【創(chuàng)新技術之一】
突破高爐“黑箱”：MEAI高爐冶煉過程全三維可視化在線輔助分析系統(tǒng)及其實際應用
在高爐煉鐵領域，理解和控制高爐內部的冶煉運行狀態(tài)是確保高爐長期穩(wěn)定順行、提升生產效率和節(jié)能降耗的關鍵。然而，我們的理解多半依賴于常規(guī)的傳感器檢測或者傳統(tǒng)的高爐可視化方法，如爐頂成像、風口攝像、激光測料面等。這些方法僅能提供間接的、表面的、有限的信息，使我們的洞察力停留在高爐黑箱的外部。MEAI高爐冶煉過程全三維可視化在線輔助分析系統(tǒng)打破了這種限制，使我們能深入到高爐的"黑箱"之中，全方位、全景深地揭示高爐冶煉過程的內在機理。
全新的視角：全三維高爐冶煉過程可視化
系統(tǒng)的五大創(chuàng)新模塊
MEAI高爐冶煉過程全三維可視化在線輔助分析系統(tǒng)的精髓在于其五大核心模塊，以業(yè)界最高技術規(guī)格進行深入研發(fā)：
1、全三維操作爐型、爐墻結厚及渣皮形貌
2、全三維布料料層分布
3、全三維軟熔帶分布形貌
4、全三維爐缸侵蝕形貌及保護層分布
5、全三維煤氣流場分布
以上五大模塊互為支撐，除了這五大模塊以外，還有一些改進的工藝模型作為輔助，共同構成了一個全面、立體的高爐冶煉過程揭示體系，共同揭示了高爐當前的冶煉狀況，讓操作者能夠360度立體直觀地了解高爐內的冶煉過程，并為高爐下一步操作提供全三維量化依據，以便進行精確的操作調劑。
實踐的檢驗：應用案例和驗證
全新定義的高爐可視化
MEAI高爐冶煉過程全三維可視化在線輔助分析系統(tǒng)重新定義了高爐可視化，它不僅提供了一種全新的視角來理解和掌握高爐冶煉過程，也為高爐長期穩(wěn)定順行提供了強大的輔助分析功能。對冶金煉鐵行業(yè)而言，這套系統(tǒng)的出現(xiàn)無疑是一種革新，它將幫助我們更好地理解高爐冶煉過程，優(yōu)化操作，提升產品質量，推動行業(yè)的科技發(fā)展。
未來展望
MEAI高爐冶煉過程全三維可視化在線輔助分析系統(tǒng)是高爐可視化技術的重大突破，它提供了我們以前無法得到的、全方位、深度的洞察。隨著這種技術的進一步發(fā)展，我們期待在未來看到更加智能化、自動化的高爐操作，實現(xiàn)真正意義上的“高爐專家診斷”，為煉鐵行業(yè)的可持續(xù)發(fā)展做出更大的貢獻。
【創(chuàng)新技術之二】
MEAI新型鐵前一體化多方案智能優(yōu)化配料系統(tǒng)：降低鐵前成本的強大工具
當今的鋼鐵工業(yè)生產，如何有效地降低成本和提高效率是所有企業(yè)都必須面對的重要挑戰(zhàn)。MEAI新型鐵前一體化多方案智能優(yōu)化配料系統(tǒng)，其核心是由MEAI團隊基于人工智能技術和鐵前配料工藝研究的深度融合，歷經多年研發(fā)而成的一套專門用于鐵前領域優(yōu)化配料的強大模型算法，實現(xiàn)了真正意義上的鐵前“一體化”多方案智能優(yōu)化配料。這個系統(tǒng)為企業(yè)提供了一種強大的降本增效的解決方案，為企業(yè)的持續(xù)發(fā)展注入了新的活力。
系統(tǒng)技術優(yōu)勢
MEAI新型鐵前一體化多方案智能優(yōu)化配料系統(tǒng)的技術優(yōu)勢主要體現(xiàn)在以下幾個方面：
深度融合人工智能技術：系統(tǒng)通過對長期生產積累的數據進行深度挖掘和分析，能夠量化各評價指標的權重分配比例，自動生成客觀的評價體系?；阼F前各工藝段配料工藝與人工智能技術深度融合，研發(fā)了一套專門用于鐵前配料優(yōu)化的強大模型算法，打破了傳統(tǒng)局限，大大拓展了配料的思路，為鐵礦粉采購及各工藝段的配料優(yōu)化提供了有力的支撐，幫助企業(yè)降低成本。
強大的預測功能：系統(tǒng)基于燒結現(xiàn)場實際過程數據的積累，能夠實現(xiàn)燒結礦質量的大數據預測，并在智能優(yōu)化配料中實現(xiàn)燒結礦質量的目標控制。這種預測能力，不僅可以幫助企業(yè)提前做好生產準備，降低生產風險，也能進一步提高生產效率，降低成本。
