Development of a system for analyzing the completion of the sintering process using wide-angle thermal imagers at the discharge end of sinter machines

Increasing sinter plant productivity through more precise control of the sintering process

SCOPE OF WORK

Equipment installation site selection

Determined optimal locations for thermal imager installation and key technological parameters influencing the completion of the sintering process.

Process analysis

Technological processes were analyzed, and the correlation between acquired data sets was investigated.

Algorithm development

Developed a recommendation formation algorithm and a mathematical model.

System software development

Mathematical and software support for the sintering process completion analysis system.

Sinter plant operator advisory system developed

Trial operations

Trial operation of the sintering process completion analysis system.

Instruction and training conducted

Instruction on system usage and commissioning act.

THERMAL IMAGERS

1. Wide-angle thermal imagers mounted at the discharge end of the sintering machine.

2. For correct configuration, the working zone being measured must be fully within the thermal imager's field of view.

3. Visibility zone is determined by imager position and configuration settings.

4. Installation sites are selected to ensure the target surface is in direct line of sight with an observation angle of at least 60 degrees.

5. Results processing for qualitative analysis involves the decoding and analysis of thermograms.

6. This software complex is built using the Industry 4.0 platform ARKA v4.0.0.23.

SYSTEM PARAMETERS

Reaction delay and averaging time

Sets the cumulative averaging time for measurement results (in milliseconds) before status checks (I–III). The averaging time for grate temperature is set separately for adherence assessment (IV). These parameters determine the sensitivity and inertia of the advisory system.

Sinterability and heating uniformity control

Sets the allowable temperature difference (°C) for assessing material sinterability, as well as for assessing layer level uniformity and grate heating uniformity (III). Exceeding the threshold signals technological process violations.

Material sticking control

Sets the allowable temperature difference (°C) for assessing raw material sticking to the grates. Exceeding this value signals a sticking risk, allowing the operator to adjust process parameters and avoid downtime.

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Client

Location

Sinter Plant No. 5: Machines No. 1, 2