Predictive analytics in heavy industry

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  1. 1. NON-DESTRUCTIVE BLAST FURNACE WALL TESTING by Michael J. Vermeer Dr. Yulian Kin, Advisor Eric S. Roades Krasimir Zahariev Bernard W. Parsons II Friday, December 8, 2006
  2. 2. Background Blast Furnace is a tall vertical shaft used for refining iron ore into molten iron Refractory brick forms the interior lining which comes into contact with the iron and other refining materials As iron is refined in the blast furnace, erosion occurs on this refractory lining Improved technology to monitor the erosion in this lining will significantly increase profitability and productivity of blast furnace operation A project to develop this technology is made possible especially by the 21st Century Science and Technology Fund of Indiana
  3. 3. Project Purpose and Description The focus of this project is to investigate the use of acoustic measurement techniques to measure the thickness changes in a blast furnace wall. This was done through several phases of studies performed to validate different aspects to the acoustic method In the first part of the project, it was verified that the concept worked to determine depth in a regular, undamaged brick Next it was used to detect shifting depths, as damage was applied to a brick in laboratory conditions A study was also performed to investigate the effect of the steel lining on the outside of the furnace Finally, the method was applied to an actual blast furnace to monitor the wall thickness over time
  4. 4. Project Timeline TASKS Mar Apr May Jun Jul Aug Sep Oct Nov Dec 1. Perform Modal Analysis 2. Build Prototypes and Conduct Measurements 3. Determine Material Properties 4. Process Results 5. Simulate and Assess Damage 6. Study Effect of Steel Lining on Measurements 7. Apply Acoustic Method to Field Measurements 8. Make Recommendations 9. Document and Report Findings
  5. 5. Derivation of Formula where, v = velocity = wavelength f = compressive frequency node antinode dfv d fv = = = 2 2
  6. 6. Acoustic Method (IRAS) The figure below shows the test setup for all of the experimental measurements taken Impactor strikes block (or wall) near the point of measurement Laser Vibrometer measures displacement vs. time Computer performs Fast Fourier Transform (FFT) on displacement signal, from which shifts in compressive natural frequency can be determined
  7. 7. Damage Study Depth Measured Using Vibrometer and Workbench vs. Actual Depth 0.150 0.160 0.170 0.180 0.190 0.200 1 2 3 4 Experiment Number Depth(m) L-actual (m) L-vibrometer (m) L-ansys (m)
  8. 8. Plated Study Comparison of Major Modes Between Plated and Unplated Blocks 0.0 1000.0 2000.0 3000.0 4000.0 5000.0 6000.0 7000.0 8000.0 9000.0 10000.0 1 2 3 4 5 6 7 8 Mode # ModalFrequency(Hz) Unplated modes (Hz) Plated modes (Hz)
  9. 9. Application to Blast Furnace Wall Ring B Ring A
  10. 10. Blast Furnace Application Method A Uses the equation derived above to determine thickness Can directly evaluate thickness of wall Does not require knowledge of previous wall thickness Requires knowledge of material properties Needs validation data 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 0 2 4 6 8 10 12 14 X: 0.785 Y: 12.56 Frequency (kHz) Magnitude Frequency Comparison - Ring A, Position #1 X: 1.04 Y: 4.649 Apr06 Jul06
  11. 11. Blast Furnace Application Method A Results April and July Furnace Profiles - Ring A 0 1 2 3 4 5 1 2 3 4 5 6 7 8 910 11 12 13 14 15 16 17 Outer Radius April Radius July Radius April and July Furnace Profiles - Ring B 0 1 2 3 4 5 1 2 3 4 5 6 7 8 910 11 12 13 14 15 16 17 Outer Radius April Radius July Radius July 06 Radius April 06 Radius
  12. 12. Blast Furnace Application Method B Based on comparing the shift in Frequency to the shift in Depth Does not require specific knowledge of material properties Requires an accurate baseline inner profile Needs validation data 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3 0 0.5 1 1.5 2 2.5 Frequency (kHz) Magnitude Frequency Comparison - Ring A, Position #1 Aug05 Oct05 Apr06 Jul06
  13. 13. Blast Furnace Application Method B Results Blast Furnace Depth Measurements - Ring A 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 1 2 3 4 5 6 7 8 910 11 12 13 14 15 16 17 Outer Inner Depth wrt APR Depth wrt AUG Blast Furnace Depth Measurements - Ring B 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 1 2 3 4 5 6 7 8 910 11 12 13 14 15 16 17 Outer Inner Depth wrt APR Depth wrt AUG July 06 wrt April 06 July 06 wrt Aug 05
  14. 14. Blast Furnace Application Method B Profile Location 6 Vertical Profile 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 Radius from Furnace Center (m) Heightaboveplatform(m) Outer Wall JUL w rt APR JUL w rt AUG Inner Wall Location 16 Vertical Profile 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 Radius from Furnace Center (m) Heightaboveplatform(m) Outer Wall JUL w rt APR JUL w rt AUG Inner Wall July 06 wrt April 06 July 06 wrt Aug 05
  15. 15. Recommendations This project displays promising results Further validation is required Further analysis should be made of Rings A and B at BF #3 Establish baseline wall thickness data Install thermocouples so that CFD analysis can be performed for comparison Obtain and perform analysis of precise materials that compose the wall at measurement locations of BF #3
  16. 16. Conclusions This project was devoted to researching the application of the acoustic method for wall thickness monitoring Though further validation is required, results strongly indicate that the wall thickness of a blast furnace can be monitored using acoustics
  17. 17. Acknowledgements Dr. Yulian Kin Eric S. Roades Krasimir Zahariev Bernard W. Parsons II Pete Peters & CMET Dept. Rick Rickerson & METS Dept. 21st Century Science and Technology Fund of Indiana Mittal Steel Et. Al.

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