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炼铁厂智能安全监控体系的应用现状与展望

Application status and prospect of intelligent safety monitoring system in ironworks

  • 摘要: 钢铁工业中炼铁工序因涉及高温、高压等复杂高危环境, 一线员工长期面临较高安全风险。在智能制造与产业数字化转型背景下, 构建面向炼铁过程的智能化安全监控体系已成为行业实现高质量发展的核心路径之一。本文系统回顾了炼铁安全监控从强制管理到智能预警的演进历程, 基于"人-机-物-环-工"5要素框架, 分析了人员、设备、工艺3大核心维度的研究进展与应用实践。当前相关技术在多源信息感知、风险智能识别、跨系统协同预警等方面已取得显著突破, 人员安全依托异构定位、视觉识别与生理状态监测融合, 可实现违章作业、疲劳上岗等典型风险的量化预警; 设备安全基于多源状态感知与混合智能模型, 初步构建关键设备全生命周期故障预测与健康管理体系; 工艺安全借助全域感知与数据融合技术, 智能诊断模型显著延长炉况异常预警窗口, 部分系统已实现跨工序协同调控。结合武钢、柳钢等企业的工程实践, 智能化安全监控体系在降低高炉休风率、提升劳动生产率、优化能源消耗等方面取得可量化效益, 但在规模化部署中仍面临数据孤岛、模型泛化能力不足、建设运维成本高、复合型人才短缺与标准缺失等瓶颈。面向未来, 构建本质安全、智能高效的炼铁生产环境, 需进一步发展嵌入冶金机理的混合驱动模型, 以提升模型解释性与工况适应性, 同时搭建安全导向的统一数据平台打通信息壁垒, 支撑跨系统协同预警与调控。

     

    Abstract: In the steel industry, the ironmaking process involves complex and high-risk environments with extreme temperatures and high pressures, exposing frontline workers to high safety risks for long time. Against the background of smart manufacturing and industrial digital transformation, building an intelligent safety monitoring system for the ironmaking process has become one of the core paths for the high-quality development of the industry. This paper systematically reviews the evolution of ironmaking safety monitoring from mandatory management to intelligent early warning, and analyzes the research progress and application practices of three core dimensions including personnel, equipment and process based on the "Human-Machine-Material-Environment-Process" framework. Significant breakthroughs have been made in multi-source information perception, intelligent risk identification and cross-system coordinated early warning. Personnel safety can realize quantitative early warning of typical risks such as irregular operation and on-the-job fatigue through the integration of heterogeneous positioning, visual recognition and physiological state monitoring. Equipment safety initially constructs a full-life-cycle fault prediction and health management (PHM) system for key equipment based on multi-source state perception and hybrid intelligent models; process safety significantly extends the early warning window for abnormal furnace conditions by means of global perception and data fusion technologies, and some systems have realized cross-process coordinated control. Combined with the engineering practices of enterprises such as Wuhan Iron and Steel Co., Ltd. and Liuzhou Iron and Steel Co., Ltd., the intelligent safety monitoring system has achieved quantifiable benefits in reducing blast furnace downtime, improving labor productivity and optimizing energy consumption. However, it still faces bottlenecks in large-scale deployment, such as data silos, insufficient model generalization ability, high construction and operation costs, shortage of interdisciplinary talents and lack of unified standards. For the future, to build an intrinsically safe, intelligent and efficient ironmaking production environment, it is necessary to further develop hybrid-driven models embedded with metallurgical mechanisms to improve model interpretability and working condition adaptability. At the same time, a safety-oriented unified data platform should be built to break information barriers and support cross-system coordinated early warning and regulation.

     

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