CN103092171B - Cement digital management and control system - Google Patents

Cement digital management and control system Download PDF

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Publication number
CN103092171B
CN103092171B CN201310006841.9A CN201310006841A CN103092171B CN 103092171 B CN103092171 B CN 103092171B CN 201310006841 A CN201310006841 A CN 201310006841A CN 103092171 B CN103092171 B CN 103092171B
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cement
module
submodule
manufacture
raw
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CN201310006841.9A
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CN103092171A (en
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田海奎
杨思思
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武安市新峰水泥有限责任公司
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    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P80/00Climate change mitigation technologies for sector-wide applications
    • Y02P80/10Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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 digital managing and control system
Technical field
The present invention relates to technical field of cement production, particularly relate to a kind of cement digital managing and control system.
Background technology
The production of cement normally with lime stone and clay for primary raw material, through broken, batching, levigately make raw material, then feed mature calcined material in cement kiln, then grog is added proper amount of gypsum (sometimes going back admixture composite material or additive) is levigate to be formed.
As shown in Figure 1, the production of cement, generally can divide raw material preparation, sinter leaching and cement production systD three operations, wherein, raw material preparation is divided into dry method and wet method two kinds, and dry method generally adopts closed-circuit operation system, namely raw material is after grinding machine is levigate, enter powder concentrator sorting, meal passes back into the operation of grinding row grinding again, and most material that adopts is dried and the technique of grinding in grinding machine simultaneously.The raw material preparation of dry method specifically can comprise limestone crushing and conveying, associating pre-homogenization yard, material allocation and raw material grinding, raw material enter the flow process such as kiln and exhaust-gas treatment.The equipment of sinter leaching mainly contains shaft kiln and rotary kiln two class, and shaft kiln is applicable to the less factory of production scale, and large and medium-sized factory adopts rotary kiln usually.Kiln cylinder body horizontally-arranged (slightly gradient, is about 3%), and can do gyration be called rotary kiln.Adopt the sinter leaching of rotary kiln specifically can comprise the flow processs such as pulverized coal preparation, the pre-thermal decomposition of kiln tail, calcined by rotary kiln and kiln hood clinker cooling.Cement production systD operation adopts closed-circuit grinding technique (i.e. closed-circuit operation system) usually, can comprise disintegrating machine grog batching, cement grinding mill and the flow process such as cement outbound and packaging.
For above-mentioned each production process, all relate to plurality of devices, such as, just heavy plate-type feeding machine is related to, single block hammer crusher, dust-precipitator, exhaust blower, centrifugal fan, motor, dust-precipitator gas-holder, belt feeder, pulsed stand-alone band dust-precipitator, circle stockyard stacker-reclaimer etc. in the operation of only limestone crushing and conveying.Often kind of equipment all relates to various parameter and index.
Because large-scale cement line production system is huge, equipment is numerous, and operation runs complicated, and control also relative complex, the latency broken down is many.And once break down, even can device damage be caused, no matter fault size, all indirectly or can bring economic loss directly to 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 operation runs complicated problem, proposes a kind of cement digital managing and control system, to improve security and the economy of manufacture of cement.
In order to solve the problem, the invention provides a kind of cement digital managing and control system, comprise: analog subsystem, production and optimization subsystem and database, wherein, analog subsystem is connected with optimization subsystem with production, and database is connected with optimization subsystem with producing with described analog subsystem respectively;
Described analog subsystem is used for carrying out simulation calculation to manufacture of cement;
Described production and the data optimized subsystem and be used for according to storing in the result of calculation of described analog subsystem and database, analyze and judge whether normal current operating parameter and cement manufacture plant run, after prediction current time, whether operational factor is normal, and is optimized control to manufacture of cement;
Described database is for storing historical operating parameter and current operating parameter, the scope of operational factor and the corresponding relation of operational factor and equipment state of each production equipment.
Preferably, said system also has following characteristics:
Described analog subsystem comprises: data acquisition module, data check module, equipment state calculate module, automatic measure on line module and analog module, wherein, data acquisition module is connected with data check module, and equipment state calculates that module is connected with analog module with data check module respectively with automatic measure on line module;
Described data acquisition module is used for the current operating parameter of each production equipment in Real-time Collection manufacture of cement, and is sent to described data check module;
Described data check module is used for the scope according to the operational factor set in database, the current operating parameter that data acquisition module collects is tested, qualified current operating parameter is sent to database, equipment state calculates module and automatic measure on line module;
Described equipment state calculates that module is used for the scope of equipment operational factor in current operating parameter and database to compare, and determines the running status of each equipment current, the running status of each equipment current and current operating parameter are sent to analog module;
Described automatic measure on line module is used for according to current operating parameter, revises, and revised mathematical model is sent to analog module to the coefficient of each mathematical model of manufacture of cement;
Described analog module is included in line locking emulation submodule, and described on-line synchronous emulation submodule is used for carrying out synchronization simulation calculating according to each mathematical model of current operating parameter and manufacture of cement to manufacture of cement.
Preferably, said system also has following characteristics:
Described data check module is further used for, if judge in checkout procedure, current operating parameter is defective, then substitute underproof current operating parameter by the value that simulation analysis value in database or history simulation analysis obtain, report to the police and show underproof current operating parameter 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 carrying out simulation calculation according to the off-line operation parameter of input and each mathematical model of manufacture of cement to manufacture of cement.
Preferably, said system also has following characteristics:
Described analog module also comprises online predictive simulation submodule, and described on-line prediction emulation submodule is used for each mathematical model according to current operating parameter and manufacture of cement, carries out faster than real time simulation calculating to manufacture of cement.
Preferably, said system also has following characteristics:
Described production comprises with optimization subsystem: security module and on-line decision control module, wherein,
Described security module is used for running real time data, historical data and emulated data according to cement manufacture plant, analyze and judge whether current operating parameter and cement manufacture plant run normal, and after prediction current time, whether operational factor is normal;
On-line decision control module is used for being optimized the raw meal proportioning of manufacture of cement and cement ingredient, is optimized control to raw mill system, coal mill, dore furnace, primary heater and cement mill system.
