillation frequency affected by the temperature is very small, used to generate a fixed frequency pulse signal sent to subtract counter, high-temperature coefficient crystal With the temperature of its vibration frequency of significant changes, the resulting signal as the subtraction of the two pulse counter input, the figure also implies counting the door, when the count is the door opened the temperature sensor on the low temperature coefficient of oscillator clock pulse count, and then complete the temperature measurement. Count the door open time by high-temperature coefficient of oscillator is determined before each measurement, first base corresponding to -55 respectively, and temperature into subtraction counter register, subtraction counter and temperature registers are preset at -55 corresponding to a base value. Subtraction counter to the low temperature coefficient crystal oscillator pulse signals generated by subtraction count, when the subtraction counter preset value is reduced to 0, the temperature register value plus 1, subtraction counter preset will be loaded again, subtraction counter re-start the low temperature coefficient crystal oscillator generated pulse signal count, and so on until the subtraction counter 2 count to 0, stop the cumulative value of the temperature register at this time the temperature register value shall be measured in the temperature. Figure 4, the slope of the accumulator used to compensate for temperature measurement and correction in the process of non-linear, the output of subtraction to correct preset counter value, as long as the count has not closed the door to repeat the process until the temperature register value reached under test temperature.

Bus connector ST-X junction box protect the box with the ST-D combined to form a double-iron shell, durable, easy installation, and water-resistant, anti-fumigation, anti-corrosion, elegant appearance, easy wiring. Internal terminal block, using imported products, contact good contact, wiring convenient and easy to maintain. Up to 10 temperature sensors and the corresponding connections, there is a path output terminal. Specifications Number of ports: 10 channels Input Voltage: DC5V 10% Ambient temperature: -40 ~ 80 Figure 5 Bus Connector

Dimension: 260x230x90mm The role of the bus connector is a simple digital temperature sensor connection, it is important to connect the sensor is placed on the protection of box office contacts, through the connectors and circuit connections, ensuring the stability of electrical connections. Temperature Acquisition ST-A temperature of the collector's role includes digital temperature sensor to provide power to multiple digital temperature sensor for temperature collected and stored in accordance with the order that Lonworks the use of advanced Technology to ensure the system's high-speed information exchange and data collection, enhance reliability of the system. Temperature Acquisition using the standard waterproof casing, can adapt to the scene of the harsh environment, sealed good, anti-fumigation. And the temperature of the collector with over-voltage, over current, surge, isolation, lightning protection circuit. Temperature sensor via the bus connector to connect to the temperature of collector, the connection cable lengths up to 100 meters, each temperature of the collector can be connected to 20 temperature sensors. Technical parameters: Input voltage: AC220V 20% Temperature Points: 20 points Means of communication: Lonworks field bus Communication distance: 1800m (non-relay) Figure 6 Temperature Collector

Dimension: 300x250x120mm Sampling rate: 5 points / sec

Operating temperature: -20 ~ 80 Collector with the controller as the core to the power of external assistance, the whole and communications, data acquisition channel, sound and light directions and other functions, to form a complete equipment. ST-N Data Converters Figure 8 Data Converters ST-N data converters is a complete system data and issue commands read the important equipment is connected collector and system management computer link. It is the Lonworks bus data can be directly converted into the computer's RS232 input and output data, and effective under the bit machine and put up a bridge between the host computer. Data converters use a standard explosion-proof casing, can adapt to the scene of the harsh environment, sealed good, anti-fumigation. Lonworks cable-free relay maximum transmission distance of more than 1800 meters. Figure 9, the work of the original data converters Data converters installed in the main control room, function is relatively simple, using Lonworks communication module and the RS232 communications circuits built, other parts, including power and status indication. 1-wire bus 1-wire bus is a single-Maxim, a wholly owned subsidiary of Dallas, a proprietary Technology, and now most of the standard serial data communication, such as SPI/I2C/MICROWIRE different, it uses a single signal line, both the transmit clock also transmit data, and data transmission in both directions. It has to save I / O port line resources, simple structure, low cost, easy expansion and maintenance of the bus and many other advantages. 1-wire single-bus for a single host system, to control one or more slave devices. When only one slave in the bus when the system can operate in accordance with a single-node system, and when the number of slaves in the bus when the system in accordance with multi-node system operation.

Timing: Collector when used gap (time slots) to read and write digital temperature sensor data bits and write command word bits: (1) initialization Timing see (Figure 10) host bus t0 moment to send a reset pulse (a minimum of 480us lowlevel signals) followed by the release of the bus at the time t1, and entry into the receiving state digital temperature sensor to detect the rising edge of the bus and then, after waiting for 15-60us temperature sensor in t2 there is always sent pulses (low-level continuous 60-240 us) in the dotted line as shown in Figure Figure 10 Initialization (2) The write gap When the host bus t0 time from high to low when pulling arise when the gap was shown in Figure 11 Figure 12 beginning from the moment t0 within 15us should be required to write the bit sent to the bus after the sensor in t on the bus between 15-60us Sampling If the low write bit is 0 shown in Figure 11 if the high bit is written to write one shown in Figure 12 consecutive gap between the two should be more than 1us. Figure 11 Figure 12 to write a write 0 (3) The reading gap Figure 13, host bus t0 time from high to low when the bus pulled to maintain low 1 s only after the time t1, when the bus pulled up reading gap created when the gap in the t1 time t2 after the time t2 before the time of the effective distance t0 as 15 s that t2 must be completed before the time of host read bits and t0 within 60 s-120 s after the release of the bus

