Implementação da automação de parâmetros para melhoria do processo de conformação por prensagem de massa de tamponamento para furos de corrida em altos-fornos

Abstract

A steel industry has played a vital role in global economic development, with blast furnaces being an essential component of this sector. Operational efficiency and the quality of products from blast furnaces are crucial for industry competitiveness. Pressing forming of burden materials aims to optimize the distribution of thermal and chemical loads in furnaces, directly affecting the quality of produced pig iron. Challenges in this process include variations in raw material characteristics, environmental fluctuations, and the need for precise control of forming variables. Inadequate control of these parameters can lead to low-quality pig iron, reduced yield, and increased operational costs. In this context, parameter automation emerges as a promising solution to address these challenges. Utilizing advanced technologies such as high-precision sensors, intelligent control systems, and optimization algorithms, real-time monitoring and adjustment of forming parameters become possible. This not only reduces human intervention, minimizing errors and enhancing operational safety, but also contributes to consistent improvement in forming material production, thus enhancing pig iron quality and overall blast furnace efficiency. The anticipated benefits of parameter automation implementation are extensive. Apart from improving final product quality and operational efficiency, waste reduction, standardized end products, decreased energy consumption, and optimized resource utilization are expected outcomes. Therefore, this research aims to explore the theoretical foundations of burden material pressing for blast furnaces, investigate available parameter automation technologies, and empirically assess the impacts of implementing these technologies in an actual industrial setting. To support this investigation, a comprehensive analysis of current literature, relevant case studies, and controlled experiments will be conducted. This study focuses on a project carried out at Shinagawa Refractories, located in Vinhedo-SP, which aimed to comprehensively automate forming parameters in a machine producing burden materials for blast furnaces in the steel industry. Previously, the machine primarily operated manually, resulting in inconsistent quality, production inefficiencies, lack of traceability, and material wastage. In response to these issues, a broad parameter interface encompassing three key categories—forming, pressing, and lubrication—was established. Each of the 30+ distinct burden material formulations required its own set of parameters due to variations in extrusion behavior. The project extended over several months due to the comprehensive parameter set and the need to customize parameters for each specific formulation. Following project implementation, the machine's performance over the subsequent five months yielded highly positive results across various dimensions. Particularly noteworthy were the excellent production volume records and increased productivity.