Preferably, said system also has following characteristics:
Described security module comprises: parameter real-time oversight submodule, on-line early warning submodule and anomaly parameter detecting submodule, wherein,
Described parameter real-time oversight submodule is used for the current operating parameter of the current cement manufacture plant of real-time oversight, reports to the police when operational factor is abnormal;
Described on-line early warning submodule is used for the result according to carrying out faster than real time simulation calculating to manufacture of cement, and after judging current time, whether operational factor is normal;
Described anomaly parameter detecting submodule is used for according to the variation tendency of manufacture of cement current operating parameter, operational factor, the variation range etc. of operational factor, judges that whether cement manufacture plant running status is normal.
Preferably, said system also has following characteristics:
Described on-line decision control module comprises Raw Material System and optimizes submodule, coal dust preparation system optimization submodule, firing system optimization submodule and cement system optimization submodule, wherein,
Described Raw Material System optimizes submodule by the record data according to history blanking, calculates raw ingredients development trend, carries out burdening calculation, thus the optimization to raw meal proportioning; And, control and expert decision system according to PID, recirculating air, coarse powder bin hot blast, coarse powder bin cold wind, fine powder bin hot blast and fine powder bin cold wind are regulated, to control raw mill outlet temperature, coarse powder bin entrance negative pressure and fine powder bin entrance negative pressure, thus the optimal control to raw mill system;
Described coal dust preparation system is optimized submodule and is controlled and expert decision system according to PID, regulates the recirculating air of coal mill, hot blast and cold wind, to control outlet temperature and the entrance negative pressure of coal mill, thus the optimal control to coal mill;
Described firing system is optimized submodule and is controlled and expert decision system according to PID, regulates coal amount, to control the temperature of dore furnace, thus the optimal control to dore furnace; And, control and expert decision system according to PID, blower fan valve opening is regulated, to control primary heater top hole pressure, thus the optimal control to primary heater.
Described cement system optimizes submodule by the record data according to history blanking, calculates cement composition development trend, carries out burdening calculation, thus the optimization to cement ingredient; And, control and expert decision system according to PID, the hot blast of cement mill system and cold wind are regulated, to control outlet temperature and the entrance negative pressure of cement mill system, thus the optimal control to cement mill system.
Preferably, said system also has following characteristics:
Described production with optimize subsystem and comprise further: economic module, described economic module for calculating comprehensive energy consumption and the distribution energy consumption of manufacture of cement, and by 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 analyzes submodule to mark, wherein,
Described online energy consumption index calculating sub module is 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 being 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 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 dries coal consumption, preparation of fuel power consumption, exhaust-gas treatment power consumption, sinter leaching power consumption, sinter leaching coal consumption, grog stores with conveying power consumption, supplement production power consumption, composite material dries coal consumption, composite material prepares power consumption, cement grinding power consumption etc.
The present invention can bring significant direct, indirect benefit for 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 timely, accurate, realize optimum efficiency;
(2) based on systematic analysis, optimizing operation controls, and reduces the consumption of coal, electricity, oil, water, realizes direct economic benefit;
(3) in-circuit emulation early warning, abnormal examinations, fault diagnosis etc. ensure cement mill safe operation, and safe be the maximum economic benefit in cement mill.
Accompanying drawing explanation
Fig. 1 is manufacture of cement schematic flow sheet;
Fig. 2 is the cement digital 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 relation schematic diagram that the on-line synchronous emulation of the embodiment of the present invention emulates with on-line prediction;
Fig. 5 is the production of the embodiment of the present invention and optimization subsystem schematic diagram;
Fig. 6 is that the raw mill system optimization of the embodiment of the present invention controls schematic diagram;
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 will be described in detail to embodiments of the invention by reference to the accompanying drawings.It should be noted that, when not conflicting, the embodiment in the application and the feature in embodiment can combination in any mutually.
As shown in Figure 2, the cement digital managing and control system of the embodiment of the present invention, comprising: analog subsystem, production and optimization subsystem and database, wherein, analog subsystem is connected with optimization subsystem with production, and database is connected with optimization subsystem with producing with described analog subsystem respectively;
Described analog subsystem is used for carrying out simulation calculation to manufacture of cement;
Described production and the data optimized subsystem and be used for according to storing in the result of calculation of described analog subsystem and database, analyze and judge whether normal current operating parameter and cement manufacture plant run, after prediction current time, whether operational factor is normal, and is optimized control to manufacture of cement;
Described database is for storing historical operating parameter and current operating parameter, the scope of operational factor and the corresponding relation of operational factor and equipment state of each production equipment.
Wherein, database comprises historical data base and real-time data base, wherein the historical operating parameter of each production equipment of historical data library storage, and real-time data base stores the current operating parameter of each production equipment.In addition, because often kind of operational factor all has the parameter characteristic such as its range of normal value, exceptional value scope, so database also stored for the information of this aspect.
Such as, for 5000t/d grog dry process production line, in sinter leaching system, following important parameter is had:
1. high-temperature blower speed: 800-830 rpm, effect ensures system ventilation and air quantity, wind coal charge sufficient heat exchange.
2. Coaling of Decomposing Furnace: outlet temperature, at 865 degree to 875 degree, makes carbonate fully decompose, and alleviates kiln load.
3. kiln hood feeds coal amount: at 10.5 to 11.5 tons, material is being burnt till with sufficient chemical reaction.
4. grate-cooler one section of speed: 8 to 9 times per minute, and grog heat is fully recovered in kiln, improves burning zone temperature.
5. grate-cooler two sections of speed: 12 to 14 times per minute, makes grog chilling, improve grog performance.
6. grate-cooler three sections of speed: 16 to 18 times per minute, reduce clinker temperature, improve grog grindability.
7. kiln head exhaust fan speed: 85%-95% controls kiln hood negative pressure, and kiln hood waste gas is discharged in air.