Lonworks Bus Technology Echelon's LonWorks is the United States launched in 1992, the local operating network, initially mainly used in building automation, but soon developed into industrial field networks. LonWorks Technology as the design and implementation of interoperable control network provides a complete, open, product-oriented solution. LonWorks Technology is the core of the Neuron Chip (Neuron Chip). The chip is equipped with three microprocessors: MAC processor to complete media access control; network processor to complete 3 to 6-layer OSI network protocol; application processor to complete the user on-site control applications. Between them to pass the data via the public memory. In the control unit needs to capture and control functions, for which special Neuron Chip Set 11 I / O port. These I / O port can be flexibly configured according to different needs and peripheral equipment interfaces such as RS232, parallel port, timer / counter, interval processing, digital I / O and so on. Reposted elsewhere in the Research Papers Download http://www.hi138.com Traffic Monitoring Subsystem Flow monitoring subsystem include: electromagnetic flowmeter (secondary instrument), acquisition module, protocol converters. Figure 14 Traffic Monitoring Subsystem

Electromagnetic Flowmeter Technical parameters: The measured medium is water; Water resistance structure; Does not change the original pipeline structure; Figure 15 Electromagnetic Flowmeter

Does not change the flow direction; Rated Pressure 1.6Mpa; Protection class IP67; Flange-mounted. Converter Technical parameters:

Protection class IP65; Output interface 4 ~ 20mA; Measurement accuracy 0.5%; Figure 16 Flow of secondary tables Acquisition Module Technical parameters: Isolation voltage 3000VDC; The effective resolution of 16 bits; Channel 8-channel differential; Figure 17 Acquisition I / O Modules

Enter supporting 4 ~ 20mA; communication protocol Modbus-485; Protocol Converter Most industrial computer systems come with standard RS-232 port. While the RS-232 has been widely used, but its transmission rate, transmission distance and the network capacity and there are still certain restrictions. RS-422 and RS-485 standard data and control signals through the use of differential signal transmission, the RS-232 to overcome the deficiencies. Isolated converter allows you the earlier RS-232 systems that take full advantage of RS-422 and RS-485 advantages. It can transparently convert RS-232 signals to RS-422 and RS-485 signals. You do not change any of the PC hardware and software. Converter can help you easily establish a set of PC-based hardware, industrial grade long-range communication systems. It is able to extend the communication distance of 1200 meters (4000 feet), or an additional 32 connected nodes. Control of implementation of the subsystem This system to control the content contains two aspects: the valve opening degree of control and pressure pump start-stop control. When the blast furnace cooling system needs to flow to small-scale adjustments, through the intelligent electric valve controller to adjust the valve opening so as to adjust to the designated opening degree; when opening the valve has been adjusted to the largest still did not play a role in controlling heat flow, given by controlling the relay to start the pressure pump. Intelligent electric valve controller System has a communication function, can receive host computer's instructions, remote digital control. Operation processed control signal generated by AC motor drives. Volume of the valve control valve opening, in applications will often need to be based on the actual valve open or closed, or open to a certain extent, and even in some law of the dynamic switch. Single-chip microprocessor and peripheral chips using composed of intelligent position control unit, receiving a uniform standard DC signals (eg, 4 ~ 20 mA current signal), via signal processing and A / D conversion sent to the microprocessor, micro-processing machine will handle the data as a control after the results of the command and control targets compared to verify the control results.

Pump Relay Controller Controller acceptance of host computer commands, command execution closed or disconnected in accordance with pressure pump control relays, thereby controlling the pressure pump start-stop. Operational Analysis and Control of storage subsystem The subsystem features include: computing, real-time data broadcasting, analysis, control and storage. Operational Features 1. Heat intensity calculation In the corresponding bus access to the various monitoring points on the temperature, flow, and other data, and the monitoring data in accordance with their numbers compare with a database query in number, after which corresponds to their physical location, to complete the calculation. Namely, to find in the database to a location on the water temperature sensor number, into the water temperature sensor number, meter number, etc., and based on these numbers in the temperature and flow data in the query, you can obtain the corresponding values. And then query the database to the user to set the size, heat capacity and other data, based on these data the completion of heat flux intensity calculated as follows: Q = q * C * * (To-Ti) A Q: heat flux intensity (W/m2); q: flow rate (L / s); C: heat capacity (J / Kg * ); : Medium Density (Kg / L); To: water temperature ( ); Ti: Entry water temperature ( ); A: single-walled cooling area (m2) 2 furnace wall thickness mathematical model The model analysis of the cooling wall heat transfer process, you can simplify that the furnace wall, the heat loss have all been taken away by cooling water. Model assumes that (1) furnace wall heat transfer to conduction heat transfer in the main, gas and slag skin, cooling water and water in order to convection heat transfer between the inner wall of the main; (2) The furnace wall heat conduction along the radial direction only, namely the establishment of this model is the one-dimensional heat transfer model;

(3) temperature change over time is very small, so the system can be considered as steady state or quasi-steady state; (4) The model of the material involved in the calculations, such as coating, cooling, and body wall hanging slag and so on, are each uniform; (5) furnace cooling water, cooling wall, hanging slag thermal conductivity coefficient is isotropic, but it is varies with temperature changes, that is, the variable property heat transfer problem. (6) The heat transfer process does not 'heat', and no heat accumulation.

