CN103092171A - Cement digital management and control system - Google Patents

Cement digital management and control system Download PDF

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Publication number
CN103092171A
CN103092171A CN2013100068419A CN201310006841A CN103092171A CN 103092171 A CN103092171 A CN 103092171A CN 2013100068419 A CN2013100068419 A CN 2013100068419A CN 201310006841 A CN201310006841 A CN 201310006841A CN 103092171 A CN103092171 A CN 103092171A
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cement
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operational factor
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manufacture
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CN103092171B (en
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田海奎
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WUHAN XINFENG CEMENT CO Ltd
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WUHAN XINFENG CEMENT CO Ltd
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P80/00—Climate change mitigation technologies for sector-wide applications
    • Y02P80/10—Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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Abstract

The invention discloses a cement digital management and control system which comprises a simulate sub system, a production and optimization sub system and a data base. The simulate sub system is connected with the production and optimization sub system. The data base is respectively connected with the simulate sub system and the production and optimization sub system. The simulate sub system is used for performing simulating calculation to cement production. The production and optimization sub system is used for analyzing and judging whether current operating parameters and operation of cement production devices are normal, forecasting whether the operation parameters are normal after current time and controlling the cement production in an optimized mode. The data base is used for storing historic operation parameters and the current operation parameters, the range of the operation parameters and corresponding relationship between the operation parameters and state of the devices. Online simulated analysis technology, historic data analysis technology and an advanced diagnosing and optimizing method are adopted as methods of a digital management and control system so that economical and safe operation of a cement factory is achieved.

Description

Cement digitizing managing and control system
Technical field
The present invention relates to the technology of producing cement field, relate in particular to a kind of cement digitizing managing and control system.
Background technology
The production of cement normally take lime stone and clay as primary raw material, through fragmentation, batching, the levigate raw material of making, then feeds mature calcined material in cement kiln, then grog is added levigate the forming of proper amount of gypsum (sometimes going back admixture composite material or additive).
As shown in Figure 1, the production of cement, generally can divide raw material preparations, grog burns till and three operations of cement production systD, wherein, raw material preparations is divided into two kinds of dry method and wet methods, and dry method generally adopts the closed-circuit operation system, be that raw material is after grinding machine is levigate, enter the powder concentrator sorting, meal passes back into the mill operation of capable grinding again, and most material that adopts is dried the also technique of grinding simultaneously in grinding machine.The raw material preparation of dry method can comprise that specifically limestone crushing and conveying, associating pre-homogenization yard, material allocation and raw material grinding, raw material enter the flow processs such as kiln and exhaust-gas treatment.The equipment that grog burns till mainly contains shaft kiln and rotary kiln two classes, and shaft kiln is applicable to production scale less factory, and large and medium-sized factory adopts rotary kiln usually.Kiln cylinder body horizontally-arranged (slightly gradient, be about 3%), and can make the rotary kiln that is called of gyration.Adopt the grog of rotary kiln to burn till flow processs such as specifically can comprising pulverized coal preparation, the pre-thermal decomposition of kiln tail, calcined by rotary kiln and kiln hood clinker cooling.The cement production systD operation adopts closed-circuit grinding technique (being the closed-circuit operation system) usually, can comprise disintegrating machine grog batching, cement grinding mill and the flow processs such as cement outbound and packing.
For above-mentioned each production process, all relate to plurality of devices, such as, only just relate to heavy plate-type feeding machine in the operation of limestone crushing and conveying, single block hammer crusher, dust-precipitator, exhaust blower, centrifugal fan, motor, dust-precipitator gas-holder, belt feeder, pulsed stand-alone band dust-precipitator, round stockyard stacker-reclaimer etc.Every kind of equipment all relates to various parameters and index.
Because the large-scale cement line production system is huge, equipment is numerous, and the operation operation is complicated, controls also relative complex, and the latency that breaks down is many.And in a single day break down, even can cause device damage, no matter fault is big or small, all can indirectly or directly bring economic loss to the cement mill.
Summary of the invention
The large-scale cement line production system that the present invention is directed to prior art is huge, and equipment is numerous, and the complicated problem of operation operation proposes a kind of cement digitizing managing and control system, to improve security and the economy of manufacture of cement.
In order to address the above problem, the invention provides a kind of cement digitizing managing and control system, comprise: analog subsystem, production and optimization subsystem and database, wherein, analog subsystem is connected with the optimization subsystem with production, and database is connected with producing with the optimization subsystem with described analog subsystem respectively;
Described analog subsystem is used for manufacture of cement is carried out simulation calculation;
Described production and optimization subsystem are for the data of storing according to result of calculation and the database of described analog subsystem, analyze and judge whether normal current operational factor and cement manufacture plant move, after the prediction current time, whether operational factor is normal, and manufacture of cement is optimized control;
Described database is used for history run parameter and current operational factor, the scope of operational factor and the corresponding relation of operational factor and equipment state of each production equipment of storage.
Preferably, said system also has following characteristics:
Described analog subsystem comprises: data acquisition module, data check module, equipment state are calculated module, online self-learning module and analog module, wherein, data acquisition module is connected with the data check module, and equipment state calculates that module is connected with analog module with the data check module respectively with online self-learning module;
Described data acquisition module is used for the current operational factor of each production equipment of Real-time Collection manufacture of cement, and is sent to described data check module;
Described data check module is for the scope of the operational factor of setting according to database, the current operational factor that the data acquisition module collects is tested, qualified current operational factor is sent to database, equipment state reckoning module and online self-learning module;
Described equipment state calculates that module is used for the scope of current operational factor and database equipment operational factor is compared, and determines the running status of current each equipment, and running status and the current operational factor of current each equipment is sent to analog module;
Described online self-learning module is used for according to current operational factor, the coefficient of each mathematical model of manufacture of cement is revised, and revised mathematical model is sent to analog module;
Described analog module is included in line locking emulation submodule, and described on-line synchronous emulation submodule is used for according to each mathematical model of current operational factor and manufacture of cement, manufacture of cement being carried out synchronization simulation and calculates.
Preferably, said system also has following characteristics:
Described data check module is further used for, if the current operational factor of judgement is defective in checkout procedure, the value that obtains with simulation analysis value in database or historical simulation analysis substitutes underproof current operational factor, reports to the police and shows underproof current operational factor and substitution value thereof.
Preferably, said system also has following characteristics:
Described analog module also comprises off-line analysis emulation submodule, and described off-line analysis emulation submodule is used for according to the off-line operation parameter of input and each mathematical model of manufacture of cement, manufacture of cement being carried out simulation calculation.
Preferably, said system also has following characteristics:
Described analog module also comprises on-line prediction emulation submodule, and described on-line prediction emulation submodule is used for each mathematical model according to current operational factor and manufacture of cement, manufacture of cement is carried out faster than real time simulation calculate.
Preferably, said system also has following characteristics:
Described production comprises with the optimization subsystem: security module and on-line decision control module, wherein,
Described security module is used for according to cement manufacture plant operation real time data, historical data and emulated data, analyze and judge whether current operational factor and cement manufacture plant move normal, and after the prediction current time, whether operational factor is normal;
The on-line decision control module is used for raw meal proportioning and the cement ingredient of manufacture of cement are optimized, and raw mill system, coal mill, dore furnace, primary heater and cement mill system are optimized control.
Preferably, said system also has following characteristics:
Described security module comprises: parameter real-time oversight submodule, online early warning submodule and anomaly parameter detecting submodule, wherein,
Described parameter real-time oversight submodule is used for the current operational factor of the current cement manufacture plant of real-time oversight, reports to the police when operational factor is abnormal;
Described online early warning submodule is used for according to manufacture of cement being carried out the result that faster than real time simulation is calculated, and whether operational factor is normal afterwards to judge current time;
Described anomaly parameter detecting submodule is used for operational factor current according to manufacture of cement, the variation tendency of operational factor, the variation range of operational factor etc., judges whether the cement manufacture plant running status is normal.
