Tianchuang Robot joins hands with Xianggang to build a full-stack intelligent operation and maintenance management system for blast furnace tuyere of the ironmaking plant

Xianggang is a high-quality steel production base with a level of 10 million tons in southern China. It is also a wide and thick plate production base with the highest production capacity in the world. It is committed to building a steel demonstration enterprise with high-quality products, sophisticated management, complementary industries, intelligence, efficiency, green and low-carbon.

In response to the on-site environment and process requirements of the blast furnace tuyere platform of Xianggang's ironmaking plant, Tianchuang Robot uses robots to replace traditional operation and maintenance personnel to carry out autonomous and intelligent inspection work, accurately guiding the daily operation and maintenance decisions and maintenance management of the ironmaking plant, providing long-term stable and efficient production for the blast furnace. It provides a strong guarantee for long-term stable and efficient production and provides strong support for the high-quality development of Xianggang with the theme of green and intelligent.

Customer Profile

Xiangtan Iron and Steel Group Co., Ltd. is located in the center of the Changsha-Zhuzhou-Xiangtan Economic Circle, the national "two-oriented society" reform pilot zone. It is a high-quality steel production base with a tens of millions of tons in southern China. It has an annual production scale of 12 million tons of steel. It has full-process technical equipment such as coking, sintering, iron-making, steel-making, rolling, etc., and is leading the main equipment and production process industry.

Project Background

Blast furnace ironmaking has the advantages of good technical economy, simple process, large production volume, high labor efficiency, and low energy consumption. This production process technology is currently the mainstream of ironmaking in the world, and most ironmaking in my country is used. This project will pilot the tuyere platform of the No. 4 blast furnace of Xianggang Iron and Steel Works, and use robots to achieve all-round intelligent and unmanned inspection and maintenance goals such as equipment status identification, environmental monitoring, and fault diagnosis in the area.

Business Challenges

Equipment operation and maintenance work in the metallurgical and steel industry is highly streamlined, has high operation risks, and heavy inspection tasks, making it difficult for manual inspections to cover all aspects. By using manual entry methods, data accuracy cannot be guaranteed, paper records are difficult to archive, and historical details are traced back. The process is cumbersome.

Project Objectives

• Establish a full-stack intelligent inspection, operation, maintenance and control system.

• Carry out all-weather non-contact detection and monitoring of equipment status and environmental conditions in the blast furnace tuyere platform area to ensure safe operation.

• Improve the quality and efficiency of inspection and reduce the risks of inspection operations by operation and maintenance personnel.

• Strengthen perception, optimize control, and sharpen operations for the steel industry's digital inspection, operation and maintenance upgrades.

Solutions

The blast furnace direct blowing pipe injects hot air into the blast furnace, which is an important guarantee for the safe production of the blast furnace. The blast furnace direct blowing pipe withstands high temperature, corrosion, thermal fatigue and abrasive erosion for a long time, and is easily burned, causing cooling water to flow into the interior of the blast furnace, causing the furnace temperature to decrease. In severe cases, it may also lead to water vapor explosion, causing the outflow of molten iron and causing a major production accident. Therefore, timely understanding of the temperature change trend of the straight pipe on the tuyere platform, detecting the huge noise caused by gas leakage and the straight pipe burning through, and avoiding the occurrence of major vicious accidents are important prerequisites for ensuring production safety.

In view of the environmental characteristics of the scene such as high temperature, noise, and harmful gases in the working area of the tuyere platform of the No. 4 blast furnace of Xianggang Iron and Steel Works, as well as the distribution of equipment to be monitored on site and the execution of inspection tasks, we have built a full-stack intelligent inspection, operation and maintenance management system with robots as the core, integrated calibration and recognition algorithms, and integrated A centralized control system composed of the system platform.

Blast furnace tuyere platform full-stack intelligent inspection, operation, maintenance and control system

The full-stack intelligent inspection, operation, maintenance and control system of the blast furnace tuyere platform mainly consists of a robot body unit, a centralized control system platform, a charging unit, and a communication unit. Comprehensively replace manual work to realize intelligent and unmanned inspection and monitoring and data report management of the blast furnace tuyere platform area of Xianggang Ironmaking Plant.

The intelligent robot independently performs tasks according to the inspection plan, and conducts automatic inspections of the gooseneck, bellows, elbow, straight blowing pipe, coal gun, hot air shroud and flange upper and lower parts of the tuyere platform and high-temperature areas at relevant positions. At the same time, Through the sensors carried by the robot, the gas concentration of carbon monoxide in the surrounding environment is monitored in real time and the abnormal noise caused by abnormal operation of the equipment is detected.

Through the centralized control system platform, real-time management and control of inspection robots can be carried out online for inspection tasks, and the inspection status and results can be transmitted to the operation and maintenance personnel. The inspection report and alarm information can be obtained in the first time, and the maintenance personnel can be instructed to accurately reach the fault point through two-way voice. After the inspection task is completed, the inspection report can be generated, and the robot inspection screen and inspection results can be stored, which facilitates the operation and maintenance personnel to analyze the equipment operation trend based on data and adjust maintenance strategies and work priorities in a timely manner.

Value Effectiveness

1.Equipment Digital Operation and Maintenance Management

Realize dynamic inspection and intelligent monitoring of the tuyere platform of the fourth blast furnace in the ironmaking plant, improve the frequency of inspection and fault identification accuracy, effectively avoid missing detection of measurement points, reduce subjective and objective interference factors in monitoring results, and control the inspection quality.

2.Efficient Hidden Danger Investigation and Early Warning Mechanism

Display information and data to the management and operation personnel of the dispatch center in a visual manner, and conduct statistics and intelligent analysis based on status information such as process sections and equipment to provide support for management decisions, realize remote control of the operation of the bioreactor, and improve work efficiency.

3.Standardized Ledger for Operation and Maintenance Data

Daily inspection data is classified and stored in real time to facilitate query, statistics and judgment of fault problems. Automatically generate inspection reports or reports to reduce the cost and time of manually selecting useful variables.

4.Ensure Personnel Safety and Release Human Resources

Reduce 1 manual on-site operation point and eliminate 4 3D positions. Reduce the labor intensity of operation and maintenance personnel, release manpower, and engage in more valuable operation and maintenance data analysis and predictive maintenance work. Avoid operation safety risks, keep employees away from dangerous areas, and truly achieve intrinsic safety at the source.