一體化多方案智能優(yōu)化配料：系統(tǒng)能夠根據各工藝段的要求，既能實現(xiàn)各獨立工藝段的多方案優(yōu)化配料推薦，也可以基于高爐終端的工藝要求實現(xiàn)一體化多方案優(yōu)化配料推薦，同步給出多種“混勻-燒結-高爐”的一體化配料優(yōu)化方案，同時確保高爐爐料結構合理性，實現(xiàn)高性價比預配料，有效降低鐵水成本。
強大的擴展性和適應性：MEAI系統(tǒng)具有強大的擴展性和適應性，無論是面對嚴苛的條件，還是復雜的控制目標，甚至是用戶的個性化需求，系統(tǒng)都能夠靈活應對，提供滿足需求的優(yōu)化方案。這種高度的靈活性和適應性，使得該系統(tǒng)能夠在各種不同的生產環(huán)境中發(fā)揮出強大的效能。
降低人員經驗要求：MEAI系統(tǒng)對于崗位人員經驗要求大幅度降低，實現(xiàn)“零門檻”。這意味著，即使是沒有專業(yè)背景的操作員，也能夠快速上手并有效運用這個系統(tǒng)，從而進一步提高生產效率。
系統(tǒng)功能模塊
在MEAI新型鐵前一體化多方案智能優(yōu)化配料系統(tǒng)中，各個功能模塊都有其獨特的作用，共同構成了一個完整的優(yōu)化配料解決方案。
在線數據采集及原料信息數據庫模塊：負責完成原料信息數據的在線采集，并建立鐵前原料資源數據庫。這個數據庫將包含所有關于原料的信息，為后續(xù)的配料優(yōu)化提供了重要的數據支持。
新型鐵礦粉評價體系：基于人工經驗權重的評價功能，以及基于評價權重智能挖掘的評價功能，為鐵礦粉的評價提供了全新的評價體系。這個體系能夠從用戶對原料使用效果的經驗中，通過智能數據挖掘，量化各評價指標的權重分配比例。
鐵前配料核算體系模塊：負責混勻配料核算、燒結配料核算、高爐配料核算以及一體化配料核算。這些模塊的核算功能主要替代現(xiàn)場EXCLE人工核算，并提供更強的核算功能，確保核算的準確性，有效避免人為錯誤。
多方案智能優(yōu)化配料體系：這是系統(tǒng)的核心，它提供了一系列既相互獨立又相互關聯(lián)的優(yōu)化配料模塊和功能，既能滿足單一工藝段的配料優(yōu)化需求，也能滿足鐵前一體化配料優(yōu)化的需求，最終目標是打破傳統(tǒng)配料局限性，實現(xiàn)精細化配料，即在保證質量的前提下，通過自動生成的多種優(yōu)化配料方案，有效地降低成本。功能包括：
（1）混勻配料多方案優(yōu)化：系統(tǒng)能夠提供多種混勻配料的優(yōu)化方案，滿足不同的生產需求并降低混勻料成本。
（2）燒結配料多方案優(yōu)化：根據燒結過程的特點和需求，系統(tǒng)能夠提供多種燒結配料的優(yōu)化方案，降低燒結成本。
（3）高爐配料多方案優(yōu)化：考慮到高爐生產的特殊性，系統(tǒng)能夠貼合當前生產狀況提供多種可執(zhí)行的高爐配料優(yōu)化方案，有效降低鐵水成本。
（4）燒結礦質量預測：通過對燒結過程數據的分析和學習，系統(tǒng)能夠預測燒結礦的質量，為配料優(yōu)化提供參考。
（5）一體化多方案智能優(yōu)化配料：系統(tǒng)能夠貼合混勻、燒結、高爐的實際生產情況，提供一體化的多方案優(yōu)化配料方案。這些方案都基于各工藝段設定的目標，通過強大的人工智能模型算法自動生成，實現(xiàn)真正意義上的“一體化”優(yōu)化配料，打破傳統(tǒng)的配料局限，為操作者提供更多的配料思路和優(yōu)化方案選擇。
系統(tǒng)應用驗證
該系統(tǒng)已在多家鋼鐵企業(yè)進行了應用試算（部分試算案例如下圖所示），應用試算采用現(xiàn)場人工配料單對應的原燃料數據，錄入系統(tǒng)后按照相同的目標要求進行優(yōu)化配料，確定符合當前生產狀況可執(zhí)行的方案，并與人工配料成本進行比較，確定成本優(yōu)化空間，實際應用情況總結如下：