Preferably, said system also has following characteristics:
Described on-line decision control module comprises that Raw Material System is optimized submodule, coal dust preparation system is optimized submodule, firing system optimization submodule and cement system and optimized submodule, wherein,
Described Raw Material System is optimized submodule by the record data according to historical blanking, calculates the raw ingredients development trend, carries out burdening calculation, thereby to the optimization of raw meal proportioning; And, control and expert decision system according to PID, recirculating air, meal storehouse hot blast, meal storehouse cold wind, fine powder storehouse hot blast and fine powder storehouse cold wind are regulated, controlling raw mill outlet temperature, meal storehouse entrance negative pressure and fine powder storehouse entrance negative pressure, thereby to the optimal control of raw mill system;
Described coal dust preparation system is optimized submodule and is controlled and expert decision system according to PID, recirculating air, hot blast and the cold wind of coal mill regulated, and controlling outlet temperature and the entrance negative pressure of coal mill, thereby to the optimal control of coal mill;
Described firing system is optimized submodule and is controlled and expert decision system according to PID, the coal amount regulated, and controlling the temperature of dore furnace, thereby to the optimal control of dore furnace; And, control and expert decision system according to PID, the blower fan valve opening is regulated, controlling the primary heater top hole pressure, thereby to the optimal control of primary heater.
Described cement system is optimized submodule by the record data according to historical blanking, calculates the cement composition development trend, carries out burdening calculation, thereby to the optimization of cement ingredient; And, control and expert decision system according to PID, hot blast and the cold wind of cement mill system are regulated, controlling outlet temperature and the entrance negative pressure of cement mill system, thereby to the optimal control of cement mill system.
Preferably, said system also has following characteristics:
Described production further comprises with the optimization subsystem: economic module, and described economic module is used for calculating comprehensive energy consumption and the distribution energy consumption of manufacture of cement, and with energy consumption data and international, domestic standard energy consumption index comparing.
Preferably, said system also has following characteristics:
Described economic module comprises connected online energy consumption index calculating sub module and efficiency to mark analysis submodule, wherein,
Described online energy consumption index calculating sub module is used for calculating comprehensive energy consumption and the distribution energy consumption of manufacture of cement;
Described efficiency is analyzed submodule to mark and is used for described online energy consumption index calculating sub module is calculated energy consumption data and international, domestic standard energy consumption index comparing;
Described comprehensive energy consumption comprises grog comprehensive energy consumption, the comprehensive coal consumption of grog, the comprehensive power consumption of grog, cement comprehensive energy consumption, the comprehensive power consumption of cement and the comprehensive coal consumption of cement;
Described distribution energy consumption comprises that the broken power consumption of raw material, raw material prehomogenization power consumption, raw material stoving coal consumption, raw grinding power consumption, raw material homogenizing power consumption, fuel oven dry coal consumption, preparation of fuel power consumption, exhaust-gas treatment power consumption, grog burn till power consumption, grog burns till coal consumption, grog storage and carries power consumption, supplement production power consumption, composite material oven dry coal consumption, composite material to prepare power consumption, cement grinding power consumption etc.
The present invention can bring significant direct, indirect benefit for the cement mill:
(1) by a large amount of on-line analysis data, in real time/historical data, realize scientific management, precision management, make the process management such as cement mill goods and materials, maintenance reasonable, economical, make the decision-making of production management in time, accurately, realize optimum efficiency;
(2) based on systematic analysis, optimize operation and control, reduce the consumption of coal, electricity, oil, water, realize direct economic benefit;
(3) in-circuit emulation early warning, abnormal examination, fault diagnosis etc. ensure the cement mill safe operation, and safety is the economic benefit of cement mill maximum.
Description of drawings
Fig. 1 is the manufacture of cement schematic flow sheet;
Fig. 2 is the cement digitizing managing and control system schematic diagram of the embodiment of the present invention;
Fig. 3 is the analog subsystem schematic diagram of the embodiment of the present invention;
Fig. 4 is the schematic diagram that concerns of the on-line synchronous emulation of the embodiment of the present invention and on-line prediction emulation;
Fig. 5 is the production and optimization subsystem schematic diagram of the embodiment of the present invention;
Fig. 6 is that schematic diagram is controlled in the raw mill system optimization of the embodiment of the present invention;
Fig. 7 is the coal mill optimal control schematic diagram of the embodiment of the present invention;
Fig. 8 is the dore furnace optimal control schematic diagram of the embodiment of the present invention;
Fig. 9 is the primary heater optimal control schematic diagram of the embodiment of the present invention;
Figure 10 is the cement mill system optimal control schematic diagram of the embodiment of the present invention.
Embodiment
Hereinafter in connection with accompanying drawing, embodiments of the invention are elaborated.Need to prove, in the situation that do not conflict, the embodiment in the application and the feature in embodiment be combination in any mutually.
As shown in Figure 2, the cement digitizing managing and control system of the embodiment of the present invention comprises: analog subsystem, production and optimization subsystem and database, wherein, analog subsystem is connected with the optimization subsystem with production, and database is connected with producing with the optimization subsystem with described analog subsystem respectively;
Described analog subsystem is used for manufacture of cement is carried out simulation calculation;
Described production and optimization subsystem are for the data of storing according to result of calculation and the database of described analog subsystem, analyze and judge whether normal current operational factor and cement manufacture plant move, after the prediction current time, whether operational factor is normal, and manufacture of cement is optimized control;
Described database is used for history run parameter and current operational factor, the scope of operational factor and the corresponding relation of operational factor and equipment state of each production equipment of storage.
Wherein, database comprises historical data base and real-time data base, the history run parameter of each production equipment of historical data library storage wherein, and real-time data base is stored the current operational factor of each production equipment.In addition, all have the parameter characteristics such as its range of normal value, exceptional value scope due to every kind of operational factor, so database has also been stored the information of this aspect.
Such as, take 5000t/d grog dry process production line as example, in the grog firing system, following important parameter is arranged:
1. high-temperature blower speed: 800-830 rpm, effect is to guarantee system ventilation and air quantity, wind coal charge sufficient heat exchange.
2. Coaling of Decomposing Furnace: outlet temperature to 875 degree, fully decomposes carbonate at 865 degree, alleviates the kiln load.
3. kiln hood is fed the coal amount: at 10.5 to 11.5 tons, material is being burnt till with sufficient chemical reaction.
4. one section speed of grate-cooler: 8 to 9 per minutes, the grog heat fully is recovered in kiln, improves burning zone temperature.
5. two sections speed of grate-cooler: 12 to 14 per minutes, make the grog chilling, improve the grog performance.
6. three sections speed of grate-cooler: 16 to 18 per minutes, reduce clinker temperature, improve the grog grindability.
7. kiln head exhaust fan speed: 85%-95% controls the kiln hood negative pressure, and kiln hood waste gas is discharged in atmosphere.
8. kiln owner's current of electric: between 600 to 800A, the calcining of reaction mass in kiln changes.
9. kiln hood primary air fan pressure: 26-28kpa, guarantee that by adjusting rotation speed of fan pulverized coal conveying is stable.
10. kiln hood coal powder injection air duct pressure: 18--20kpa, coal amount under the reality of reaction head coal.
11. kiln tail coal powder injection air duct pressure: 34--37kpa, coal amount under the reality of reaction tail coal
12. kiln exhaust gas body analyser: O 2Content 2.0%--3.5%, CO 2Whether fully content detect coal dust burning less than 0.2%.
13. smoke-box gas analyzer: O 2Content 2.0% left and right, CO 2Whether fully content detect coal dust burning less than 0.05%.
14. roots blower: 27A23 electric current 95-105A27A22 electric current 95-105A27A27 electric current 135-145A27A21 electric current 135-145A, the actual lower coal amount of reaction.
15. smoke-box temperature: 1050 ℃--1150 ℃, whether reaction kiln thermal regulation is stable.