Analysis of the heat transfer process: Furnace gas and furnace charge and the slag skin in order to convection heat transfer between the hot side the main heat flux intensity q1 as follows: Furnace wall (remnants of brick lining slag skin) within the conduction heat transfer, heat flux intensity q2 as follows: (3) Cooling-wall surface layer of body heat conduction heat transfer, heat flux intensity q3 as follows: (4) from the cooling wall to the cooling water body between the four thermal resistance: airgap layer thermal resistance r1; pipe coating thermal conductivity of thermal resistance r2; the heat pipe wall thermal resistance r3; pipe inner surface convection thermal resistance and water r4. Therefore, from the body wall into the cooling water cooling heat transfer through the air gap heat transfer, coating thermal conductivity, water wall thermal conductivity and wall heat transfer and cooling water, the process of heat transfer process is more complex. To simplify the processing, will stave body and cooling water with an equivalent heat transfer between the convective heat transfer, said, so heat intensity q4 as follows: In accordance with the principle of equal heat flow: q = q1 = q2 = q3 = q4 Q1 ~ q4 will be replaced with the q available:

Paper Keywords: blast furnace cooling water temperature difference between flow temperature sensor monitoring system for digital automatic control Abstract: Using digital temperature sensors, electromagnetic flow meters for blast furnace cooling water system for monitoring the temperature and flow parameters, while the basis of these data and historical records and artificial setting parameters for analysis and comparison to confirm the cooling water system of blast furnace operation status, poor state and the necessary adjustments. Introduction In the blast furnace production process, as reflected in the furnace produces a lot of heat, no lining materials are difficult to sustain such a high temperature, they must be reasonable furnace cooling, while the effective control of the cooling medium in order to achieve effective cooling so that neither endanger the life of refractories, but also will not be affected by leakage of the cooling element BF operation. Therefore, the cooling medium on the blast furnace necessary monitoring and control is particularly important. This paper presented the blast furnace water-cooled parts of a system to monitor and control the composition and working principle. Blast furnace cooling water system of the more important of several parameters: The role of Blast Furnace Cooling: 1. Lower lining temperature, so that lining to maintain a certain intensity, to maintain a reasonable operating furnace, blast furnace to extend the life and safety in production. 2. The formation of a protective slag skin, steel and graphite layer, to protect the work of lining and replaced the lining. 3. Protection of furnace shell, the pillars and other metal structures, from the effect of heat stress, and some equipment, such as draft, slag mouth, hot-air valve such as water cooled to prolong their life. 4. Some of the cooling equipment can play a supportive part of the brick lining effect. Its role, and the relative importance of reducing the temperature, the heat away to form a protective slag skin, to maintain a rational furnace. Therefore, the cooling system in different locations in the amount of heat taken away is very important, there are cooler heat balance analysis shows that the cooling water taken away by the heat and water, and out of the water temperature, water is proportional to the specific heat capacity, while the specific heat capacity of water is a constant, Therefore, cooling water, an important parameter that we need to monitor the water flow into and out of the water temperature. Through our branch pipe cooler inlet or outlet flow meter is installed to obtain the flow value, through the inlet and outlet temperature sensors were installed to get out of the water temperature, obtained by calculating the difference in temperature. The cooling water system of blast furnace control and regulation of water flow is mainly to adjust, adjust the cooling water flow is the primary means of regulating water control valve opening and start-pressure pumps to increase water pressure in two ways. So we have to do is to monitor the blast furnace of the cooling water out of the water temperature and flow rate, through the heat flux intensity is calculated, and then under the heat flux intensity on the blast furnace wall thickness of the current position to diagnose the situation, and partial or total volume of water to make the appropriate adjustment. System Introduction

System from the temperature monitoring function is divided into subsystems, flow monitoring subsystem, control the implementation of subsystems, operation analysis control storage subsystem and the query subsystem five parts (Figure 1). Figure 1 Schematic diagram of blast furnace cooling system control Temperature Monitoring Temperature Monitoring Subsystem subsystem constitutes a Temperature monitoring subsystem devices including: digital temperature sensor, bus connector, the temperature collector, data converters and so on. System structure (figure 2): Figure 2: Schematic diagram of temperature monitoring subsystem Temperature Sensor Temperature sensors used in the United States imported digital temperature sensing element, its high precision, anti-interference ability, and wide temperature range of features makes the lowtemperature measurement systems use very large. Its shell is made of stainless steel, waterproof, corrosion-resistant, can be in poor conditions and temperature environments. The probe easy to install, replace them convenient and good maintainability. The internal digital temperature sensor has a separate address number, the system based on sub-technical parameters Operating voltage: DC5V 10% Measurement Accuracy: 0.1 Temperature range: -55 ~ 125 Communication lines: RVVP 3x0.3 (ambient temperature 70 ) Or AFP 3x0.3 (ambient temperature 220 ) Dimensions: probe length 50mm, male thread M16 Figure 3 Digital Temperature Sensor Principles of Digital Temperature Sensor temperature Figure 4 Principle of Digital Temperature Sensor temperature Measuring principle of temperature sensor shown in Figure (Figure 4) as shown in Figure medium and low temperature coefficient of the crystal oscillation frequency affected by the temperature is very small, used to generate a fixed frequency pulse signal sent to subtract counter, high-temperature coefficient crystal With the temperature of its vibration frequency of significant changes, the resulting signal as the subtraction of the two pulse counter input, the figure also implies counting the door, when the count is the door opened, the temperature sensor on the low temperature coefficient of oscillator clock pulse count, and then complete the temperature measurement. Count the door open time by high-temperature coefficient of oscillator is determined before each measurement, first base corresponding to -55 respectively, and temperature into subtraction counter register, subtraction counter and temperature registers are preset at -55 corresponding to a base value. Subtraction counter to the low temperature coefficient crystal oscillator pulse signals generated by subtraction count, when the subtraction counter preset value is reduced to 0, the temperature register value plus 1, subtraction counter preset will be loaded again, subtraction counter re-start the low temperature coefficient crystal oscillator generated

