With the improvement of infrared thermal imaging temperature measurement technology, it is an important means to realize temperature measurement. With the rapid development of computer technology, control technology and network communication technology, online real-time infrared temperature measurement of furnace body has become possible, which will facilitate the early detection and diagnosis of furnace body faults, save a lot of manpower and material resources, and realize the automation of infrared temperature measurement of furnace body. It is the key to equip the anode furnace with an infrared online temperature measurement and analysis system to accurately sense the wear or damage of the refractory bricks in real time and in advance, prevent the further falling off of the refractory bricks, and even prevent the furnace body from cracking. Copper water leakage is the key to the anode furnace.

1.Production of anode furnace before using infrared thermal imager

During the operation of the anode furnace, because the temperature near the gas-liquid junction of the gas burner in the furnace and the mixing port of the nitrogen mixing system is too high or the thermal shock is too large, the refractory bricks will be damaged or fall off, and even the furnace body will be broken in serious cases. Before these faults occur, the temperature of local areas on the surface of the anode furnace body will be abnormally high. If the abnormal temperature of the furnace body is not found in time, the furnace body equipment will be damaged, resulting in copper water leakage and other conditions, which will threaten the personal safety of the personnel working in the dangerous operation area, and also bring huge economic losses to the company. At present, the infrared thermometers used are all tested by manually holding them near the anode furnace body. There are great safety risks for personnel. At the same time, this method has a huge vacancy period, and it can not monitor the furnace body temperature in real time 24 hours, which can not meet the requirements of intelligent chemical plants.

As the reduction efficiency of domestic copper smelters is generally low, about 30%, a large amount of natural gas is burned in the furnace, which not only increases the thermal load of the furnace, but also increases the thermal load of the equipment on the exhaust pipe furnace, especially the air cooler and bag dust collector. Once the temperature is uncontrollable, the dust collection filter bag is likely to be burned out, resulting in serious environmental liability accidents, Therefore, it is very important to monitor and adjust the flue gas temperature of anode furnace in real time, and it is imperative to detect and monitor the temperature of furnace body and furnace in real time to achieve visual management.

2.Production of anode furnace after using infrared thermal imager

In view of the above problems, the infrared thermal imaging temperature scanning detection device is carried out, and the thermal imager scans or monitors all the monitored target areas at a fixed time. The monitoring picture is transmitted to the monitoring computer in real time through optical fiber, so as to improve production labor efficiency, strengthen the supervision of furnace safety, optimize process operation, and independently develop the imaging system of infrared thermometer on anode furnace.

As shown in Figure 1 and Figure 2, the self infrared thermal imager has been put into use, and the following achievements have been achieved through on-site production practice:

• Real time display captures the maximum temperature in the picture, and the full Screen multi-point simultaneous scanning temperature measurement display;
• Automatic full screen scanning to capture the highest and lowest temperatures;
• Analyze the temperature of any straight line in the image;
• The temperature scanning analysis is carried out for the relevant areas on the image, and the areas can be moved and changed in size at will, and there can be many different areas for analysis at the same time;
• Analyze and compare multiple regions at the same time; Temperature scanning of any point and line in the image, and recording and analyzing the change trend;
• Scan the temperature in any area in the image, and record and analyze the change trend;
• Automatically calculate the temperature difference between the measured point and the set temperature; And form a digital display, which is convenient for operators to understand and master the temperature distribution of the furnace body.

By summarizing the experience of using the infrared thermal imager, the on-site operators can intuitively judge the temperature distribution of each area of the furnace body by comparing the color distribution of the picture with the color temperature distribution coordinates, and can control the safety of the furnace body in real time. In addition, the on-site temperature measurement and spot inspection are carried out for the areas with high temperature, and the double-layer guarantee ensures the safe use of the furnace body.

For areas with low temperature and dark color, the operator will strengthen the spot inspection in the furnace, confirm the specific situation of the dark color area, and timely arrange the anode furnace to add quartz sand for slag washing and slag discharge, so as to prevent the formation of large slagging blocks in the furnace due to low temperature, resulting in the gradual reduction of the furnace volume, which cannot meet the production needs. At the same time, it can also effectively avoid the shift of the center of gravity of the furnace body caused by the formation of slagging blocks due to low temperature, reduce the driving load of the anode furnace body, and ensure the safe and stable operation of the furnace body.

In addition, through the infrared thermal imaging system, it can also indirectly reflect the combustion atmosphere and effect of the furnace. When the temperature of the furnace body rises as a whole, there is overheating in the anode furnace. The operator can indirectly judge that the furnace temperature is too high according to the color change displayed by the infrared thermal imaging system, and timely reduce the fuel quantity of the burner, so as to control the temperature in the furnace and reduce the thermal load of the smoke exhaust system, and protect the smoke exhaust pipeline and the dust collection equipment on the pipeline.

In the reduction period of anode refining, due to the process characteristics, the reduction efficiency is low, most of the natural gas is burned in the furnace, and the overheating phenomenon in the furnace is more frequent. Through the color change displayed by the infrared thermal imaging system, the operator can timely increase or reduce the amount of nitrogen, adjust the depth of the reduction air pipe into the copper water, the flow of the burner during reduction, and the flow of nitrogen in the mixing system to reasonably adjust the temperature in the furnace, It is of great significance for the safety control of anode furnace to monitor and control the state of anode furnace more finely.

3.Summary

Through the use tracking and accumulation of infrared thermal imager, the application of infrared thermal imager in anode furnace is summarized as follows:

(1) Sufficient temperature measurement range:The surface temperature of the anode furnace is a comprehensive reflection of the working conditions in the furnace, and its temperature is subject to the influence of the smelting temperature in the furnace, the thermal conductivity of the refractory bricks, the thickness and wear of the refractory bricks, etc. generally, the surface temperature of the anode furnace ranges from 100 degrees to 350 degrees, and the infrared on-line thermometer has a large enough temperature measurement range to meet the temperature variation range of the anode furnace body, And the corresponding color shows the corresponding temperature changes, which can clearly and quickly provide operators with a grasp of the temperature distribution and changes of the furnace body. In the face of abnormal conditions, they can take corresponding emergency measures in time and accurately to reduce safety risks.

(2) Temperature measurement points:The whole anode furnace body covers multiple temperature measurement points, which can easily perceive the temperature change of the furnace body, but because the infrared temperature measurement is the average value of the infrared radiation energy of the measured target surface, when the measured target surface is larger, the infrared thermometer obtains the average temperature on the measured target surface. When the measured target surface is equal to or greater than the area of a refractory brick, the small temperature change on the refractory brick cannot be detected, It can only be found when the refractory bricks fall off or a large area of refractory bricks fall off. Therefore, the daily manual temperature measurement point inspection of the key areas of the anode furnace (tuyere area, slag line area, burner area, copper outlet area) is still irreplaceable.

(3) Temperature measurement accuracy:The selection and configuration of high-performance infrared thermometer ensures the technical performance of the infrared on-line temperature measurement and analysis system. When the system is used on the anode furnace, it is of great significance to the real-time monitoring of the furnace safety in the production process of the anode furnace.

(4) Adjust in time according to the real-time data of the infrared thermal imager:The adjustment and optimization of process parameters such as the dilute oxygen burner of anode furnace, breathable brick, the flow of redox medium, and the determination of the angle of redox air duct can realize more optimized and refined operation on the premise of ensuring the safe and stable operation of furnace body.

Applicable Machine