Above-mentioned parameter is the range of normal value of equipment.Correspondingly, above-mentioned parameter also has the exceptional value scope, in the situation that steady running, below 800 rpms, perhaps 830-1000 rpm is exceptional value, represents that this equipment operation is undesired such as high-temperature blower speed.
The below describes in detail respectively with the optimization subsystem to analog subsystem and production.
● analog subsystem
Analog subsystem can comprise to raw material preparations, grog burn till, the emulation of the systems such as cement production systD, take 5000t/d grog dry process production line as example, specifically can comprise:
1, raw material preparation system
(1) limestone crushing and induction system
Emulation scope: heavy plate-type feeding machine, single block hammer crusher, dust-precipitator, exhaust blower, centrifugal fan, motor, dust-precipitator gas-holder, belt feeder, pulsed stand-alone band dust-precipitator, round stockyard stacker-reclaimer etc.
(2) associating pre-homogenization yard system
Emulation scope: the belt feeder of screening coal, the outstanding scraper reclaimer of side, belt feeder etc.And the pre-homogenization yard of all kinds of auxiliary materials, former Coal Stack Yard, various stackers, reclaimer, fly-ash separator, rubber conveyer etc.
(3) material allocation and raw material grinding system
Emulation scope: belt conveyer scale, dust-precipitator dust collecting fan, rotor weigher, enter to grind in belt, flyash storehouse side gas-holder and all air bubbles, electric block, oven dry and unload raw material grinding mill etc.
(4) raw material enter kiln system
Emulation scope: roots blower, weightless storehouse, belt conveyer scale, inflation device for discharging, go in ring district gas charging system, air conveyer flume, bag collector, ventilation blower fan, enter kiln hoister, air compressor, gas-holder etc.
(5) exhaust treatment system
Emulation scope: conditioning Tower, electric precipitator, all kinds of blower fan, all kinds of valves etc.
2, grog firing system
The emulation scope includes but not limited to following system:
Coal dust preparation system, kiln tail preheating decomposition system, calcined by rotary kiln system, kiln hood clinker cooling system
Emulation scope: cyclone preheater, dore furnace, rotary kiln, grate-cooler, high-temperature blower, induced draft fan, cooling blower, seal fan, primary air fan, fuel system, coal burner, revolution gear wheel, grog tray conveyer, clinker warehouse, coal mill, electric precipitation, other blower fans and pump, petrol station, baffle plate, valve etc.
3, cement production systD system
The emulation scope includes but not limited to following system:
Disintegrating machine grog feed proportioning system, cement mill system and cement outbound and packaging system
Emulation scope: constant feeder, belt conveyor, hoister, V-type powder concentrator, roll squeezer, powder concentrator, dust-precipitator, cement grinding mill, bulk machine, roots blower, carloader etc.
4, distribution system
(1) 10KV distribution system
Emulation scope: the change of high factory, 10KV bus, each section bus working power switch, Backup Power Switch etc.
(2) 400V distribution system
Emulation scope: the low compression bonded line of all protections, station-service of low pressure factory's change and the high and low side switch of transformer, 400V bus, emergency power supply and 400V Auxiliary System and control, signal circuit etc.
5, control system
The emulation scope: all in control system are regulated parameter.
As shown in Figure 3, the cement online simulation subsystem of the embodiment of the present invention comprises: data acquisition module, data check module, equipment state are calculated module, online self-learning module and analog module, wherein, data acquisition module is connected with the data check module, and equipment state calculates that module is connected with analog module with the data check module respectively with online self-learning module;
Described data acquisition module is used for the current operational factor of each production equipment of Real-time Collection manufacture of cement, and is sent to described data check module;
Described data check module is for the scope of the operational factor of setting according to database, the current operational factor that the data acquisition module collects is tested, qualified current operational factor is sent to database, equipment state reckoning module and online self-learning module;
Described equipment state calculates that module is used for the scope of current operational factor and database equipment operational factor is compared, and determines the running status of current each equipment, and running status and the current operational factor of current each equipment is sent to analog module;
Described online self-learning module is used for according to current operational factor, the coefficient of each mathematical model of manufacture of cement is revised, and revised mathematical model is sent to analog module;
Described analog module is included in line locking emulation submodule, and described on-line synchronous emulation submodule is used for according to each mathematical model of current operational factor and manufacture of cement, manufacture of cement being carried out synchronization simulation and calculates.
The below is described in detail each module:
One, data acquisition module:
The current operational factor of each production equipment in this module Real-time Collection manufacture of cement, also can adopt the method with dcs (DCS) and auxiliary control system shared data acquisition system, and can be with the form udp broadcast issue with exception report of the current operational factor that collects.The current operational factor that collects can be saved in database in addition, for inquiry, and can be with the input data of historical data as off-line simulation.Data buffer storage is preserved the historical data of 15 days at least.
The online simulation subsystem is by data acquisition, thereby make analog subsystem directly obtain on-the-spot running status and operational motion, calculate according to the full physical process mathematical model that the design parameter of operational outfit, system and characterisitic parameter are set up, and provide data supporting for production optimization and analytic system, management optimization and decision system etc.
Two, data check module:
Because the data that collect may be number of non-compliances certificate i.e. " bad values ", the data check module can be tested to the current operational factor that the data acquisition module collects.Its foundation is exactly the scope of parameters in above-mentioned database.When the verification of data check module to the data that collect neither normal value, neither exceptional value, so just judge that current operational factor is defective, the value that obtains with simulation analysis value in database or historical simulation analysis substitutes underproof current operational factor, but also can remind the staff by the mode of reporting to the police, and show the list of underproof current operational factor and substitution value thereof by the station that works online.If verification is qualified, qualified current operational factor is sent to database, equipment state reckoning module and online self-learning module.
Three, equipment state is calculated module:
This module is analyzed current operational factor, the scope of equipment operational factor in current operational factor and database is compared, determine the running status of current each equipment, such as normal state or anomalous mode, thereby determine equipment, the safety of equipment, economic level, carry out to be used for predicting contingent fault, find out failure cause, the analytical equipment state proposes the maintenance suggestion time; Patrol and examine in time discovering device hidden danger of data and equipment state curve by analysis in addition.
Four, online self-learning module:
Online self-learning module is set out by physics, chemical basic principle, as Combustion, fluid mechanics, thermal conduction study etc., according to current operational factor, accurately extrapolate cement mill operational outfit and system performance parameter (coefficient of mathematical model) under current working, coefficient to existing mathematical model is revised, and the simulation calculation that makes analog module is closing to reality more.
Because the characteristic in actual motion is difficult to explain with simple theory, theoretical value and actual condition have fractional error, by self study, automatically revise online simulation subsystem coefficient, make realistic model more can represent accurately actual condition.Self learning model refers to the mathematical model based on basic physics, principles of chemistry foundation, revises in real time the mathematical model coefficient in the middle of the actual condition operational process, makes the synchronous operation within error range of emulation operating mode and actual condition.
Five, analog module
Analog module can reach according to the data of equipment current working or historical operating mode in the Real-Time Sharing database and calculate according to each mathematical model of manufacture of cement, set up the operating condition identical with physical device, namely have equipment running status is copied to function on analog module fully.
Analog module specifically comprises: on-line synchronous emulation submodule, off-line analysis emulation submodule and on-line prediction emulation submodule.
(1) on-line synchronous emulation submodule
On-line synchronous emulation submodule carries out synchronization simulation according to each mathematical model of current operational factor and manufacture of cement to manufacture of cement and calculates.
The on-line synchronous simulation model is basic operational mode, is exactly that analog subsystem obtains online the execute-in-place instruction and synchronously carries out simulation calculation, unless withdraw under special circumstances its operation, otherwise on-line operation continuously always just.On-line synchronous emulation submodule calculates that by equipment state module or database constantly receive the operational factor (comprising mode of operation signal and measuring-signal) from the scene, follows the tracks of with this and calculates and analyze.