pulse signal count, and so on until the subtraction counter 2 count to 0, stop the cumulative value of the temperature register at this time the temperature register value shall be measured in the temperature. Figure 4, the slope of the accumulator used to compensate for temperature measurement and correction in the process of non-linear, the output of subtraction to correct preset counter value, as long as the count has not closed the door to repeat the process until the temperature register value reached under test temperature. Bus connector ST-X junction box protect the box with the ST-D combined to form a double-iron shell, durable, easy installation, and water-resistant, anti-fumigation, anti-corrosion, elegant appearance, easy wiring. Internal terminal block, using imported products, contact good contact, wiring convenient and easy to maintain. Up to 10 temperature sensors and the corresponding connections, there is a path output terminal. Specifications Number of ports: 10 channels Input Voltage: DC5V 10% Ambient temperature: -40 ~ 80 Figure 5 Bus Connector

Dimension: 260x230x90mm The role of the bus connector is a simple digital temperature sensor connection, it is important to connect the sensor is placed on the protection of box office contacts, through the connectors and circuit connections, ensuring the stability of electrical connections. Temperature Acquisition ST-A temperature of the collector's role includes digital temperature sensor to provide power to multiple digital temperature sensor for temperature collected and stored in accordance with the order that Lonworks the use of advanced Technology to ensure the system's high-speed information exchange and data collection, enhance reliability of the system. Temperature Acquisition using the standard waterproof casing, can adapt to the scene of the harsh environment, sealed good, anti-fumigation. And the temperature of the collector with over-voltage, over current, surge, isolation, lightning protection circuit. Temperature sensor via the bus connector to connect to the temperature of collector, the connection cable lengths up to 100 meters, each temperature of the collector can be connected to 20 temperature sensors. Technical parameters: Input voltage: AC220V 20% Temperature Points: 20 points Means of communication: Lonworks field bus Communication distance: 1800m (non-relay) Figure 6 Temperature Collector

Dimension: 300x250x120mm Sampling rate: 5 points / sec Operating temperature: -20 ~ 80 Collector with the controller as the core to the power of external assistance, the whole and communications, data acquisition channel, sound and light directions and other functions, to form a complete equipment. ST-N Data Converters Figure 8 Data Converters ST-N data converters is a complete system data and issue commands read the important equipment is connected collector and system management computer link. It is the Lonworks bus data can be directly converted into the computer's RS232 input and output data, and effective under the bit machine and put up a bridge between the host computer. Data converters use a standard explosion-proof casing, can adapt to the scene of the harsh environment, sealed good, anti-fumigation. Lonworks cable-free relay maximum transmission distance of more than 1800 meters. Figure 9, the work of the original data converters Data converters installed in the main control room, function is relatively simple, using Lonworks communication module and the RS232 communications circuits built, other parts, including power and status indication. 1-wire bus 1-wire bus is a single-Maxim, a wholly owned subsidiary of Dallas, a proprietary Technology, and now most of the standard serial data communication, such as SPI/I2C/MICROWIRE different, it uses a single signal line, both the transmit clock also transmit data, and data transmission in both directions. It has to save I / O port line resources, simple structure, low cost, easy expansion and maintenance of the bus and many other advantages. 1-wire single-bus for a single host system, to control one or more slave devices. When only one slave in the bus when the system can operate in accordance with a single-node system, and when the number of slaves in the bus when the system in accordance with multi-node system operation. Timing: Collector when used gap (time slots) to read and write digital temperature sensor data bits and write command word bits: (1) initialization Timing see (Figure 10) host bus t0 moment to send a reset pulse (a minimum of 480us lowlevel signals) followed by the release of the bus at the time t1, and entry into the receiving state digital temperature sensor to detect the rising edge of the bus and then, after waiting for 15-60us temperature sensor in t2 there is always sent pulses (low-level continuous 60-240 us) in the dotted line as shown in Figure Figure 10 Initialization (2) The write gap

When the host bus t0 time from high to low when pulling arise when the gap was shown in Figure 11 Figure 12 beginning from the moment t0 within 15us should be required to write the bit sent to the bus after the sensor in t on the bus between 15-60us Sampling If the low write bit is 0 shown in Figure 11 if the high bit is written to write one shown in Figure 12 consecutive gap between the two should be more than 1us. Figure 11 Figure 12 to write a write 0 (3) The reading gap Figure 13, host bus t0 time from high to low when the bus pulled to maintain low 1 s only after the time t1, when the bus pulled up reading gap created when the gap in the t1 time t2 after the time t2 before the time of the effective distance t0 as 15 s that t2 must be completed before the time of host read bits and t0 within 60 s-120 s after the release of the bus