系統(tǒng)所提供的多種配料優(yōu)化方案中，會包含現(xiàn)場料單的配料方案（或非常接近），同時系統(tǒng)會提供很多更優(yōu)方案；
與人工配料方案成本相比，系統(tǒng)所獲得的優(yōu)化配料方案可提供不同幅度的成本優(yōu)化空間，這取決于配料人員的水平；
無論配料人員水平多高，系統(tǒng)一定會提供出比人更優(yōu)化的方案；
大部分配料崗位人員容易產生天然抵觸，該系統(tǒng)是用于幫助配料人員打破傳統(tǒng)局限，有效降低成本的工具，是未來趨勢，應該積極擁抱新技術、利用新技術產生效益。
根據某鋼鐵廠的實際應用反饋，噸鐵成本可降低2到4元，隨著不斷深入應用和功能升級完善，期待該系統(tǒng)發(fā)揮更大的作用。
結論
總的來說，MEAI新型鐵前一體化多方案智能優(yōu)化配料系統(tǒng)通過各個功能模塊的協(xié)同工作，為鋼鐵企業(yè)提供了一種全面、高效的鐵前配料優(yōu)化解決方案，實現(xiàn)了真正意義上的“一體化”多方案智能優(yōu)化配料。這個系統(tǒng)不僅能夠提高配料效率，打破傳統(tǒng)配料思維局限，更重要的是，它能夠幫助企業(yè)實現(xiàn)降低成本的目標，為企業(yè)的發(fā)展提供強大的支持。在未來的鋼鐵生產中，MEAI新型鐵前一體化多方案智能優(yōu)化配料系統(tǒng)將發(fā)揮越來越重要的作用，幫助鋼鐵企業(yè)在激烈的市場競爭中取得優(yōu)勢。
（英文譯文如下）
[Innovation Technology Part 1]
Breaking Through the Blast Furnace "Black Box"
In the field of blast furnace ironmaking, understanding and controlling the smelting operation state inside the blast furnace is the key to ensuring the long-term stable operation of the blast furnace, improving production efficiency, and saving energy and reducing consumption. However, our understanding mostly relies on conventional sensor detection or traditional blast furnace visualization methods, such as top-of-furnace imaging, tuyere imaging, and laser measurement of the material surface. These methods can only provide indirect, superficial, and limited information, leaving our insight on the outside of the blast furnace "black box". The MEAI Blast Furnace Smelting Process 3D Visualization Online Auxiliary Analysis System breaks this limitation, allowing us to delve into the "black box" of the blast furnace, revealing the inner mechanism of the blast furnace smelting process in all directions and depths.