For the on-line synchronous simulation model, the initial operating mode of realistic model must be consistent with on-the-spot operating condition.Although the in-circuit emulation model can exist a large amount of process variables and intermediate quantity by all field control state and the measurement parameter of shared data bank in realistic model, they can't directly obtain from the scene, so must carry out the initialization of in-circuit emulation.basic implementation method is: first select to call near an initial operating mode of current working the starting point that internal memory calculates as initialization when the emulation of initial start on-line synchronous from the initial operating mode of having preserved, the initial operating mode that this is called in and on-the-spot actual motion state may be variant, carry out initialization to all realistic model amounts (comprising process variable and intermediate quantity) this moment, the error of analytical model result of calculation and cement mill actual value (analog quantity), when the error of all values of being verified less than error requirements and all on-off states when in full accord with on-the-spot value, think that initialization completes, real-time online synchronization simulation model drops into and calculates.
Imitate the various parameters and equipment state of object under the on-line synchronous simulation model except calculate quilt by realistic model, equipment state is calculated module and online also synchronous operation of self-learning module, analyze the running status of current each equipment, and revise in real time realistic model.The on-line synchronous simulation model just begins the log history data once startup, and the history value that records is checked trend for the related personnel by Simulation Interface, is also the foundation of carrying out historical performance analysis and some index calculation of parameter.The record of historical data is also followed the trail of for returning under the off-line analysis simulation model and operation note is reset provides data, and this is the important means of carrying out operating analysis.
On-line synchronous emulation is the functions such as online operating analysis and the fault diagnosis data that provide the foundation, and the operating process that on-line synchronous emulation is recorded and historical operating mode are the foundations that off-line simulation is analyzed.
On-line synchronous emulation submodule can be realized online soft sensor in addition.The online soft sensor technology is to utilize some easily auxiliary variables of online Measurement accuracies or historical datas of analytical test, and by on-line analysis, calculating can not be measured or a kind of method of difficult measurand in real time.For actual conditions and the needs of cement mill, choose the physical quantity that is difficult to on-line measurement and carry out online soft sensor, as raw material fineness, cement specific surface area.Raw material fineness, cement specific surface area are one of important technology indexs in cement production process, the measuring method of present field by using off-line sample examination, retardation time is long, pass through online soft sensor, be conducive to the timely adjust operation mode of operating personnel, improve cement product quality, improve the economic benefit of manufacture of cement.
(2) off-line analysis emulation submodule
Off-line analysis emulation submodule carries out simulation calculation according to the off-line operation parameter of input and each mathematical model of manufacture of cement to manufacture of cement.
Although on-line synchronous emulation is the main operational mode of analog module, only there is on-line synchronous emulation submodule can not embody function and the effectiveness of analog module fully.The online simulation subsystem except carry out that Synchronization Analysis calculates and the functions such as real-time operating analysis, fault diagnosis, also to realize the analysis to the history run event, the pre-authentication of significant technical, the formulation of emergent accident processing specification and the functions such as optimization selection of operational mode.These functions are carried out under the off-line analysis simulation model.
The off-line analysis simulation model is exactly that analog subsystem breaks away from on-the-spot service data and the mode of independent operating fully.
The initial operating mode of the startup of off-line analysis simulation model is obtained by following mode:
(1) the initial operating mode of the current operating condition of on-line synchronous emulation as off-line analysis emulation, namely directly obtain the data of current on-line synchronous emulation from shared drive;
(2) initial operating mode (IC), this is that slip-stick artist or user arrange the standard original state under the various operating conditions of maintenance;
(3) reset and be kept at historical data in historical data base by the on-line synchronous simulation model, the time of historical data can select institute to record any historical juncture.
By off-line analysis emulation submodule, in can setting up, control operations staff operation training system, production management personnel operational management training system, field apparatus operative employee local operation training system, electrical operation personnel operation training system, thermal technology's personnel control system are researched and analysed system, industrial accident phenomenon demonstration training system, industrial accident processing rehearsal training system, production run personnel checking system on duty, production run personnel promotion checking system etc., train accordingly on the off-line simulation machine by the related personnel, improve the corresponding operating level.
(3) on-line prediction emulation submodule
On-line prediction emulation submodule carries out faster than real time simulation to manufacture of cement and calculates according to each mathematical model of current operational factor and manufacture of cement.
The on-line prediction simulation model is for using realistic model to calculate the predict device running status in future with super real-time (Faster Than Real-time is faster than in real time) speed.Obviously, by problem that can the operation of precognition equipment to the prediction of equipment state, remind in advance the operations staff, thereby in time correct operation problem, prevent the generation of major accident or shutdown.
As shown in Figure 4, when on-line prediction emulation starts, automatically take Δ t as the cycle, be replicated in the current operating condition data of line locking emulation from shared drive, to the super real-time calculating of current operating condition, simulation and prediction is from t0 (current time) to the t0+ Δ running status of T time period.Δ T can be set by the slip-stick artist, and scope is generally 15 minutes～1 hour, specifically is subjected to travelling speed and the capacity limit of computing machine.The scope of Δ t is generally 1 minute～and 10 minutes.
In sum, analog subsystem can carry out simulation calculation, analysis and early warning to current state in real time, for cement mill safety, economical operation provide online, intelligentized supplementary.These data can for the production of optimizing and management optimization, have in time and the decision-making foundation of science the management of cement mill and production.
● produce and optimize subsystem
As shown in Figure 2, the manufacture of cement of the embodiment of the present invention and optimization system comprise security module, economic module and on-line decision control module, wherein,
Described security module is used for according to cement manufacture plant operation real time data, historical data and emulated data, analyze and judge whether current operational factor and cement manufacture plant move normal, and after the prediction current time, whether operational factor is normal;
Described economic module is used for calculating comprehensive energy consumption and the distribution energy consumption of manufacture of cement, and with energy consumption data and international, domestic standard energy consumption index comparing;
The on-line decision control module is used for raw meal proportioning and the cement ingredient of manufacture of cement are optimized, and raw mill system, coal mill, dore furnace, primary heater and cement mill system are optimized control.
Wherein, above-mentioned economic module is optional module.
The below is described in detail each module:
One, security module:
Because the latency of cement mill system generation Shutting Down fault is many, in case technology trouble occurs, gently force attenuating output, heavy can cause Parking to occur, even can cause device damage, no matter technology trouble is big or small, all can indirectly or directly bring economic loss to the cement mill.Therefore, by failure prediction and the diagnostic function of security module, find early the technology trouble that system and equipment are potential, the anomalous event that prediction may occur in the future, and in time take treatment measures, and can improve equipment and reliability of operation, guarantee device security, operation economically.
Security module is for the functional module of cement mill safety problem, comprising: parameter real-time oversight submodule, online early warning submodule and anomaly parameter detecting submodule.
(1) parameter real-time oversight submodule:
Parameter real-time oversight submodule is used for the current operational factor of the current cement manufacture plant of real-time oversight, reports to the police when operational factor is abnormal.
Normal all parameters in service of system fluctuate in a normal scope, have namely surpassed threshold value when parameter fluctuation has exceeded normal scope, occur with the form of reporting to the police.
The threshold value of judgement comprises two types:
(1) threshold value of determining according to designing requirement, user manual and operating experience can be a fixing value.
(2) threshold value of determining according to historical data.Can be according to history value under same operating condition, effectively find abnormal in unit operation, particularly unconspicuous hidden danger.
(2) online early warning submodule:
Online early warning submodule is used for according to manufacture of cement being carried out the result that faster than real time simulation is calculated, and whether operational factor is normal afterwards to judge current time.