Figure 13 time slots Lonworks Bus Technology Echelon's LonWorks is the United States launched in 1992, the local operating network, initially mainly used in building automation, but soon developed into industrial field networks. LonWorks Technology as the design and implementation of interoperable control network provides a complete, open, product-oriented solution. LonWorks Technology is the core of the Neuron Chip (Neuron Chip). The chip is equipped with three microprocessors: MAC processor to complete media access control; network processor to complete 3 to 6-layer OSI network protocol; application processor to complete the user on-site control applications. Between them to pass the data via the public memory. In the control unit needs to capture and control functions, for which special Neuron Chip Set 11 I / O port. These I / O port can be flexibly configured according to different needs and peripheral equipment interfaces such as RS232, parallel port, timer / counter, interval processing, digital I / O and so on. Reposted elsewhere in the Research Papers Download http://www.hi138.com Traffic Monitoring Subsystem Flow monitoring subsystem include: electromagnetic flowmeter (secondary instrument), acquisition module, protocol converters. Figure 14 Traffic Monitoring Subsystem

Electromagnetic Flowmeter Technical parameters: The measured medium is water; Water resistance structure; Does not change the original pipeline structure; Figure 15 Electromagnetic Flowmeter

Does not change the flow direction; Rated Pressure 1.6Mpa; Protection class IP67; Flange-mounted. Converter Technical parameters: Protection class IP65; Output interface 4 ~ 20mA; Measurement accuracy 0.5%; Figure 16 Flow of secondary tables Acquisition Module Technical parameters: Isolation voltage 3000VDC; The effective resolution of 16 bits; Channel 8-channel differential; Figure 17 Acquisition I / O Modules

Enter supporting 4 ~ 20mA; communication protocol Modbus-485; Protocol Converter Most industrial computer systems come with standard RS-232 port. While the RS-232 has been widely used, but its transmission rate, transmission distance and the network capacity and there are still certain restrictions. RS-422 and RS-485 standard data and control signals through the use of differential signal transmission, the RS-232 to overcome the deficiencies. Isolated converter allows you the earlier RS-232 systems that take full advantage of RS-422 and RS-485 advantages. It can transparently convert RS-232 signals to RS-422 and RS-485 signals. You do not change any of the PC hardware and software. Converter can help you easily establish a set of PC-based hardware, industrial grade long-range communication systems. It is able to extend the communication distance of 1200 meters (4000 feet), or an additional 32 connected nodes. Control of implementation of the subsystem This system to control the content contains two aspects: the valve opening degree of control and pressure pump start-stop control. When the blast furnace cooling system needs to flow to small-scale adjustments, through the intelligent electric valve controller to adjust the valve opening so as to adjust to the designated opening degree; when opening the valve has been adjusted to the largest still did not play a role in controlling heat flow, given by controlling the relay to start the pressure pump. Intelligent electric valve controller System has a communication function, can receive host computer's instructions, remote digital

control. Operation processed control signal generated by AC motor drives. Volume of the valve control valve opening, in applications will often need to be based on the actual valve open or closed, or open to a certain extent, and even in some law of the dynamic switch. Single-chip microprocessor and peripheral chips using composed of intelligent position control unit, receiving a uniform standard DC signals (eg, 4 ~ 20 mA current signal), via signal processing and A / D conversion sent to the microprocessor, micro-processing machine will handle the data as a control after the results of the command and control targets compared to verify the control results. Pump Relay Controller Controller acceptance of host computer commands, command execution closed or disconnected in accordance with pressure pump control relays, thereby controlling the pressure pump start-stop. Operational Analysis and Control of storage subsystem The subsystem features include: computing, real-time data broadcasting, analysis, control and storage. Operational Features 1. Heat intensity calculation In the corresponding bus access to the various monitoring points on the temperature, flow, and other data, and the monitoring data in accordance with their numbers compare with a database query in number, after which corresponds to their physical location, to complete the calculation. Namely, to find in the database to a location on the water temperature sensor number, into the water temperature sensor number, meter number, etc., and based on these numbers in the temperature and flow data in the query, you can obtain the corresponding values. And then query the database to the user to set the size, heat capacity and other data, based on these data the completion of heat flux intensity calculated as follows: Q = q * C * * (To-Ti) A Q: heat flux intensity (W/m2); q: flow rate (L / s); C: heat capacity (J / Kg * ); : Medium Density (Kg / L); To: water temperature ( ); Ti: Entry water temperature ( ); A: single-walled cooling area (m2) 2 furnace wall thickness mathematical model The model analysis of the cooling wall heat transfer process, you can simplify that the furnace wall, the heat loss have all been taken away by cooling water. Model assumes that (1) furnace wall heat transfer to conduction heat transfer in the main, gas and slag skin, cooling water and water in order to convection heat transfer between the inner wall of the main; (2) The furnace wall heat conduction along the radial direction only, namely the establishment of this model is the one-dimensional heat transfer model; (3) temperature change over time is very small, so the system can be considered as steady state or quasi-steady state; (4) The model of the material involved in the calculations, such as coating, cooling, and body wall hanging slag and so on, are each uniform; (5) furnace cooling water, cooling wall, hanging slag thermal conductivity coefficient is

isotropic, but it is varies with temperature changes, that is, the variable property heat transfer problem. (6) The heat transfer process does not 'heat', and no heat accumulation.

