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基于视觉感知的高炉风口焦炭粒径在线监测

Online monitoring of coke particle size at blast furnace tuyere based on visual perception

  • 摘要: 高炉风口回旋区是炼铁过程的动力核心,其焦炭粒径的实时变化可直接反映焦炭热强度劣化程度及炉缸活跃性。然而,传统依靠休风取样的监测手段存在采样间歇性强、人为随机误差大且严重干扰正常生产等弊端,难以满足现代高炉智能化与连续化的监测需求。为此,本文研发了1套高炉风口焦炭粒径在线监测系统,旨在利用计算机视觉技术实现封闭热态环境下焦炭几何尺寸的实时精准感知。研究提出了1种轻量化检测模型ESG-YOLO(EffectiveSE GhostConv-YOLO)。该模型在主干网络引入GhostConv模块以实现轻量化特征提取,利用EffectiveSE机制增强边缘感知,设计加权特征融合(weighted feature fusion,WFF)模块以捕捉跨尺度特征的空间相关性,并采用Focal-PIoU2损失函数优化定位回归。试验结果表明,改进后的ESG-YOLO模型在计算量下降33.33%的前提下,平均精度均值PmA50、PmA50:95及调和平均数F1分数分别提升至98.10%、90.90%和96.40%,显著增强了模型在高温、高亮及喷煤流干扰等低信噪比环境下的鲁棒性。工业现场验证显示,系统平均推理速度达106.8 F/s(frames per second),能够实时捕捉休复风等非稳态过程中的焦炭粒径演变规律。通过分析周向粒径标准差与透气性指数之间的动态关联关系,表明粒径波动可作为表征炉缸环向不均匀性的量化先验指标。该系统的应用有效降低了人工取样强度,为利用机器视觉在线评价风口区域活跃性提供了科学依据与工程支撑。

     

    Abstract: The blast furnace tuyere raceway is the dynamic core of ironmaking process, and real time changes in coke particle size directly reflect the thermal strength degradation of coke and the activity of hearth. However, traditional monitoring methods relying on furnace stoppage sampling have disadvantages such as strong sampling intermittence, large human random errors, and significant disruption to normal production, making it difficult to meet the intelligent and continuous monitoring demands of modern blast furnaces. To address this issue, this paper developed an online monitoring system for coke particle size at the blast furnace tuyere, aiming to achieve real time and accurate perception of coke geometric dimensions in closed high temperature environment using computer vision technology. The study proposed a lightweight detection model named ESG-YOLO (EffectiveSE GhostConv-YOLO). This model introduced a GhostConv module in the backbone network for lightweight feature extraction, utilized an EffectiveSE mechanism to enhance edge perception, designed a weighted feature fusion (WFF) module to capture spatial correlations of cross scale features, and adopted the Focal-PIoU2 loss function to optimize localization regression. Experimental results show that the improved ESG-YOLO model reduces computational cost by 33.33% while increasing the mean average precision PmA50 and PmA50:95 to 98.10% and 90.90% respectively, and raising the F1 score to 96.40%. These improvements significantly enhancing the model's robustness in low signal to noise ratio environments with high temperature, high brightness, and pulverized coal injection interference. Industrial field validation demonstrates that the system achieves an average inference speed of 106.8 F/s, enabling real time capture of coke particle size evolution during unsteady processes such as furnace stoppage and restart. By analyzing the dynamic correlation between circumferential particle size standard deviation and the permeability index, the result indicates that particle size fluctuation can serve as a quantitative prior indicator for characterizing circumferential inhomogeneity in the hearth. The application of this system effectively reduces manual sampling intensity and provides scientific basis and engineering support for online evaluation of tuyere raceway activity using machine vision.

     

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