As shown in Figure 4, the on-line prediction emulation submodule of analog subsystem uses realistic model to calculate with super real-time speed, and result of calculation is sent to online early warning submodule, online early warning submodule according to the result of calculation judgement from the current time to the current time+running status of Δ T.Wherein Δ t is the cycle, and Δ T is predicted time length, is the integral multiple of Δ t.Find that thus important parameter crosses the border and the information such as protection action (putting forward the parameters such as feedback current, hoister electric current as bucket) of equipment; and abnormal possible cause and the processing suggestion that is about to appearance in service of analysis and early warning equipment, and these information are offered the user.
(3) anomaly parameter detecting submodule
Whether anomaly parameter detecting submodule is used for normal according to equipment operation real time data and historical data analysis judgment device running status.Particularly, the variation tendency of this module operational factor current according to manufacture of cement, operational factor, the variation range of operational factor, absolute value etc. judge whether the cement manufacture plant running status is normal.Wherein, equipment operation real time data is the current operational factor of manufacture of cement, and the variation tendency of operational factor and the variation range of operational factor can be moved real time data and historical data obtains by equipment.
After anomaly parameter detecting submodule finds that abnormal parameters is arranged, two kinds for the treatment of methods are arranged:
(1) parameter itself has directly been reflected the situation (as the hoister current anomaly) of plant issue, directly (or through simple analysis) as warning information output, points out the operations staff to process;
(2) other situation can not directly reflect status information of equipment as abnormal parameters, can be that problem has appearred in which equipment by the further analyzing and diagnosing of abnormal discriminant analysis model.
In addition, the also variation of analytical equipment performance of this module (comprising that unavailable performance descends) and the impact that equipment is moved thereof, thus whether differentiation proposes the maintenance suggestion.Such as:
(1) overtemperature statistics: the isoparametric overheating operation number of times of the bearing temperature of equipment components and time are carried out statistical study, and its statistic analysis result is as the foundation of fail-safe analysis, Analysis on Cyclic Life Expenditure.
(2) electric switch operation statistics: the operation history to the cement mill electric switch carries out statistical study, wherein the hot line job number of times of statistic switch, tripping operation action frequency, not hot line job number of times etc.
Above-mentioned state analysis is the basis of realizing equipment state overhauling, by the statistical study to equipment state, whether proposes the maintenance suggestion thereby differentiate.
Two, economic module
Economic module is moved real time data, historical data and the emulated data fundamental as analyzing take cement manufacture plant, on-line analysis cement mill equipment running status, economy to equipment is carried out multianalysis, help the timely discovering device running status of operations staff by performance indicators, adjusting for the systematic economy operation provides foundation.In addition, for cement industry energy resource consumption, management and current Status of Energy-Saving, according to the cement production enterprise efficiency, index and index system that mark adopts are calculated, for cement industry energy resource consumption, management and Energy Conservation supply basic foundation.
This module is main with reference to following standard:
(1) " cement unit product energy resource consumption limit "
(2) " cement production enterprise design specifications and energy consumption limit standard "
(3) " the cement production enterprise efficiency is to the mark guide "
(4) " heat output determining method of GB/T213-2003 coal "
(5) " the GB/T2589 comprehensive energy consumption is calculated general rule "
(6) " JC/T730-2007 cement rotary kiln thermal equilibrium, the thermal efficiency, comprehensive energy consumption computing method "
(7) " JC/T733-2007 cement rotary kiln Thermal Balance method "
Economic module comprises that connected online energy consumption index calculating sub module and efficiency are to mark analysis submodule.
(1) online energy consumption index calculating sub module
Online energy consumption index calculating sub module is used for calculating comprehensive energy consumption and the distribution energy consumption of manufacture of cement.
Wherein, comprehensive energy consumption comprises grog comprehensive energy consumption, the comprehensive coal consumption of grog, the comprehensive power consumption of grog, cement comprehensive energy consumption, the comprehensive power consumption of cement and the comprehensive coal consumption of cement etc.
(1) grog comprehensive energy consumption
The various energy of producing grog consumption per ton in statistics in phase are converted to the resulting comprehensive energy consumption of standard coal equivalent, and unit is kilogram standard coal equivalent (kgce/t) per ton.
Utilize kiln hood and kiln tail gas to carry out the production line of the UTILIZATION OF VESIDUAL HEAT IN such as cogeneration or heating for part, its generated energy and UTILIZATION OF VESIDUAL HEAT IN amount are not converted to standard coal equivalent to be deducted from the grog comprehensive energy consumption.
(2) the comprehensive coal consumption of grog
Produce the fuel consumption of grog per ton in statistics in phase, comprise the oven dry raw materials and fuel and burn till the fuel that grog consumes, unit is kilogram standard coal equivalent (kgce/t) per ton.
(3) the comprehensive power consumption of grog
Produce the combined power consumption of grog per ton in statistics in phase, comprise power consumption and the power consumption of producing the grog supporting process in the grog production run, unit is kilowatt hour (kwh/t) per ton.
(4) cement comprehensive energy consumption
The various energy of producing cement consumption per ton in statistics in phase are converted to the resulting comprehensive energy consumption of standard coal equivalent, and unit is kilogram standard coal equivalent (kgce/t) per ton.
When calculating cement comprehensive energy consumption index, the cement 28d compressive strength of should dispatching from the factory according to the modification method in GB16780-2007 " cement unit product energy resource consumption limit " standard is adapted to 42.5 hierarchy levels, carries out simultaneously the aspect corrections such as blending amount of mixture material.
(5) the comprehensive power consumption of cement
Produce the combined power consumption of cement per ton in statistics in phase, comprise power consumption and the power consumption of producing the cement supporting process in each process of manufacture of cement, unit is kilowatt hour (kwh/t) per ton.
(6) the comprehensive coal consumption of cement
Produce the fuel consumption of cement per ton in statistics in phase, comprise the oven dry raw materials and fuel and burn till the fuel of grog consumption and the fuel that the composite material oven dry consumes, unit is kilogram standard coal equivalent (kgce/t) per ton.
The distribution energy consumption comprises that the broken power consumption of raw material, raw material prehomogenization power consumption, raw material stoving coal consumption, raw grinding power consumption, raw material homogenizing power consumption, fuel oven dry coal consumption, preparation of fuel power consumption, exhaust-gas treatment power consumption, grog burn till power consumption, grog burns till coal consumption, grog storage and carries power consumption, supplement production power consumption, composite material oven dry coal consumption, composite material to prepare power consumption, cement grinding power consumption etc.
(1) the broken power consumption of raw material
Be used for comprising the power consumption of the various raw material fragmentations such as lime stone, sandstone, iron ore in phase in statistics, unit is kilowatt hour (kwh/t) per ton.
(2) raw material prehomogenization power consumption
Be used for the power consumption of raw material prehomogenization in phase in statistics, unit is kilowatt hour (kwh/t) per ton.
(3) raw material stoving coal consumption
Be used for the fuel consumption of raw material stoving in phase in statistics, unit is kilogram standard coal equivalent (kgce/t) per ton.
(4) raw grinding power consumption
Be used for the power consumption of raw material grinding in phase in statistics, unit is kilowatt hour (kwh/t) per ton.
(5) raw material homogenizing power consumption
Be used for the power consumption of raw material homogenizing in phase in statistics, unit is kilowatt hour (kwh/t) per ton.
(6) fuel oven dry coal consumption
Be used for the fuel consumption of fuel oven dry in phase in statistics, unit is kilogram standard coal equivalent (kgce/t) per ton.
(7) preparation of fuel power consumption
The patch fuel that will enter factory in statistics in the phase carries out pre-homogenizing, fragmentation and grinding to suitable fineness, and with the power consumption of the process that satisfies the clinker burning requirement, unit is kilowatt hour (kwh/t) per ton.
(8) exhaust-gas treatment power consumption
The processing such as in the phase, kiln discharge tail and the waste gas that goes out grinding system are carried out humidifying cooling in statistics and gather dust makes the waste gas of discharging can reach the power consumption of national requirements for environmental protection process, and unit is kilowatt hour (kwh/t) per ton.