8. kiln owner's current of electric: between 600 to 800A, the calcining change of reaction mass in kiln.
9. by adjustment rotation speed of fan, kiln hood primary air fan pressure: 26-28kpa, ensures that pulverized coal conveying is stablized.
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 2content is less than 0.2%, detects coal dust whether Thorough combustion.
13. smoke-box gas analyzer: O 2content about 2.0%, CO 2content is less than 0.05%, detects coal dust whether Thorough combustion.
14. roots blowers: 27A23 electric current 95-105A 27A22 electric current 95-105A 27A27 electric current 135-145A 27A21 electric current 135-145A, the actual lower coal amount of reaction.
15. smoke-box temperature: 1050 DEG C--1150 DEG C, whether reaction kiln thermal regulation is stablized.
Above-mentioned parameter is the range of normal value of equipment.Correspondingly, above-mentioned parameter also has exceptional value scope, and such as high-temperature blower speed is when steady running, less than 800 rpms, or 830-1000 rpm is exceptional value, represents that this equipment operation is abnormal.
Below analog subsystem and production are described in detail respectively with optimization subsystem.
● analog subsystem
Analog subsystem can comprise the emulation to systems such as raw material preparation, sinter leaching, cement production systDs, for 5000t/d grog dry process production line, specifically can comprise:
1, raw material preparation system
(1) limestone crushing and induction system
Simulation scale: 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, circle stockyard stacker-reclaimer etc.
(2) pre-homogenization yard system is combined
Simulation scale: belt feeder of screening coal, side hang scraper reclaimer, belt feeder etc.And the pre-homogenization yard of all kinds of auxiliary material, raw coal stockyard, various stacker, reclaimer, fly-ash separator, rubber conveyer etc.
(3) material allocation and raw material grinding system
Simulation scale: 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
Simulation scale: 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
Simulation scale: conditioning Tower, electric precipitator, all kinds of blower fan, all kinds of valves etc.
2, sinter leaching system
Simulation scale 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
Simulation scale: 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
Simulation scale includes but not limited to following system:
Disintegrating machine grog feed proportioning system, cement mill system and cement outbound and packaging system
Simulation scale: 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
Simulation scale: the change of high factory, 10KV bus, each section of bus working power switch, Backup Power Switch etc.
(2) 400V distribution system
Simulation scale: low pressure factory becomes and all protections of transformer high and low side switch, 400V bus, emergency power supply and 400V Auxiliary System, the low compression bonded line of station-service and control, signal circuit etc.
5, control system
Simulation scale: all regulating parameter in control system.
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 calculate module, automatic measure on line module and analog module, wherein, data acquisition module is connected with data check module, and equipment state calculates that module is connected with analog module with data check module respectively with automatic measure on line module;
Described data acquisition module is used for the current operating parameter of each production equipment in Real-time Collection manufacture of cement, and is sent to described data check module;
Described data check module is used for the scope according to the operational factor set in database, the current operating parameter that data acquisition module collects is tested, qualified current operating parameter is sent to database, equipment state calculates module and automatic measure on line module;
Described equipment state calculates that module is used for the scope of equipment operational factor in current operating parameter and database to compare, and determines the running status of each equipment current, the running status of each equipment current and current operating parameter are sent to analog module;
Described automatic measure on line module is used for according to current operating parameter, revises, and revised mathematical model is sent to analog module to the coefficient of each mathematical model of manufacture of cement;
Described analog module is included in line locking emulation submodule, and described on-line synchronous emulation submodule is used for carrying out synchronization simulation calculating according to each mathematical model of current operating parameter and manufacture of cement to manufacture of cement.
Below each module is described in detail:
One, data acquisition module:
The current operating parameter 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 the current operating parameter collected can be issued with the form udp broadcast of exception report.Can the current operating parameter collected be saved in database in addition, for inquiry, and can using the input data of historical data as off-line simulation.Data buffer storage at least preserves the historical data of 15 days.
Online simulation subsystem passes through data acquisition, thus 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 Optimizing manufacture and analytic system, management optimization and decision system etc.
Two, data check module:
Because the data collected may be numbers of non-compliances according to i.e. " bad value ", data check module can be tested to the current operating parameter that data acquisition module collects.It is according to the scope being exactly parameters in above-mentioned database.When data check module verifies the data that collect neither normal value, neither exceptional value, so just judge that current operating parameter is defective, then substitute underproof current operating parameter by the value that simulation analysis value in database or history simulation analysis obtain, but also staff can be reminded by the mode of reporting to the police, and show the list of underproof current operating parameter and substitution value thereof by the station that works online.If it is qualified to verify, then qualified current operating parameter is sent to database, equipment state calculates module and automatic measure on line module.
Three, equipment state calculates module:
This module is analyzed current operating parameter, the scope of equipment operational factor in current operating parameter and database is compared, determine the running status of each equipment current, such as normal state or anomalous mode, thus determine safety, the economic level of equipment, equipment, carry out may be used for predicting contingent fault, find out failure cause, analytical equipment state, proposes the maintenance suggestion time; Data are patrolled and examined and equipment state curve can Timeliness coverage hidden trouble of equipment additionally by analysis.
Four, automatic measure on line module:
Automatic measure on line module is set out by physics, chemical basic principle, as Combustion, fluid mechanics, thermal conduction study etc., according to current operating parameter, accurately extrapolate cement mill operational outfit and system performance parameter (coefficient of mathematical model) under current working, the coefficient of existing mathematical model is revised, makes the simulation calculation more closing to reality of analog module.
Because the characteristic in actual motion is difficult to explain by simple theory, theoretical value and actual condition have fractional error, and by self study, auto modification online simulation subsystem coefficient, makes realistic model more can represent actual condition accurately.Self learning model refers to the mathematical model set up based on basic physics, the principles of chemistry, revises mathematical model coefficient in real time, make the synchronous operation within error range of emulation operating mode and actual condition in the middle of actual condition operational process.