Analysis of the heat transfer process: Furnace gas and furnace charge and the slag skin in order to convection heat transfer between the hot side the main heat flux intensity q1 as follows: Furnace wall (remnants of brick lining slag skin) within the conduction heat transfer, heat flux intensity q2 as follows: (3) Cooling-wall surface layer of body heat conduction heat transfer, heat flux intensity q3 as follows: (4) from the cooling wall to the cooling water body between the four thermal resistance: airgap layer thermal resistance r1; pipe coating thermal conductivity of thermal resistance r2; the heat pipe wall thermal resistance r3; pipe inner surface convection thermal resistance and water r4. Therefore, from the body wall into the cooling water cooling heat transfer through the air gap heat transfer, coating thermal conductivity, water wall thermal conductivity and wall heat transfer and cooling water, the process of heat transfer process is more complex. To simplify the processing, will stave body and cooling water with an equivalent heat transfer between the convective heat transfer, said, so heat intensity q4 as follows: In accordance with the principle of equal heat flow: q = q1 = q2 = q3 = q4 Q1 ~ q4 will be replaced with the q available:

Paper Keywords: blast furnace cooling water temperature difference between flow temperature sensor monitoring system for digital automatic control Abstract: Using digital temperature sensors, electromagnetic flow meters for blast furnace cooling water system for monitoring the temperature and flow parameters, while the basis of these data and historical records and artificial setting parameters for analysis and comparison to confirm the cooling water system of blast furnace operation status, poor state and the necessary adjustments. Introduction In the blast furnace production process, as reflected in the furnace produces a lot of heat, no lining materials are difficult to sustain such a high temperature, they must be reasonable furnace cooling, while the effective control of the cooling medium in order to achieve effective cooling so that neither endanger the life of refractories, but also will not be affected by leakage of the cooling element BF operation. Therefore, the cooling medium on the blast furnace necessary monitoring and control is particularly important. This paper presented the blast furnace water-cooled parts of a system to monitor and control the composition and working principle. Blast furnace cooling water system of the more important of several parameters: The role of Blast Furnace Cooling: 1. Lower lining temperature, so that lining to maintain a certain intensity, to maintain a reasonable operating furnace, blast furnace to extend the life and safety in production. 2. The formation of a protective slag skin, steel and graphite layer, to protect the work of lining and replaced the lining. 3. Protection of furnace shell, the pillars and other metal structures, from the effect of heat stress, and some equipment, such as draft, slag mouth, hot-air valve such as water cooled to prolong their life. 4. Some of the cooling equipment can play a supportive part of the brick lining effect. Its role, and the relative importance of reducing the temperature, the heat away to form a protective slag skin, to maintain a rational furnace. Therefore, the cooling system in different locations in the amount of heat taken away is very important, there are cooler heat balance analysis shows that the cooling water taken away by the heat and water, and out of the water temperature, water is proportional to the specific heat capacity, while the specific heat capacity of water is a constant, Therefore, cooling water, an important parameter that we need to monitor the water flow into and out of the water temperature. Through our branch pipe cooler inlet or outlet flow meter is installed to obtain the flow value, through the inlet and outlet temperature sensors were installed to get out of the water temperature, obtained by calculating the difference in temperature. The cooling water system of blast furnace control and regulation of water flow is mainly to adjust, adjust the cooling water flow is the primary means of regulating water control valve opening and start-pressure pumps to increase water pressure in two ways. So we have to do is to monitor the blast furnace of the cooling water out of the water temperature and flow rate, through the heat flux intensity is calculated, and then under the heat flux intensity on the blast furnace wall thickness of the current position to diagnose the situation, and partial or total volume of water to make the appropriate adjustment. System Introduction

System from the temperature monitoring function is divided into subsystems, flow monitoring subsystem, control the implementation of subsystems, operation analysis control storage subsystem and the query subsystem five parts (Figure 1). Figure 1 Schematic diagram of blast furnace cooling system control Temperature Monitoring Temperature Monitoring Subsystem subsystem constitutes a Temperature monitoring subsystem devices including: digital temperature sensor, bus connector, the temperature collector, data converters and so on. System structure (figure 2): Figure 2: Schematic diagram of temperature monitoring subsystem Temperature Sensor Temperature sensors used in the United States imported digital temperature sensing element, its high precision, anti-interference ability, and wide temperature range of features makes the lowtemperature measurement systems use very large. Its shell is made of stainless steel, waterproof, corrosion-resistant, can be in poor conditions and temperature environments. The probe easy to install, replace them convenient and good maintainability. The internal digital temperature sensor has a separate address number, the system based on sub-technical parameters Operating voltage: DC5V 10% Measurement Accuracy: 0.1 Temperature range: -55 ~ 125 Communication lines: RVVP 3x0.3 (ambient temperature 70 ) Or AFP 3x0.3 (ambient temperature 220 ) Dimensions: probe length 50mm, male thread M16 Figure 3 Digital Temperature Sensor Principles of Digital Temperature Sensor temperature Figure 4 Principle of Digital Temperature Sensor temperature Measuring principle of temperature sensor shown in Figure (Figure 4) as shown in Figure medium and low temperature coefficient of the crystal oscillation frequency affected by the temperature is very small, used to generate a fixed frequency pulse signal sent to subtract counter, high-temperature coefficient crystal With the temperature of its vibration frequency of significant changes, the resulting signal as the subtraction of the two pulse counter input, the figure also implies counting the door, when the count is the door opened, the temperature sensor on the low temperature coefficient of oscillator clock pulse count, and then complete the temperature measurement. Count the door open time by high-temperature coefficient of oscillator is determined before each measurement, first base corresponding to -55 respectively, and temperature into subtraction counter register, subtraction counter and temperature registers are preset at -55 corresponding to a base value. Subtraction counter to the low temperature coefficient crystal oscillator pulse signals generated by subtraction count, when the subtraction counter preset value is reduced to 0, the temperature register value plus 1, subtraction counter preset will be loaded again, subtraction counter re-start the low temperature coefficient crystal oscillator generated

pulse signal count, and so on until the subtraction counter 2 count to 0, stop the cumulative value of the temperature register at this time the temperature register value shall be measured in the temperature. Figure 4, the slope of the accumulator used to compensate for temperature measurement and correction in the process of non-linear, the output of subtraction to correct preset counter value, as long as the count has not closed the door to repeat the process until the temperature register value reached under test temperature. Bus connector ST-X junction box protect the box with the ST-D combined to form a double-iron shell, durable, easy installation, and water-resistant, anti-fumigation, anti-corrosion, elegant appearance, easy wiring. Internal terminal block, using imported products, contact good contact, wiring convenient and easy to maintain. Up to 10 temperature sensors and the corresponding connections, there is a path output terminal. Specifications Number of ports: 10 channels Input Voltage: DC5V 10% Ambient temperature: -40 ~ 80 Figure 5 Bus Connector