(9) grog burns till power consumption
Be used for the power consumption that grog burns till in phase in statistics, unit is kilowatt hour (kwh/t) per ton.
(10) grog burns till coal consumption
Be used for the fuel consumption that grog burns till in phase in statistics, unit is kilogram standard coal equivalent (kgce/t) per ton.
(11) grog storage and conveying power consumption
Be used for the grog storage in statistics in phase and carry the power consumption of dispatching from the factory or being delivered to cement grinding mill allotment storehouse, unit is kilowatt hour (kwh/t) per ton.
(12) supplement production power consumption
In the power consumption of statistics supplement production equipment such as air compressor machine, water circulating pump in the phase, unit is kilowatt hour (kwh/t) per ton.
(13) composite material oven dry coal consumption
Be used for the fuel consumption of composite material oven dry in phase in statistics, unit is kilogram standard coal equivalent (kgce/t) per ton.
(14) composite material prepares power consumption
Be used for the power consumption that composite material is broken, dry in phase in statistics, unit is kilowatt hour (kwh/t) per ton.
(15) cement grinding power consumption
Be used for the power consumption of cement pulverizing course in phase in statistics, unit is kilowatt hour (kwh/t) per ton.
Through after Data Comparison, find that process energy consumption is large, can further by data analysis, search its concrete reason.Following table is listed the concrete analysis parameter of each operation.
Figure BSA00000837781900191
(2) efficiency is analyzed submodule to mark.
Efficiency is analyzed submodule to mark and is used for described online energy consumption index calculating sub module is calculated energy consumption data and international, domestic standard energy consumption index comparing, understand self each index energy consumption residing position between the same industry at home and abroad, enterprise also can annual energy efficiency indexes different from self compare simultaneously, reflects the index situation of change of self.
main energy efficiency indexes has: the grog comprehensive energy consumption, the comprehensive coal consumption of grog, the comprehensive power consumption of grog, the cement comprehensive energy consumption, the comprehensive power consumption of cement, the comprehensive coal consumption of cement, the broken power consumption of raw material, the raw material prehomogenization power consumption, the raw material stoving coal consumption, the raw grinding power consumption, raw material homogenizing power consumption, fuel oven dry coal consumption, the preparation of fuel power consumption, the exhaust-gas treatment power consumption, grog burns till power consumption, grog burns till coal consumption, grog storage and conveying power consumption, the supplement production power consumption, composite material oven dry coal consumption, composite material prepares power consumption, the cement grinding power consumption, grate-cooler power consumption etc.
The efficiency that following table has been listed different scales production line and cement grinding enterprise is to the mark baseline:
Figure BSA00000837781900202
Three, on-line decision control module
The reason that causes apparatus and process to depart from optimum operating condition is many-sided, need to be for the matching relationship of various parameters under the current operation conditions of equipment, and searching is worked as precondition and is divided into standby best operating point, and provides Optimizing Suggestions mainly for operation.
Described on-line decision control module comprises that Raw Material System is optimized submodule, coal dust preparation system is optimized submodule, firing system optimization submodule and cement system and optimized submodule.
(1) Raw Material System is optimized submodule
Raw Material System is optimized submodule and is used for raw meal proportioning is optimized and the raw mill system is optimized control.
Directly have influence on the raw ingredients quality problems because raw material enter the front burdening calculation of mill, the ratio of therefore controlling each material is an important link in Raw Material System.Raw Material System is optimized submodule by the record data according to historical blanking, calculates the raw ingredients development trend, carries out burdening calculation, thereby realizes the optimization to raw meal proportioning.Can progressively adjust discharge quantity according to the deviation of existing discharge quantity instruction and actual discharge quantity, make discharge quantity within feedback a period of time, satisfy existing actual discharge quantity instruction; And make the raw material rate remain near the fluctuation of desired value, can increase substantially raw ingredients qualification rate and quality stability.
The raw mill system is the non-linear of a multiple-input and multiple-output, the multivariate controlled device of large time-delay, and classical control system can't be completed complicated control loop, adopts Raw Material System optimization submodule to control and can receive good control effect.
The control of raw mill system will be divided into the control in meal storehouse and fine powder storehouse, and because there are two charging apertures in system, therefore a discharging opening adopts optimum value comprehensively to adjust the raw mill outlet temperature.
As shown in Figure 6, Raw Material System is optimized submodule and is controlled and expert decision system according to PID (proportional/integral/derivative), recirculating air, meal storehouse hot blast, meal storehouse cold wind, fine powder storehouse hot blast and fine powder storehouse cold wind are regulated, controlling raw mill outlet temperature, meal storehouse entrance negative pressure and fine powder storehouse entrance negative pressure, thereby realize the optimal control to the raw mill system.Expert decision system is the strategy of summing up out according to field operator's operating experience, and it regulates five air doors after raw mill outlet temperature, meal storehouse entrance negative pressure and fine powder storehouse entrance negative pressure are carried out total score simultaneously.Can realize guaranteeing to improve exerting oneself of logistics under raw mill outlet temperature and the normal prerequisite of entrance negative pressure.
In addition, Raw Material System is optimized submodule can carry out the adjusting of best inventory, on the basis of raw mill system stable operation, makes the interior material of raw mill remain on the best, to reduce unit consumption, reaches energy-conservation purpose.Adopt the algorithm of optimizing to change the feed inventory, calculate unit consumption, the judgement change direction is controlled inventory.
The feed inventory that system optimization is calculated according to raw mill, the proportioning value of comprehensive raw mill is determined actual discharge quantity, to reach feed proportioning system and raw mill system balancing.
(2) coal dust preparation system is optimized submodule
Coal dust preparation system is optimized submodule and is used for coal mill is optimized control.
Coal mill is the non-linear of a multiple-input and multiple-output, the multivariate controlled device of large time-delay, and classical control system can't be completed complicated control loop, adopts coal dust preparation system optimization submodule to control and can receive good control effect.
As shown in Figure 7, coal dust preparation system is optimized submodule according to PID control and expert decision system, and recirculating air, hot blast and the cold wind of coal mill are regulated, and with outlet temperature and the entrance negative pressure of control coal mill, thereby realization is to the optimal control of coal mill.The purpose of controlling is to keep the normal stable operation of coal mill, makes outlet temperature and entrance negative pressure within the scope of service requirement.Expert decision system is the strategy of summing up out according to field operator's operating experience, and it regulates three air doors after outlet temperature, entrance negative pressure are carried out total score simultaneously.Can realize guaranteeing to improve exerting oneself of logistics under raw mill outlet temperature and the normal prerequisite of entrance negative pressure.
In addition, coal dust preparation system is optimized submodule can carry out the adjusting of best inventory, on the basis of coal mill stable operation, makes the interior material of coal mill remain on the best, to reduce unit consumption, reaches energy-conservation purpose.Adopt the algorithm of optimizing to change the feed inventory, calculate unit consumption, the judgement change direction is controlled inventory.
(3) firing system is optimized submodule
Firing system is optimized submodule and is used for dore furnace and primary heater are optimized control.
The temperature of dore furnace is an important control parameter that guarantees the normal operation of rotary kiln.When the raw material amount was constant, the blending ratio of fuel and air must correctly be controlled.
As shown in Figure 8, firing system is optimized submodule according to PID control and expert decision system, and the coal amount is regulated, and with the temperature of control dore furnace, thereby realization is to the optimal control of dore furnace.By automatic increase and decrease coal amount, the temperature of dore furnace is regulated, it is controlled on needed setting value.Can make dore furnace keep the highest resolution ratio, not make again it cause the raw material bonding because of excess Temperature, affect the normal operation of kiln system.Wherein, expert decision system can come comprehensive judgement to carry out afterwards the adjusting of coal amount by temperature, the pressure to dore furnace.