Five, analog module
Analog module can calculate according to the data of equipment current working or history operating mode in Real-Time Sharing database and according to each mathematical model of manufacture of cement, set up the operating condition identical with physical device, namely there is the function copied to completely by equipment running status on analog module.
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 calculating according to each mathematical model of current operating parameter and manufacture of cement to manufacture of cement.
On-line synchronous simulation model is basic operational mode, is exactly that analog subsystem obtains execute-in-place command synchronization online and carries out simulation calculation, runs unless exited it under special circumstances, otherwise just on-line operation continuously always.By equipment state, on-line synchronous emulation submodule calculates that module or database constantly receive the operational factor (comprising mode of operation signal and measuring-signal) from scene, carry out tracking computation and analysis with this.
For on-line synchronous simulation model, the initial operating mode of realistic model must be consistent with on-the-spot operating condition.Although in-circuit emulation model can by all field control states of shared data bank and measurement parameter, there is a large amount of process variables and intermediate quantity in realistic model, they directly cannot obtain from scene, so must carry out the initialization of in-circuit emulation.Basic implementation method is: the starting point first selecting an initial operating mode closest to current working to call in internal memory from the initial operating mode of having preserved when initial start on-line synchronous emulates to calculate as initialization, this initial operating mode of calling in and on-the-spot actual motion state may be variant, now initialization is carried out to all realistic model amounts (comprising process variable and intermediate quantity), the error of analytical model result of calculation and cement mill actual value (analog quantity), when all errors being verified value are less than error requirements and all on-off states are completely the same with on-the-spot value, think that initialization completes, real-time online synchronization simulation model drops into and calculates.
Except being calculated by except the various parameter of imitative object and equipment state by realistic model under on-line synchronous simulation model, equipment state calculates module and the also synchronous operation of automatic measure on line module, analyze the running status of each equipment current, and revise realistic model in real time.On-line synchronous simulation model, once startup, just starts log history data, and the history value recorded checks trend for related personnel by Simulation Interface, is also the foundation of carrying out history performance analysis and the calculating of some index parameters.The record of historical data also provides data for returning under off-line analysis simulation model is followed the trail of and operation note is reset, and this is the important means of carrying out operating analysis.
On-line synchronous emulation to provide the foundation data for the function such as online operating analysis and fault diagnosis, and on-line synchronous emulate the foundation that the operating process of recording and history operating mode are off-line simulation analyses.
On-line synchronous emulation submodule can be implemented in line hard measurement in addition.Online soft sensor technology utilizes some the comparatively easily online auxiliary variable of Measurement accuracy or historical datas of analytical test, by on-line analysis, calculates and can not measure in real time or a kind of method of difficult measurand.For actual conditions and the needs of cement mill, choose the physical quantity being 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, current scene adopts the measuring method of 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 primary operating mode of analog module, only there is on-line synchronous emulation submodule can not embody function and the effectiveness of analog module completely.Online simulation subsystem to calculate and except the real-time function such as operating analysis, fault diagnosis except carrying out Synchronization Analysis, also will realize the functions such as the analysis to history run event, the pre-authentication of significant technical, the formulation of emergent accident processing specification and the optimum choice of operational mode.These functions are carried out under off-line analysis simulation model.
Off-line analysis simulation model is exactly the mode that analog subsystem departs from on-the-spot service data and independent operating completely.
The initial operating mode of startup of off-line analysis simulation model obtains by with under type:
(1) using the initial operating mode that the current operating condition of on-line synchronous emulation emulates as off-line analysis, i.e. the direct data obtaining the emulation of current on-line synchronous from shared drive;
(2) initial operating mode (IC), this is the standard original state under slip-stick artist or user arrange the various operating conditions of maintenance;
(3) reset is kept at the historical data in historical data base by on-line synchronous simulation model, and the time of historical data can select recorded any historical juncture.
Submodule is emulated by off-line analysis, control operations staff's operation training system, production management personnel operational management training system, field device operation work local operation training system, electrical operation personnel operation training system in can setting up, thermal technology's personnel control system researchs and analyses system, industrial accident phenomenon demonstrates training system, industrial accident process rehearsal training system, production run personnel checking system on duty, production run personnel promotion checking system etc., trained accordingly on off-line simulation machine by related personnel, improve corresponding operating level.
(3) on-line prediction emulation submodule
On-line prediction emulation submodule, according to each mathematical model of current operating parameter and manufacture of cement, carries out faster than real time simulation calculating to manufacture of cement.
On-line prediction simulation model calculates the running status in predict device future for using realistic model with super real-time (Faster Than Real-time, faster than in real time) speed.Obviously, by can predict the problem that equipment runs to the prediction of equipment state, remind operations staff in advance, thus correct operation problem in time, prevent the generation of major accident or shutdown.
As shown in Figure 4, on-line prediction emulation start time, automatically with Δ t for the cycle, be replicated in from shared drive line locking emulation current operating condition data, carry out super real-time calculating to current operating condition, simulation and prediction is from t0 (current time) to the running status of t0+ Δ T time section.Δ T can be set by slip-stick artist, and scope is generally 15 minutes ~ 1 hour, the concrete travelling speed by computing machine and capacity limit.The scope of Δ t is generally 1 minute ~ 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 may be used for Optimizing manufacture and management optimization, and the management of cement mill and production are had in time and the decision-making foundation of science.
● 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 running real time data, historical data and emulated data according to cement manufacture plant, analyze and judge whether current operating parameter and cement manufacture plant run normal, and after prediction current time, whether operational factor is normal;
Described economic module for calculating comprehensive energy consumption and the distribution energy consumption of manufacture of cement, and by energy consumption data and international, domestic standard energy consumption index comparing;
On-line decision control module is used for being optimized the raw meal proportioning of manufacture of cement and cement ingredient, is optimized control to raw mill system, coal mill, dore furnace, primary heater and cement mill system.
Wherein, above-mentioned economic module is optional module.