A New Perspective: 3D Visualization of the Blast Furnace Smelting Process
Five Innovative Modules of the System
The essence of the MEAI Blast Furnace Smelting Process 3D Visualization Online Auxiliary Analysis System lies in its five core modules, which are deeply researched with the highest technical specifications in the industry:
Full 3D blast furnace operative profile,
shaft wall accretion, and shaft scaffold distribution
Full 3D distribution of blast furnace burden layers
Full 3D distribution of cohesive zone
Full 3D hearth erosion and the protective layer distribution
Full 3D distribution of blast furnace gas flow
The above five modules support each other. In addition to these five modules, there are some improved process models as aids, together forming a comprehensive, three-dimensional system revealing the blast furnace smelting process, jointly revealing the current smelting status of the blast furnace, allowing operators to understand the smelting process inside the blast furnace in a 360-degree three-dimensional intuitive way, and providing a 3D quantitative basis for the next step of blast furnace operation, so as to carry out precise operation adjustment.
Test of Practice: Application Cases and Verification
A New Definition of Blast Furnace Visualization
The MEAI Blast Furnace Smelting Process 3D Visualization Online Auxiliary Analysis System redefines blast furnace visualization. It not only provides a new perspective to understand and master the blast furnace smelting process but also provides a powerful auxiliary analysis function for the long-term stable operation of the blast furnace. For the metallurgical ironmaking industry, the emergence of this system is undoubtedly an innovation, it will help us better understand the blast furnace smelting process,optimize operations, improve product quality, and promote the technological development of the industry.
Future Prospects
The MEAI Blast Furnace Smelting Process 3D Visualization Online Auxiliary Analysis System is a major breakthrough in blast furnace visualization technology. It provides us with comprehensive and in-depth insights that we could not obtain before. With the further development of this technology, we look forward to seeing more intelligent and automated blast furnace operations in the future, achieving a true "blast furnace expert diagnosis", and making greater contributions to the sustainable development of the ironmaking industry.
[Innovation Technology Part 2]
A Powerful Tool for Steel Plant to Reduce Ironmaking Costs
System Technical Advantages
The technical advantages of the MEAI new integrated multi-scheme intelligent optimization batching system for ironmaking are mainly reflected in the following aspects:
(1) Deep integration of artificial intelligence technology: The system can quantify the weight distribution ratio of various evaluation indicators by deeply mining and analyzing the data accumulated over a long period of production, and automatically generate an objective evaluation system. Based on the deep integration of the batching process in each process section of ironmaking and artificial intelligence technology, a powerful model algorithm specifically used for optimizing batching in the ironmaking field has been developed, breaking the traditional limitations, greatly expanding the thinking of batching, providing strong support for iron ore powder procurement and batching optimization in each process section, and helping enterprises reduce costs.
(2) Powerful prediction function: The system can realize the big data prediction of the quality of sintered ore based on the accumulation of actual process data on the sintering site, and realize the target control of the quality of sintered ore in intelligent optimization batching. This predictive ability can not only help enterprises prepare for production in advance, reduce production risks, but also further improve production efficiency and reduce costs.
(3) Integrated multi-scheme intelligent optimization batching: The system can recommend multi-scheme optimization batching for each independent process section according to the requirements of each process section, and can also recommend integrated multi-scheme optimization batching based on the process requirements of the blast furnace terminal, and simultaneously give multiple "mixing-sintering-blast furnace" integrated batching optimization schemes, while ensuring the rationality of the blast furnace burden structure, realizing high cost-effective pre-batching, effectively reducing the cost of hot metal.
(4) Strong expandability and adaptability: The MEAI system has strong expandability and adaptability, whether it is facing harsh conditions, complex control objectives, or even user personalized needs, the system can flexibly respond and provide optimization solutions that meet the needs. This high degree of flexibility and adaptability allows the system to play a powerful role in various different production environments.
(5) Reducing personnel experience requirements: The MEAI system greatly reduces the experience requirements for post personnel, achieving "zero threshold". This means that even operators without a professional background can quickly get started and effectively use this system, thereby further improving production efficiency.
System Function Modules
In the MEAI new integrated multi-scheme intelligent optimization batching system for ironmaking, each function module has its unique role, together forming a complete optimization batching solution.
(1) Online data collection and raw material information database module: Responsible for completing the online collection of raw material information data and establishing a raw material resource database for ironmaking. This database will contain all information about raw materials, providing important data support for subsequent batching optimization.
(2) New iron ore powder evaluation system: Based on the evaluation function of artificial experience weight and the evaluation function based on evaluation weight intelligent mining, it provides a new evaluation system for the evaluation of iron ore powder. This system can quantify the weight distribution ratio of various evaluation indicators from the user's experience of the use effect of raw materials through intelligent data mining.
(3) Ironmaking batching accounting system module: Responsible for the accounting of mixing batching, sintering batching, blast furnace batching, and integrated batching. The accounting functions of these modules mainly replace the on-site EXCLE manual accounting and provide stronger accounting functions to ensure the accuracy of the accounting and effectively avoid human errors.
(4) Multi-scheme intelligent optimization batching system: This is the core of the system. It provides a series of optimization batching modules and functions that are both independent and interconnected. It can meet the batching optimization needs of a single process section and also meet the needs of integrated batching optimization for ironmaking. The ultimate goal is to break the limitations of traditional batching, achieve refined batching, and effectively reduce costs by automatically generating various optimization batching schemes while ensuring quality. The functions include:
1) Multi-scheme optimization of mixing batching: The system can provide multiple optimization schemes for mixing batching to meet different production needs and reduce the cost of mixing materials.
2) Multi-scheme optimization of sintering batching: According to the characteristics and needs of the sintering process, the system can provide multiple optimization schemes for sintering batching to reduce sintering costs.
3) Multi-scheme optimization of blast furnace batching: Considering the special nature of blast furnace production, the system can provide multiple executable blast furnace batching optimization schemes that fit the current production situation, effectively reducing the cost of hot metal.
4) Prediction of sinter ore quality: Through the analysis and learning of sintering process data, the system can predict the quality of sintered ore, providing a reference for batching optimization.
5) Integrated multi-scheme intelligent optimization batching: The system can provide an integrated multi-scheme optimization batching scheme that fits the actual production situation of mixing, sintering, and blast furnace. These schemes are all based on the goals set by each process section, and are automatically generated through powerful artificial intelligence model algorithms, achieving true "integrated" optimization batching, breaking the limitations of traditional batching, and providing operators with more batching ideas and optimization scheme choices.
System Application Verification
The system has been applied for trial calculation in several steel companies (some trial calculation cases are shown in the following figures). The application trial calculation uses the raw fuel data corresponding to the on-site manual batching list, enters the system after the same target requirements for optimization batching, determines the executable scheme that meets the current production situation, and compares with the manual batching cost to determine the cost optimization space. The actual application situation is summarized as follows:
(1) Among the various batching optimization schemes provided by the system, there will be the batching scheme of the on-site material list (or very close), and the system will provide many more optimal schemes;
(2) Compared with the cost of manual batching schemes, the optimized batching schemes obtained by the system can provide different degrees of cost optimization space, which depends on the level of batching personnel;
(3) No matter how high the level of batching personnel, the system will definitely provide a more optimized scheme than humans;
According to the actual application feedback from a certain steel plant, the cost per ton of hotmetal can be reduced by 2 to 4 RMB. With the continuous deepening of application and function upgrade, we look forward to this system playing a greater role.
Conclusion