The primary heater top hole pressure is a leading indicator of reflection systematic air flow balance.As shown in Figure 9, firing system is optimized submodule according to PID control and expert decision system, and the blower fan valve opening is regulated, and with control primary heater top hole pressure, thereby realization is to the optimal control of primary heater.Wherein expert decision system can be undertaken by the inlet and outlet pressure to primary heater top hole pressure, primary heaters at different levels adjusting the blower fan valve opening after comprehensive judgement.
(4) cement system is optimized submodule
Cement system is optimized submodule and is used for cement ingredient is optimized and cement mill system is optimized control.
The burdening calculation that material enters before mill directly has influence on the cement quality problem, and the ratio of therefore controlling each material is an important link in cement system.Cement system is optimized submodule by the record data according to historical blanking, calculates the cement composition development trend, carries out burdening calculation, thereby realizes the optimization to cement ingredient.Can progressively adjust discharge quantity according to the deviation of existing discharge quantity instruction and actual discharge quantity, make discharge quantity within feedback a period of time, satisfy existing actual discharge quantity instruction; And make the cement rate remain near the fluctuation of desired value, can increase substantially cement composition qualification rate and quality stability.
Cement mill system is the non-linear of a multiple-input and multiple-output, the multivariate controlled device of large time-delay, and classical control system can't be completed complicated control loop, adopts cement system optimization submodule to control and can receive good control effect.
As shown in figure 10, cement system is optimized submodule according to PID control and expert decision system, and hot blast and the cold wind of cement mill system are regulated, and with outlet temperature and the entrance negative pressure of control cement mill system, thereby realization is to the optimal control of cement mill system.Expert decision system is the strategy of summing up out according to field operator's operating experience, and it regulates two air doors after outlet temperature, entrance negative pressure are carried out total score simultaneously.Can realize improving exerting oneself of logistics under the outlet temperature and the normal prerequisite of entrance negative pressure that guarantee cement mill system.
In addition, cement system is optimized submodule can carry out the adjusting of best inventory, on the basis of cement mill system stable operation, makes the interior material of cement grinding mill remain on the best, to reduce unit consumption, reaches energy-conservation purpose.Adopt the algorithm of optimizing to change the feed inventory, calculate unit consumption, the judgement change direction is controlled inventory.
The feed inventory that optimization is calculated according to cement mill system, the proportioning value of comprehensive cement grinding mill is determined actual discharge quantity, to reach feed proportioning system and cement mill system balance.
In sum, produce with the optimization subsystem and integrate Real-time Production Process supervision, optimal control, Real-time Production Process management, have the functions such as Real-time Production Process monitoring, efficiency analysis, Optimized Operation, equipment performance calculating, analysis of economic index and diagnosis, optimization operation, fault diagnosis, equipment Operation safety and economy can be provided, improve on-line analysis and guidance, and be the management decision service.
Digitizing managing and control system of the present invention is realized economical operation, the safe operation of cement mill, and is reduced environmental emission take the in-circuit emulation analytical technology, historical data analysis technology of innovation, advanced diagnosis optimization method as means.
The above is only the preferred embodiments of the present invention, is not limited to the present invention, and for a person skilled in the art, the present invention can have various modifications and variations.Within the spirit and principles in the present invention all, any modification of doing, be equal to replacement, improvement etc., within all should being included in protection scope of the present invention.

Claims (10)

1. cement digitizing managing and control system, it is characterized in that, comprising: analog subsystem, production and optimization subsystem and database, wherein, analog subsystem is connected with the optimization subsystem with production, and database is connected with producing with the optimization subsystem with described analog subsystem respectively;
Described analog subsystem is used for manufacture of cement is carried out simulation calculation;
Described production and optimization subsystem are for the data of storing according to result of calculation and the database of described analog subsystem, analyze and judge whether normal current operational factor and cement manufacture plant move, after the prediction current time, whether operational factor is normal, and manufacture of cement is optimized control;
Described database is used for history run parameter and current operational factor, the scope of operational factor and the corresponding relation of operational factor and equipment state of each production equipment of storage.
2. the system as claimed in claim 1, is characterized in that,
Described analog subsystem comprises: data acquisition module, data check module, equipment state are calculated module, online self-learning module and analog module, wherein, data acquisition module is connected with the data check module, and equipment state calculates that module is connected with analog module with the data check module respectively with online self-learning module;
Described data acquisition module is used for the current operational factor of each production equipment of Real-time Collection manufacture of cement, and is sent to described data check module;
Described data check module is for the scope of the operational factor of setting according to database, the current operational factor that the data acquisition module collects is tested, qualified current operational factor is sent to database, equipment state reckoning module and online self-learning module;
Described equipment state calculates that module is used for the scope of current operational factor and database equipment operational factor is compared, and determines the running status of current each equipment, and running status and the current operational factor of current each equipment is sent to analog module;
Described online self-learning module is used for according to current operational factor, the coefficient of each mathematical model of manufacture of cement is revised, and revised mathematical model is sent to analog module;
Described analog module is included in line locking emulation submodule, and described on-line synchronous emulation submodule is used for according to each mathematical model of current operational factor and manufacture of cement, manufacture of cement being carried out synchronization simulation and calculates.
3. system as claimed in claim 2, is characterized in that,
Described data check module is further used for, if the current operational factor of judgement is defective in checkout procedure, the value that obtains with simulation analysis value in database or historical simulation analysis substitutes underproof current operational factor, reports to the police and shows underproof current operational factor and substitution value thereof.
4. system as claimed in claim 2, is characterized in that,
Described analog module also comprises off-line analysis emulation submodule, and described off-line analysis emulation submodule is used for according to the off-line operation parameter of input and each mathematical model of manufacture of cement, manufacture of cement being carried out simulation calculation.
5. system as claimed in claim 2, is characterized in that,
Described analog module also comprises on-line prediction emulation submodule, and described on-line prediction emulation submodule is used for each mathematical model according to current operational factor and manufacture of cement, manufacture of cement is carried out faster than real time simulation calculate.
6. the system as claimed in claim 1, is characterized in that,
Described production comprises with the optimization subsystem: security module and on-line decision control module, wherein,
Described security module is used for according to cement manufacture plant operation real time data, historical data and emulated data, analyze and judge whether current operational factor and cement manufacture plant move normal, and after the prediction current time, whether operational factor is normal;
The on-line decision control module is used for raw meal proportioning and the cement ingredient of manufacture of cement are optimized, and raw mill system, coal mill, dore furnace, primary heater and cement mill system are optimized control.
7. system as claimed in claim 6, is characterized in that,
Described security module comprises: parameter real-time oversight submodule, online early warning submodule and anomaly parameter detecting submodule, wherein,
Described parameter real-time oversight submodule is used for the current operational factor of the current cement manufacture plant of real-time oversight, reports to the police when operational factor is abnormal;
Described online early warning submodule is used for according to manufacture of cement being carried out the result that faster than real time simulation is calculated, and whether operational factor is normal afterwards to judge current time;
Described anomaly parameter detecting submodule is used for operational factor current according to manufacture of cement, the variation tendency of operational factor, the variation range of operational factor etc., judges whether the cement manufacture plant running status is normal.
8. system as claimed in claim 6, is characterized in that,
Described on-line decision control module comprises that Raw Material System is optimized submodule, coal dust preparation system is optimized submodule, firing system optimization submodule and cement system and optimized submodule, wherein,
Described Raw Material System is optimized submodule by the record data according to historical blanking, calculates the raw ingredients development trend, carries out burdening calculation, thereby to the optimization of raw meal proportioning; And, control and expert decision system according to PID, recirculating air, meal storehouse hot blast, meal storehouse cold wind, fine powder storehouse hot blast and fine powder storehouse cold wind are regulated, controlling raw mill outlet temperature, meal storehouse entrance negative pressure and fine powder storehouse entrance negative pressure, thereby to the optimal control of raw mill system;
Described coal dust preparation system is optimized submodule and is controlled and expert decision system according to PID, recirculating air, hot blast and the cold wind of coal mill regulated, and controlling outlet temperature and the entrance negative pressure of coal mill, thereby to the optimal control of coal mill;
Described firing system is optimized submodule and is controlled and expert decision system according to PID, the coal amount regulated, and controlling the temperature of dore furnace, thereby to the optimal control of dore furnace; And, control and expert decision system according to PID, the blower fan valve opening is regulated, controlling the primary heater top hole pressure, thereby to the optimal control of primary heater.