Below each module is described in detail:
One, security module:
Because the latency of cement mill system generation Shutting Down fault is many, once there is technology trouble, gently then force attenuating output, heavy then Parking can be caused to occur, even can cause device damage, no matter technology trouble size, all indirectly or economic loss can be brought directly to cement mill.Therefore, by failure prediction and the diagnostic function of security module, find system and the potential technology trouble of equipment early, the anomalous event that prediction may occur in the future, and take treatment measures in time, equipment and reliability of operation can be improved, guarantee device security, run economically.
Security module is the functional module for cement mill safety problem, comprising: parameter real-time oversight submodule, on-line early warning submodule and anomaly parameter detecting submodule.
(1) parameter real-time oversight submodule:
Parameter real-time oversight submodule is used for the current operating parameter of the current cement manufacture plant of real-time oversight, reports to the police when operational factor is abnormal.
System in normally running all parameters fluctuate in a normal scope, when namely parameter fluctuation has exceeded threshold value beyond normal scope, then with report to the police form occur.
The threshold value judged comprises two types:
(1) according to the threshold value that designing requirement, user manual and operating experience are determined, can be a fixing value.
(2) according to the threshold value that historical data is determined.According to history value under same operating condition, can effectively find the exception, particularly unconspicuous hidden danger in unit operation.
(2) on-line early warning submodule:
On-line early warning submodule is used for the result according to carrying out faster than real time simulation calculating to manufacture of cement, and after judging current time, whether operational factor is normal.
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 on-line early warning submodule, on-line early warning submodule to judge from current time to current time+the running status of Δ T according to result of calculation.Wherein Δ t is the cycle, and Δ T is predicted time length, is the integral multiple of Δ t.Find that important parameter crosses the border and the information such as protection act (as bucket puies forward the parameter such as feedback current, hoister electric current) of equipment thus; and analysis and early warning equipment is about to possible cause and the treatment advice of the exception occurred in running, and these information are supplied to user.
(3) anomaly parameter detecting submodule
Anomaly parameter detecting submodule be used for according to equipment run real time data and historical data analysis judgment device running status whether normal.Particularly, the variation tendency of this module according to manufacture of cement current operating parameter, operational factor, the variation range, absolute value etc. of operational factor, judge that whether cement manufacture plant running status is normal.Wherein, it is manufacture of cement current operating parameter that equipment runs real time data, and the variation tendency of operational factor and the variation range of operational factor run real time data by equipment and historical data obtains.
After anomaly parameter detecting submodule finds that there is abnormal parameters, there are two kinds for the treatment of methods:
(1) parameter itself is directly reflected to the situation (as hoister current anomaly) of plant issue, directly (or through simple analysis) exports as warning information, prompting operations staff process;
(2) other situation, as abnormal parameters directly can not reflect status information of equipment, is that problem has appearred in which equipment by the further analyzing and diagnosing of abnormal discriminant analysis model.
In addition, this module is the change (comprising unavailable hydraulic performance decline) of analytical equipment performance and the impact on equipment operation thereof also, thus differentiates whether propose maintenance suggestion.Such as:
(1) overtemperature statistics: carry out statistical study to the isoparametric overheating operation number of times of the bearing temperature of equipment components and time, its statistic analysis result is as the foundation of fail-safe analysis, Analysis on Cyclic Life Expenditure.
(2) electric switch operation statistics: statistical study is carried out to the operation history of cement mill electric switch, wherein the hot line job number of times, trip operation number of times, not hot line job number of times etc. of statistic switch.
Above-mentioned state analysis is the basis realizing equipment state overhauling, by the statistical study to equipment state, thus differentiates whether propose maintenance suggestion.
Two, economic module
Economic module runs real time data, historical data and the emulated data fundamental for analyzing with cement manufacture plant, on-line analysis cement mill equipment running status, multianalysis is carried out to the economy of equipment, operations staff's Timeliness coverage equipment running status is helped, for systematic economy combustion adjustment provides foundation by performance indicators.In addition, for cement industry energy resource consumption, management and current Status of Energy-Saving, according to cement production enterprise efficiency, the index of mark employing and index system are calculated, for cement industry energy resource consumption, management and Energy Conservation are for basic foundation.
This module is mainly 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) " cement production enterprise efficiency is to mark guide "
(4) " heat output determining method of GB/T213-2003 coal "
(5) " GB/T2589 comprehensive energy consumption calculates 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 connected online energy consumption index calculating sub module and efficiency analyzes submodule to mark.
(1) online energy consumption index calculating sub module
Online energy consumption index calculating sub module is 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 producing grog consumption per ton within the statistics phase are converted to comprehensive energy consumption that standard coal equivalent obtains, 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 grog comprehensive energy consumption.
(2) the comprehensive coal consumption of grog
Within the statistics phase, produce the fuel consumption of grog per ton, comprise the fuel of drying raw materials and fuel and burning till grog consumption, unit is kilogram standard coal equivalent (kgce/t) per ton.
(3) the comprehensive power consumption of grog
Within the statistics phase, produce the combined power consumption of grog per ton, comprise the power consumption in grog production run and the power consumption producing grog supporting process, unit is kilowatt hour (kwh/t) per ton.
(4) cement comprehensive energy consumption
The various energy producing cement consumption per ton within the statistics phase are converted to comprehensive energy consumption that standard coal equivalent obtains, and unit is kilogram standard coal equivalent (kgce/t) per ton.
When calculating cement comprehensive energy consumption index, 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 the aspect corrections such as blending amount of mixture material simultaneously.
(5) the comprehensive power consumption of cement
Within the statistics phase, produce the combined power consumption of cement per ton, comprise the power consumption in each process of manufacture of cement and the power consumption producing cement supporting process, unit is kilowatt hour (kwh/t) per ton.
(6) the comprehensive coal consumption of cement
Within the statistics phase, produce the fuel consumption of cement per ton, comprise and dry raw materials and fuel and burn till the fuel of grog consumption and the fuel of composite material oven dry consumption, unit is kilogram standard coal equivalent (kgce/t) per ton.
Distribution energy consumption comprises 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 dries coal consumption, preparation of fuel power consumption, exhaust-gas treatment power consumption, sinter leaching power consumption, sinter leaching coal consumption, grog stores with conveying power consumption, supplement production power consumption, composite material dries coal consumption, composite material prepares power consumption, cement grinding power consumption etc.
(1) the broken power consumption of raw material
For comprising the power consumption of the various raw material fragmentations such as lime stone, sandstone, iron ore within the statistics phase, unit is kilowatt hour (kwh/t) per ton.
(2) raw material prehomogenization power consumption
For the power consumption of raw material prehomogenization within the statistics phase, unit is kilowatt hour (kwh/t) per ton.
(3) raw material stoving coal consumption
For the fuel consumption of raw material stoving within the statistics phase, unit is kilogram standard coal equivalent (kgce/t) per ton.
(4) raw grinding power consumption
For the power consumption of raw material grinding within the statistics phase, unit is kilowatt hour (kwh/t) per ton.
(5) raw material homogenizing power consumption
For the power consumption of raw material homogenizing within the statistics phase, unit is kilowatt hour (kwh/t) per ton.
(6) fuel dries coal consumption
For the fuel consumption that fuel is dried within the statistics phase, unit is kilogram standard coal equivalent (kgce/t) per ton.
(7) preparation of fuel power consumption
The patch fuel entering factory is carried out pre-homogenizing, fragmentation and grinding within the statistics phase to suitable fineness, to meet the power consumption of the process of clinker burning requirement, unit is kilowatt hour (kwh/t) per ton.
(8) exhaust-gas treatment power consumption
The process such as carry out humidifying cooling to kiln discharge tail and the waste gas that goes out grinding system and gather dust within the statistics phase, make the waste gas of discharge can reach the power consumption of national requirements for environmental protection process, unit is kilowatt hour (kwh/t) per ton.
(9) sinter leaching power consumption
For the power consumption of sinter leaching within the statistics phase, unit is kilowatt hour (kwh/t) per ton.
(10) sinter leaching coal consumption
For the fuel consumption of sinter leaching within the statistics phase, unit is kilogram standard coal equivalent (kgce/t) per ton.
(11) grog stores and conveying power consumption
Store for grog within the statistics phase and dispatch from the factory with conveying or be delivered to the power consumption that cement grinding mill allocates storehouse, unit is kilowatt hour (kwh/t) per ton.
(12) supplement production power consumption
The power consumption of the supplement production such as air compressor machine, water circulating pump equipment within the statistics phase, unit is kilowatt hour (kwh/t) per ton.
(13) composite material dries coal consumption
For the fuel consumption that composite material is dried within the statistics phase, unit is kilogram standard coal equivalent (kgce/t) per ton.
(14) composite material prepares power consumption
Broken for composite material within the statistics phase, to dry power consumption, unit is kilowatt hour (kwh/t) per ton.
(15) cement grinding power consumption
For the power consumption of cement pulverizing course within the statistics phase, unit is kilowatt hour (kwh/t) per ton.
After Data Comparison, find that process energy consumption is large, then further by data analysis, its concrete reason can be searched.Following table lists the concrete analysis parameter of each operation.
(2) efficiency analyzes submodule to mark.
Efficiency is analyzed submodule to mark and is used for described online energy consumption index calculating sub module being calculated energy consumption data and international, domestic standard energy consumption index comparing, understand the position that self each index energy consumption is residing 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: 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, the comprehensive coal consumption of cement, 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 dries coal consumption, preparation of fuel power consumption, exhaust-gas treatment power consumption, sinter leaching power consumption, sinter leaching coal consumption, grog stores and conveying power consumption, supplement production power consumption, composite material dries coal consumption, composite material prepares power consumption, cement grinding power consumption, grate-cooler power consumption etc.
Following table lists the efficiency of different scales production line and cement grinding enterprise to mark baseline:
Three, on-line decision control module
The reason causing apparatus and process to depart from optimum operating condition is many-sided, needs the matching relationship for parameter various under equipment current operating conditions, the best operating point of equipment under searching conditions present, and provides Optimizing Suggestions mainly for operation.
Described on-line decision control module comprises Raw Material System and optimizes submodule, coal dust preparation system optimization submodule, firing system optimization submodule and cement system optimization submodule.
(1) Raw Material System optimizes submodule
Raw Material System is optimized submodule and is used for being optimized raw meal proportioning and being optimized control to raw mill system.
Because the burdening calculation before raw material enter mill directly has influence on raw ingredients quality problems, the ratio therefore controlling each material is an important link in Raw Material System.Raw Material System optimizes submodule by the record data according to history blanking, calculates raw ingredients development trend, carries out burdening calculation, thus realizes the optimization to raw meal proportioning.Progressively can 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, meet existing actual discharge quantity instruction; And make raw material rate remain on fluctuation near desired value, raw ingredients qualification rate and quality stability can be increased substantially.
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 cannot complete complicated control loop, adopts Raw Material System to optimize submodule and carries out controlling to receive good control effects.
The control of raw mill system will be divided into the control of coarse powder bin and fine powder bin, and because system has two charging apertures, a discharging opening, therefore adopts optimum value to carry out structure adjusting 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, coarse powder bin hot blast, coarse powder bin cold wind, fine powder bin hot blast and fine powder bin cold wind are regulated, to control raw mill outlet temperature, coarse powder bin entrance negative pressure and fine powder bin entrance negative pressure, thus realize the optimal control to raw mill system.Expert decision system is the strategy of summing up out according to the operating experience of field operator, after it carries out total score to raw mill outlet temperature, coarse powder bin entrance negative pressure and fine powder bin entrance negative pressure, regulates five air doors simultaneously.Can be implemented under ensureing raw mill outlet temperature and the normal prerequisite of entrance negative pressure, improve exerting oneself of logistics.
In addition, Raw Material System optimizes the adjustment that submodule can carry out best inventory, on the basis of raw mill system stable operation, makes material in raw mill remain on the best, to reduce unit consumption, reaches energy-conservation object.Adopt the algorithm of optimizing to change feed inventory, calculate unit consumption, judge change direction, control inventory.
According to the feed inventory that raw mill system optimization is calculated, the proportioning value of comprehensive raw mill determines actual discharge quantity, to reach feed proportioning system and raw mill system balancing.
(2) coal dust preparation system optimizes submodule
Coal dust preparation system is optimized submodule and is used for being optimized control to coal mill.
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 cannot complete complicated control loop, adopts coal dust preparation system to optimize submodule and carries out controlling to receive good control effects.
As shown in Figure 7, coal dust preparation system is optimized submodule and is controlled and expert decision system according to PID, regulates the recirculating air of coal mill, hot blast and cold wind, to control outlet temperature and the entrance negative pressure of coal mill, thus realizes the optimal control to coal mill.The object controlled is that the normal table maintaining coal mill runs, and 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 the operating experience of field operator, after it carries out total score to outlet temperature, entrance negative pressure, regulates three air doors simultaneously.Can be implemented under ensureing raw mill outlet temperature and the normal prerequisite of entrance negative pressure, improve exerting oneself of logistics.
In addition, coal dust preparation system optimizes the adjustment that submodule can carry out best inventory, on the basis of coal mill stable operation, makes material in coal mill remain on the best, to reduce unit consumption, reaches energy-conservation object.Adopt the algorithm of optimizing to change feed inventory, calculate unit consumption, judge change direction, control inventory.
(3) firing system optimizes submodule
Firing system is optimized submodule and is used for being optimized control to dore furnace and primary heater.
The temperature of dore furnace is the important controling parameters ensureing that rotary kiln normally runs.When raw material amount is constant, the blending ratio of fuel and air must correctly control.
As shown in Figure 8, firing system is optimized submodule and is controlled and expert decision system according to PID, regulates coal amount, to control the temperature of dore furnace, thus realizes the optimal control to dore furnace.Regulating by automatically increasing or decreasing the temperature of coal amount to dore furnace, making it control in required setting value.The resolution ratio that dore furnace can be made to keep the highest, does not make again it cause because temperature is too high raw material to bond, affects the normal operation of kiln system.Wherein, expert decision system can be carried out comprehensive descision by the temperature to dore furnace, pressure and carried out the adjustment of coal amount afterwards.
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 and is controlled and expert decision system according to PID, regulates blower fan valve opening, to control primary heater top hole pressure, thus realizes the optimal control to primary heater.Wherein expert decision system can adjust blower fan valve opening after carrying out comprehensive descision to the inlet and outlet pressure of primary heater top hole pressure, primary heater at different levels.
(4) cement system optimizes submodule
Cement system is optimized submodule and is used for being optimized cement ingredient and being optimized control to cement mill system.
Burdening calculation before material enters mill directly has influence on cement quality problem, and the ratio therefore controlling each material is an important link in cement system.Cement system optimizes submodule by the record data according to history blanking, calculates cement composition development trend, carries out burdening calculation, thus realizes the optimization to cement ingredient.Progressively can 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, meet existing actual discharge quantity instruction; And make cement rate remain on fluctuation near desired value, cement composition qualification rate and quality stability can be increased substantially.
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 cannot complete complicated control loop, adopts cement system to optimize submodule and carries out controlling to receive good control effects.
As shown in Figure 10, cement system is optimized submodule and is controlled and expert decision system according to PID, regulates the hot blast of cement mill system and cold wind, to control outlet temperature and the entrance negative pressure of cement mill system, thus realizes the optimal control to cement mill system.Expert decision system is the strategy of summing up out according to the operating experience of field operator, after it carries out total score to outlet temperature, entrance negative pressure, regulates two air doors simultaneously.Under can be implemented in the outlet temperature and the normal prerequisite of entrance negative pressure ensureing cement mill system, improve exerting oneself of logistics.
In addition, cement system optimizes the adjustment that submodule can carry out best inventory, on the basis of cement mill system stable operation, makes material in cement grinding mill remain on the best, to reduce unit consumption, reaches energy-conservation object.Adopt the algorithm of optimizing to change feed inventory, calculate unit consumption, judge change direction, control inventory.
According to the feed inventory that cement mill system optimization is calculated, the proportioning value of comprehensive cement grinding mill determines actual discharge quantity, to reach feed proportioning system and cement mill system balances.
In sum, produce with optimize that subsystem integrates that Real-time Production Process is supervised, optimal control, Real-time Production Process manage, there is the functions such as Real-time Production Process monitoring, efficiency analysis, Optimized Operation, equipment performance calculating, analysis of economic index and diagnosis, optimizing operation operation, fault diagnosis, the security that equipment can be provided to run and economy, improve on-line analysis and guidance, and be management decision service.
Digitizing managing and control system of the present invention for means with the in-circuit emulation analytical technology of innovation, historical data analysis technology, advanced diagnosis optimization method, realizes the economical operation of cement mill, safe operation, and reduces environmental emission.
The foregoing is only the preferred embodiments of the present invention, be not limited to the present invention, 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 amendment done, equivalent replacement, improvement etc., all should be included within protection scope of the present invention.