Dimension: 260x230x90mm The role of the bus connector is a simple digital temperature sensor connection, it is important to connect the sensor is placed on the protection of box office contacts, through the connectors and circuit connections, ensuring the stability of electrical connections. Temperature Acquisition ST-A temperature of the collector's role includes digital temperature sensor to provide power to multiple digital temperature sensor for temperature collected and stored in accordance with the order that Lonworks the use of advanced Technology to ensure the system's high-speed information exchange and data collection, enhance reliability of the system. Temperature Acquisition using the standard waterproof casing, can adapt to the scene of the harsh environment, sealed good, anti-fumigation. And the temperature of the collector with over-voltage, over current, surge, isolation, lightning protection circuit. Temperature sensor via the bus connector to connect to the temperature of collector, the connection cable lengths up to 100 meters, each temperature of the collector can be connected to 20 temperature sensors. Technical parameters: Input voltage: AC220V 20% Temperature Points: 20 points Means of communication: Lonworks field bus Communication distance: 1800m (non-relay) Figure 6 Temperature Collector

Dimension: 300x250x120mm Sampling rate: 5 points / sec Operating temperature: -20 ~ 80 Collector with the controller as the core to the power of external assistance, the whole and communications, data acquisition channel, sound and light directions and other functions, to form a complete equipment. ST-N Data Converters Figure 8 Data Converters ST-N data converters is a complete system data and issue commands read the important equipment is connected collector and system management computer link. It is the Lonworks bus data can be directly converted into the computer's RS232 input and output data, and effective under the bit machine and put up a bridge between the host computer. Data converters use a standard explosion-proof casing, can adapt to the scene of the harsh environment, sealed good, anti-fumigation. Lonworks cable-free relay maximum transmission distance of more than 1800 meters. Figure 9, the work of the original data converters Data converters installed in the main control room, function is relatively simple, using Lonworks communication module and the RS232 communications circuits built, other parts, including power and status indication. 1-wire bus 1-wire bus is a single-Maxim, a wholly owned subsidiary of Dallas, a proprietary Technology, and now most of the standard serial data communication, such as SPI/I2C/MICROWIRE different, it uses a single signal line, both the transmit clock also transmit data, and data transmission in both directions. It has to save I / O port line resources, simple structure, low cost, easy expansion and maintenance of the bus and many other advantages. 1-wire single-bus for a single host system, to control one or more slave devices. When only one slave in the bus when the system can operate in accordance with a single-node system, and when the number of slaves in the bus when the system in accordance with multi-node system operation. Timing: Collector when used gap (time slots) to read and write digital temperature sensor data bits and write command word bits: (1) initialization Timing see (Figure 10) host bus t0 moment to send a reset pulse (a minimum of 480us lowlevel signals) followed by the release of the bus at the time t1, and entry into the receiving state digital temperature sensor to detect the rising edge of the bus and then, after waiting for 15-60us temperature sensor in t2 there is always sent pulses (low-level continuous 60-240 us) in the dotted line as shown in Figure Figure 10 Initialization (2) The write gap

When the host bus t0 time from high to low when pulling arise when the gap was shown in Figure 11 Figure 12 beginning from the moment t0 within 15us should be required to write the bit sent to the bus after the sensor in t on the bus between 15-60us Sampling If the low write bit is 0 shown in Figure 11 if the high bit is written to write one shown in Figure 12 consecutive gap between the two should be more than 1us. Figure 11 Figure 12 to write a write 0 (3) The reading gap Figure 13, host bus t0 time from high to low when the bus pulled to maintain low 1 s only after the time t1, when the bus pulled up reading gap created when the gap in the t1 time t2 after the time t2 before the time of the effective distance t0 as 15 s that t2 must be completed before the time of host read bits and t0 within 60 s-120 s after the release of the bus

Figure 13 time slots Lonworks Bus Technology Echelon's LonWorks is the United States launched in 1992, the local operating network, initially mainly used in building automation, but soon developed into industrial field networks. LonWorks Technology as the design and implementation of interoperable control network provides a complete, open, product-oriented solution. LonWorks Technology is the core of the Neuron Chip (Neuron Chip). The chip is equipped with three microprocessors: MAC processor to complete media access control; network processor to complete 3 to 6-layer OSI network protocol; application processor to complete the user on-site control applications. Between them to pass the data via the public memory. In the control unit needs to capture and control functions, for which special Neuron Chip Set 11 I / O port. These I / O port can be flexibly configured according to different needs and peripheral equipment interfaces such as RS232, parallel port, timer / counter, interval processing, digital I / O and so on. Reposted elsewhere in the Research Papers Download http://www.hi138.com Traffic Monitoring Subsystem Flow monitoring subsystem include: electromagnetic flowmeter (secondary instrument), acquisition module, protocol converters. Figure 14 Traffic Monitoring Subsystem