Described cement system is optimized submodule by the record data according to historical blanking, calculates the cement composition development trend, carries out burdening calculation, thereby to the optimization of cement ingredient; And, control and expert decision system according to PID, hot blast and the cold wind of cement mill system are regulated, controlling outlet temperature and the entrance negative pressure of cement mill system, thereby to the optimal control of cement mill system.
9. system as described in any one in claim 6～8, is characterized in that,
Described production further comprises with the optimization subsystem: economic module, and described economic module is used for calculating comprehensive energy consumption and the distribution energy consumption of manufacture of cement, and with energy consumption data and international, domestic standard energy consumption index comparing.
10. system as claimed in claim 9, is characterized in that,
Described economic module comprises connected online energy consumption index calculating sub module and efficiency to mark analysis submodule, wherein,
Described online energy consumption index calculating sub module is used for calculating comprehensive energy consumption and the distribution energy consumption of manufacture of cement;
Described efficiency is analyzed submodule to mark and is used for described online energy consumption index calculating sub module is calculated energy consumption data and international, domestic standard energy consumption index comparing;
Described comprehensive energy consumption comprises grog comprehensive energy consumption, the comprehensive coal consumption of grog, the comprehensive power consumption of grog, cement comprehensive energy consumption, the comprehensive power consumption of cement and the comprehensive coal consumption of cement;
Described distribution energy consumption comprises that the broken power consumption of raw material, raw material prehomogenization power consumption, raw material stoving coal consumption, raw grinding power consumption, raw material homogenizing power consumption, fuel oven dry coal consumption, preparation of fuel power consumption, exhaust-gas treatment power consumption, grog burn till power consumption, grog burns till coal consumption, grog storage and carries power consumption, supplement production power consumption, composite material oven dry coal consumption, composite material to prepare power consumption, cement grinding power consumption etc.
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CN105069233A (en) * 2015-08-12 2015-11-18 武汉福安神州建材有限公司 Cement performance data analysis system and method
CN106155026A (en) * 2016-08-19 2016-11-23 广东亚仿科技股份有限公司 A kind of cement plant coal consumption and carbon emission monitoring method
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CN110109345A (en) * 2019-05-27 2019-08-09 华电电力科学研究院有限公司 Scraper plate stacker-reclaimer method for fetching, system, electronic equipment and computer media
CN110501946A (en) * 2019-08-22 2019-11-26 万洲电气股份有限公司 A kind of energy management system based on coal mill energy-saving analysis diagnosis
CN110673484A (en) * 2019-10-18 2020-01-10 中国科学院力学研究所 Control system for self-adaptive energy-saving operation of optimal working condition of industrial furnace
CN111582839A (en) * 2020-05-22 2020-08-25 绵阳钢猫科技有限公司 Intelligent cement factory management and control system and management and control method
CN112179127A (en) * 2020-09-23 2021-01-05 万洲电气股份有限公司 Energy-saving system for analysis, diagnosis and optimization of rotary cement kiln
CN113093674A (en) * 2021-04-01 2021-07-09 万洲电气股份有限公司 Cement production comprehensive unit consumption automatic analysis optimization system based on big data analysis
CN113111511A (en) * 2021-04-13 2021-07-13 厦门信达环能科技有限公司 Cement clinker sintering heat consumption calculation method based on flue gas component analysis
CN113554264A (en) * 2021-06-07 2021-10-26 华北电力科学研究院有限责任公司 Alarm method and device for power generation equipment
CN114545866A (en) * 2020-11-11 2022-05-27 台泥资讯股份有限公司 Method for controlling coal consumption system
TWI768545B (en) * 2020-11-16 2022-06-21 臺泥資訊股份有限公司 Method of controlling coal management system
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CN116483045A (en) * 2023-06-25 2023-07-25 荔峰科技(广州)有限公司 Intelligent management and control system for cement clinker production safety based on data analysis
US12038738B2 (en) 2019-03-20 2024-07-16 Tata Consultancy Services Limited Method and system for monitoring and optimizing the operation of an alumina rotary kiln

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CN104339453B (en) * 2014-10-08 2017-07-18 济南大学 A kind of self adaptation cement raw material batching system and its distribution based on typical condition
CN104339453A (en) * 2014-10-08 2015-02-11 济南大学 Typical-working-condition-based adaptive cement raw meal batching system and batching method thereof
CN105069233A (en) * 2015-08-12 2015-11-18 武汉福安神州建材有限公司 Cement performance data analysis system and method
CN106155026A (en) * 2016-08-19 2016-11-23 广东亚仿科技股份有限公司 A kind of cement plant coal consumption and carbon emission monitoring method
CN106155026B (en) * 2016-08-19 2019-03-08 广东亚仿科技股份有限公司 A kind of cement plant coal consumption and carbon emission monitoring method
CN106814719A (en) * 2017-03-01 2017-06-09 济南大学 A kind of whole grinding Optimal Control System of cement joint half and method
CN106814719B (en) * 2017-03-01 2019-01-04 济南大学 A kind of whole grinding Optimal Control System of cement joint half and method
US12038738B2 (en) 2019-03-20 2024-07-16 Tata Consultancy Services Limited Method and system for monitoring and optimizing the operation of an alumina rotary kiln
CN110109345A (en) * 2019-05-27 2019-08-09 华电电力科学研究院有限公司 Scraper plate stacker-reclaimer method for fetching, system, electronic equipment and computer media
CN110501946A (en) * 2019-08-22 2019-11-26 万洲电气股份有限公司 A kind of energy management system based on coal mill energy-saving analysis diagnosis
CN110673484A (en) * 2019-10-18 2020-01-10 中国科学院力学研究所 Control system for self-adaptive energy-saving operation of optimal working condition of industrial furnace
CN111582839A (en) * 2020-05-22 2020-08-25 绵阳钢猫科技有限公司 Intelligent cement factory management and control system and management and control method
CN112179127A (en) * 2020-09-23 2021-01-05 万洲电气股份有限公司 Energy-saving system for analysis, diagnosis and optimization of rotary cement kiln
CN114545866A (en) * 2020-11-11 2022-05-27 台泥资讯股份有限公司 Method for controlling coal consumption system
TWI768545B (en) * 2020-11-16 2022-06-21 臺泥資訊股份有限公司 Method of controlling coal management system
CN113093674A (en) * 2021-04-01 2021-07-09 万洲电气股份有限公司 Cement production comprehensive unit consumption automatic analysis optimization system based on big data analysis
CN113111511A (en) * 2021-04-13 2021-07-13 厦门信达环能科技有限公司 Cement clinker sintering heat consumption calculation method based on flue gas component analysis
CN113111511B (en) * 2021-04-13 2022-10-28 厦门信达环能科技有限公司 Cement clinker sintering heat consumption calculation method based on flue gas component analysis
CN113554264A (en) * 2021-06-07 2021-10-26 华北电力科学研究院有限责任公司 Alarm method and device for power generation equipment
CN113554264B (en) * 2021-06-07 2023-11-17 华北电力科学研究院有限责任公司 Alarm method and device for power generation equipment
CN116414096A (en) * 2023-04-26 2023-07-11 武汉慧友佳华电子有限公司 Intelligent chemical plant production management and control system
CN116483045A (en) * 2023-06-25 2023-07-25 荔峰科技(广州)有限公司 Intelligent management and control system for cement clinker production safety based on data analysis
CN116483045B (en) * 2023-06-25 2023-09-15 荔峰科技(广州)有限公司 Intelligent management and control system for cement clinker production safety based on data analysis

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