Claims (9)

1. a cement digital managing and control system, it is characterized in that, comprising: analog subsystem, production and optimization subsystem and database, wherein, analog subsystem is connected with optimization subsystem with production, and database is connected with optimization subsystem with producing with described analog subsystem respectively;
Described analog subsystem is used for carrying out simulation calculation to manufacture of cement;
Described production and the data optimized subsystem and be used for according to storing in the result of calculation of described analog subsystem and database, analyze and judge whether normal current operating parameter and cement manufacture plant run, after prediction current time, whether operational factor is normal, and is optimized control to manufacture of cement;
Described database is for storing historical operating parameter and current operating parameter, the scope of operational factor and the corresponding relation of operational factor and equipment state of each production equipment; Wherein,
Described analog subsystem comprises: data acquisition module, data check module, equipment state calculate module, automatic measure on line module and analog module, wherein, data acquisition module is connected with data check module, and equipment state calculates that module is connected with analog module with data check module respectively with automatic measure on line module;
Described data acquisition module is used for the current operating parameter of each production equipment in Real-time Collection manufacture of cement, and is sent to described data check module;
Described data check module is used for the scope according to the operational factor set in database, the current operating parameter that data acquisition module collects is tested, qualified current operating parameter is sent to database, equipment state calculates module and automatic measure on line module;
Described equipment state calculates that module is used for the scope of equipment operational factor in current operating parameter and database to compare, and determines the running status of each equipment current, the running status of each equipment current and current operating parameter are sent to analog module;
Described automatic measure on line module is used for according to current operating parameter, revises, and revised mathematical model is sent to analog module to the coefficient of each mathematical model of manufacture of cement;
Described analog module is included in line locking emulation submodule, and described on-line synchronous emulation submodule is used for carrying out synchronization simulation calculating according to each mathematical model of current operating parameter and manufacture of cement to manufacture of cement.
2. the system as claimed in claim 1, is characterized in that,
Described data check module is further used for, if judge in checkout procedure, current operating parameter is defective, then substitute underproof current operating parameter by the value that simulation analysis value in database or history simulation analysis obtain, report to the police and show underproof current operating parameter and substitution value thereof.
3. the system as claimed in claim 1, is characterized in that,
Described analog module also comprises off-line analysis emulation submodule, and described off-line analysis emulation submodule is used for carrying out simulation calculation according to the off-line operation parameter of input and each mathematical model of manufacture of cement to manufacture of cement.
4. the system as claimed in claim 1, is characterized in that,
Described analog module also comprises online predictive simulation submodule, and described on-line prediction emulation submodule is used for each mathematical model according to current operating parameter and manufacture of cement, carries out faster than real time simulation calculating to manufacture of cement.
5. the system as claimed in claim 1, is characterized in that,
Described production comprises with optimization subsystem: security module and on-line decision control module, wherein,
Described security module is used for running real time data, historical data and emulated data according to cement manufacture plant, analyze and judge whether current operating parameter and cement manufacture plant run normal, and after prediction current time, whether operational factor is normal;
On-line decision control module is used for being optimized the raw meal proportioning of manufacture of cement and cement ingredient, is optimized control to raw mill system, coal mill, dore furnace, primary heater and cement mill system.
6. system as claimed in claim 5, is characterized in that,
Described security module comprises: parameter real-time oversight submodule, on-line early warning submodule and anomaly parameter detecting submodule, wherein,
Described parameter real-time oversight submodule is used for the current operating parameter of the current cement manufacture plant of real-time oversight, reports to the police when operational factor is abnormal;
Described on-line early warning submodule is used for the result according to carrying out faster than real time simulation calculating to manufacture of cement, and after judging current time, whether operational factor is normal;
Described anomaly parameter detecting submodule is used for according to the variation tendency of manufacture of cement current operating parameter, operational factor, the variation range of operational factor, judges that whether cement manufacture plant running status is normal.
7. system as claimed in claim 5, is characterized in that,
Described on-line decision control module comprises Raw Material System and optimizes submodule, coal dust preparation system optimization submodule, firing system optimization submodule and cement system optimization submodule, wherein,
Described Raw Material System optimizes submodule by the record data according to history blanking, calculates raw ingredients development trend, carries out burdening calculation, thus the optimization to raw meal proportioning; And, control and expert decision system according to PID, recirculating air, coarse powder bin hot blast, coarse powder bin cold wind, fine powder bin hot blast and fine powder bin cold wind are regulated, to control raw mill outlet temperature, coarse powder bin entrance negative pressure and fine powder bin entrance negative pressure, thus the optimal control to raw mill system;
Described coal dust preparation system is optimized submodule and is controlled and expert decision system according to PID, regulates the recirculating air of coal mill, hot blast and cold wind, to control outlet temperature and the entrance negative pressure of coal mill, thus the optimal control to coal mill;
Described firing system is optimized submodule and is controlled and expert decision system according to PID, regulates coal amount, to control the temperature of dore furnace, thus the optimal control to dore furnace; And, control and expert decision system according to PID, blower fan valve opening is regulated, to control primary heater top hole pressure, thus the optimal control to primary heater;
Described cement system optimizes submodule by the record data according to history blanking, calculates cement composition development trend, carries out burdening calculation, thus the optimization to cement ingredient; And, control and expert decision system according to PID, the hot blast of cement mill system and cold wind are regulated, to control outlet temperature and the entrance negative pressure of cement mill system, thus the optimal control to cement mill system.
8., as the system in claim 5 ~ 7 as described in any one, it is characterized in that,
Described production with optimize subsystem and comprise further: economic module, described economic module for calculating comprehensive energy consumption and the distribution energy consumption of manufacture of cement, and by energy consumption data and international, domestic standard energy consumption index comparing.
9. system as claimed in claim 8, is characterized in that,
Described economic module comprises connected online energy consumption index calculating sub module and efficiency analyzes submodule to mark, wherein,
Described online energy consumption index calculating sub module is 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 being 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 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 dries coal consumption, preparation of fuel power consumption, exhaust-gas treatment power consumption, sinter leaching power consumption, sinter leaching coal consumption, grog storage and conveying power consumption, supplement production power consumption, composite material dries coal consumption, composite material prepares power consumption and cement grinding power consumption.
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CN201741027U (en) * 2010-07-21 2011-02-09 长沙国浪节能科技有限公司 Cement grinding process optimizing control system
CN101980262A (en) * 2010-10-14 2011-02-23 冶金自动化研究设计院 Computer-based iron and steel enterprise energy simulation platform
CN102402186A (en) * 2011-12-20 2012-04-04 西安艾贝尔科技发展有限公司 Optimized control method for milling process in cement plant

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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

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