Electromagnetic Flowmeter Technical parameters: The measured medium is water; Water resistance structure; Does not change the original pipeline structure; Figure 15 Electromagnetic Flowmeter

Does not change the flow direction; Rated Pressure 1.6Mpa; Protection class IP67; Flange-mounted. Converter Technical parameters: Protection class IP65; Output interface 4 ~ 20mA; Measurement accuracy 0.5%; Figure 16 Flow of secondary tables Acquisition Module Technical parameters: Isolation voltage 3000VDC; The effective resolution of 16 bits; Channel 8-channel differential; Figure 17 Acquisition I / O Modules

Enter supporting 4 ~ 20mA; communication protocol Modbus-485; Protocol Converter Most industrial computer systems come with standard RS-232 port. While the RS-232 has been widely used, but its transmission rate, transmission distance and the network capacity and there are still certain restrictions. RS-422 and RS-485 standard data and control signals through the use of differential signal transmission, the RS-232 to overcome the deficiencies. Isolated converter allows you the earlier RS-232 systems that take full advantage of RS-422 and RS-485 advantages. It can transparently convert RS-232 signals to RS-422 and RS-485 signals. You do not change any of the PC hardware and software. Converter can help you easily establish a set of PC-based hardware, industrial grade long-range communication systems. It is able to extend the communication distance of 1200 meters (4000 feet), or an additional 32 connected nodes. Control of implementation of the subsystem This system to control the content contains two aspects: the valve opening degree of control and pressure pump start-stop control. When the blast furnace cooling system needs to flow to small-scale adjustments, through the intelligent electric valve controller to adjust the valve opening so as to adjust to the designated opening degree; when opening the valve has been adjusted to the largest still did not play a role in controlling heat flow, given by controlling the relay to start the pressure pump. Intelligent electric valve controller System has a communication function, can receive host computer's instructions, remote digital

control. Operation processed control signal generated by AC motor drives. Volume of the valve control valve opening, in applications will often need to be based on the actual valve open or closed, or open to a certain extent, and even in some law of the dynamic switch. Single-chip microprocessor and peripheral chips using composed of intelligent position control unit, receiving a uniform standard DC signals (eg, 4 ~ 20 mA current signal), via signal processing and A / D conversion sent to the microprocessor, micro-processing machine will handle the data as a control after the results of the command and control targets compared to verify the control results. Pump Relay Controller Controller acceptance of host computer commands, command execution closed or disconnected in accordance with pressure pump control relays, thereby controlling the pressure pump start-stop. Operational Analysis and Control of storage subsystem The subsystem features include: computing, real-time data broadcasting, analysis, control and storage. Operational Features 1. Heat intensity calculation In the corresponding bus access to the various monitoring points on the temperature, flow, and other data, and the monitoring data in accordance with their numbers compare with a database query in number, after which corresponds to their physical location, to complete the calculation. Namely, to find in the database to a location on the water temperature sensor number, into the water temperature sensor number, meter number, etc., and based on these numbers in the temperature and flow data in the query, you can obtain the corresponding values. And then query the database to the user to set the size, heat capacity and other data, based on these data the completion of heat flux intensity calculated as follows: Q = q * C * * (To-Ti) A Q: heat flux intensity (W/m2); q: flow rate (L / s); C: heat capacity (J / Kg * ); : Medium Density (Kg / L); To: water temperature ( ); Ti: Entry water temperature ( ); A: single-walled cooling area (m2) 2 furnace wall thickness mathematical model The model analysis of the cooling wall heat transfer process, you can simplify that the furnace wall, the heat loss have all been taken away by cooling water. Model assumes that (1) furnace wall heat transfer to conduction heat transfer in the main, gas and slag skin, cooling water and water in order to convection heat transfer between the inner wall of the main; (2) The furnace wall heat conduction along the radial direction only, namely the establishment of this model is the one-dimensional heat transfer model; (3) temperature change over time is very small, so the system can be considered as steady state or quasi-steady state; (4) The model of the material involved in the calculations, such as coating, cooling, and body wall hanging slag and so on, are each uniform; (5) furnace cooling water, cooling wall, hanging slag thermal conductivity coefficient is

isotropic, but it is varies with temperature changes, that is, the variable property heat transfer problem. (6) The heat transfer process does not 'heat', and no heat accumulation.

Analysis of the heat transfer process: Furnace gas and furnace charge and the slag skin in order to convection heat transfer between the hot side the main heat flux intensity q1 as follows: Furnace wall (remnants of brick lining slag skin) within the conduction heat transfer, heat flux intensity q2 as follows: (3) Cooling-wall surface layer of body heat conduction heat transfer, heat flux intensity q3 as follows: (4) from the cooling wall to the cooling water body between the four thermal resistance: airgap layer thermal resistance r1; pipe coating thermal conductivity of thermal resistance r2; the heat pipe wall thermal resistance r3; pipe inner surface convection thermal resistance and water r4. Therefore, from the body wall into the cooling water cooling heat transfer through the air gap heat transfer, coating thermal conductivity, water wall thermal conductivity and wall heat transfer and cooling water, the process of heat transfer process is more complex. To simplify the processing, will stave body and cooling water with an equivalent heat transfer between the convective heat transfer, said, so heat intensity q4 as follows: In accordance with the principle of equal heat flow: q = q1 = q2 = q3 = q4 Q1 ~ q4 will be replaced with the q available: