CN104516339A - Method for optimizing chemical intermittent production operation and optimized production operation system - Google Patents
Method for optimizing chemical intermittent production operation and optimized production operation system Download PDFInfo
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Abstract
The invention relates to the field of chemical engineering and provides a method for optimizing chemical intermittent production operation. The method comprises the steps of running state detection, production and detection data acquisition, comparison and judgment, operation parameter acquisition, operation parameter curing and the like. The invention further provides a chemical intermittent production operation system, a chemical production device, an intermittent production optimization system and a quality detection system. The intermittent production optimization system comprises a running state detection module, a data acquisition and storage module, a data query module, a data curing module and the like. The invention further provides an intermittent batch production control method for production control by taking a batch as a unit. After the original information islands, i.e., 'process operation data' and 'product quality inspection data', are organically combined based on a real-time database technology, the chemical intermittent production operation method is optimized, automatic reaction initiation is realized based on an optimum operation parameter, the product quality is guaranteed, and the production efficiency is improved.
Description
Technical field
The present invention relates to chemical field, particularly relating to a kind of production operation system of method through optimizing for the operation of Optimization of Chemical batch production.
Background technology
Batch production process is made up of according to certain in-sequence operational step one or more.Continuous flow procedure then refers to that raw material is converted into continuous print product through various specialized equipment, and as oil refining etc., each technological process all runs in stable duty.Batch production process is also known as batch production process, and it is formed and each operating conditions to determine production equipment according to the specific aim task of working out in advance, distributes production task, carries out the process of scheduling of production, coordination, enforcement production.Multiple batch operation as heating kettle, reactor interval unit and constitute batch production process as semicontinuous operation units such as heat interchanger, filtrator, pumps.
Batch production process, relative to continuous seepage and discrete production run, has following features: the change of each process conditions is obvious, and the requirement of state modulator is high; Production operation is many by manual intervention, and on-the-spot switching value is relatively many; Production operation order is undertaken by formula regulation; Designing requirement equipment can produce flexibly connecting of different product; Can export by bulk article.
In view of above-mentioned productive prospecting, in the control of batch production process except should meeting the indexs such as apparatus and process, quality, safety, environmental protection and regulation basic demand, also should meet the requirement of these parameters following and function aspects according to himself feature: have and can regulate the technological parameter such as temperature, pressure adjusting control function continuously; There is the opening and closing of valve, the discrete controlling functions such as the start and stop of pump; Have temperature, the sequential control function of condition that the state etc. of controlled device is all used as the conversion of each operational phase; Just like formula process, production scheduling, some special requirements such as dynamic coordinate, following function, interlocking defencive function etc.
Fig. 1 shows the conventional method of chemical industry batch production device in prior art, and process operation data and product quality data are " information islands ", not mutual each other, analysis result has hysteresis quality, belong to post-project evaluating, to how identifying that high quality of products production model cannot provide any effective help.
Summary of the invention
Technical purpose of the present invention is just the defect solving above-mentioned prior art, there is provided a kind of for the method for Optimization of Chemical batch production operation and the production operation system through optimizing, be intended to overcome " process operation data " and " product quality data " in prior art and cannot effectively combine the defect improving product quality in time, Optimization of Chemical batch production method of operating, guarantee product quality, enhance productivity.
For reaching technical purpose of the present invention, as first aspect of the present invention, provide the method for a kind of Optimization of Chemical batch production operation.The method includes the steps of:
Condition monitoring step, the running state information of Real-time Obtaining chemical production device;
Produce and detect data acquisition step, obtain and store the production operation data of chemical production device when producing product; Detect the product producing gained, and the quality test results of record product;
Multilevel iudge step, according to the quality test results of product, obtains product that quality test results meets quality requirements most as most high-quality product by multilevel iudge;
Operating parameter obtaining step, obtains production batch and the production time information of most high-quality product, and crucial production operation data when producing most high-quality product according to this production batch and production time information inquiry;
Obtained crucial production operation data are solidified as setting value by operating parameter curing schedule, and chemical production device is produced according to these crucial production operation data.
As second aspect of the present invention, provide a kind of chemical industry batch production operating system, comprise chemical production device and quality detecting system, especially, this chemical industry batch production operating system also comprises the batch production optimization system of carrying out bidirectional data exchange with chemical production device and quality detecting system respectively.This batch production optimization system comprises with lower module:
Condition monitoring module, for the running state information of Real-time Obtaining chemical production device;
Data acquisition and memory module, for obtaining and storing the production operation data of chemical production device when producing product, and for the production batch that obtains most high-quality product and production time information;
Data inquiry module, for inquiring about crucial production operation data when producing most high-quality product in data acquisition and memory module according to production batch and production time information;
Data write module, for obtained crucial production operation data being solidified as setting value, makes chemical production device produce according to these crucial production operation data.
Technical scheme provided by the present invention, the product that chemical production device is produced is detected in real time, and according to quality test results, relatively obtain " most high-quality product ", thus production operation data when finding production " most high-quality product ", and then the production operation data of chemical production device according to producing time " most high-quality product " are allowed to continue to produce like product.This just can improve product quality more timely, and, by solidification, production operation parameter is set, decrease the human intervention to production run, both avoided the product quality problem that mistake causes, and can enhance productivity again, the consistency level of product can also have been ensured better.
The present invention solidify crucial production operation data time, both these data directly can be solidified into chemical production device, make device according to this optimum configurations produce; Also this data write can be entered an automatic control module, control described chemical production device by this automatic control module and produce.In addition, the present invention is after the solidification completing once crucial production operation data is arranged, and the continuous surveillance of the checking and product quality that cyclically can also carry out production operation parameter improves, and further ensure that product quality, improves production efficiency.
As the 3rd aspect of the present invention, when carrying out batch (-type) batch production control, after often completing the production of batch, the method that Optimization of Chemical batch production provided by the present invention can be adopted to operate carries out acquisition and the solidification of crucial production operation data.Namely, after completing the production of batch, entire block is performed to said production and detection data acquisition step, multilevel iudge step, operating parameter obtaining step, operating parameter curing schedule (with automatic production control step) in the method for above-mentioned Optimization of Chemical batch production operation.Benefit is: for batch production control system taking batch operation as characteristic, by a batch management, after the optimal operation parameter being solidificated in the control system of chemical production device searching out " gold batch " by finding " most high-quality product " realizes automatically controlling, can not drop into or help enterprise to enhance productivity under few prerequisite dropped into, whether the real-time data base allowing data acquisition and memory module and data inquiry module be combined into helps each production link of enterprise statistics efficient according to the requirement of production schedules, guarantee the quality, guarantor finishes the work with measuring, thus reach the effect of enhancing production capacities, guarantee while planned production task completes smoothly to be that enterprise increases availability.
Accompanying drawing explanation
Fig. 1 gives the conventional method of chemical industry batch production device in prior art;
Fig. 2 schematically illustrates the method for Optimization of Chemical batch production of the present invention operation;
Fig. 3 schematically illustrates a kind of method for optimizing of Optimization of Chemical batch production of the present invention operation;
Fig. 4 schematically illustrates the implementation that discontinuous of the present invention optimizes production system;
Fig. 5 schematically illustrates the implementation of quality detecting system in the present invention; And
Fig. 6 schematically illustrates a kind of preferred version that discontinuous of the present invention optimizes production system.
Embodiment
Below embodiments of the invention are described in detail, but the multitude of different ways that the present invention can be defined by the claims and cover is implemented.
For reaching technical purpose of the present invention, as first aspect of the present invention, provide the method for a kind of Optimization of Chemical batch production operation, shown in Fig. 2 ~ Fig. 5.The method includes the steps of:
Step S201, condition monitoring step, the running state information of Real-time Obtaining chemical production device;
Step S202, step S301 and step S302, produce and detect data acquisition step, obtains and store the production operation data of chemical production device when producing product; Detect the product producing gained, and the quality test results of record product;
Step S303, multilevel iudge step, according to the quality test results of product, obtains product that quality test results meets quality requirements most as most high-quality product by multilevel iudge;
Step S203 and step S204, operating parameter obtaining step, obtains production batch and the production time information of most high-quality product, and crucial production operation data when producing most high-quality product according to this production batch and production time information inquiry;
Step S205, obtained crucial production operation data are solidified as setting value by operating parameter curing schedule, and chemical production device is produced according to these crucial production operation data.
Technical scheme provided by the present invention, the product that chemical production device is produced is detected in real time, and according to quality test results, relatively obtain " most high-quality product ", thus crucial production operation data when finding production " most high-quality product ", and then the crucial production operation data of chemical production device according to producing time " most high-quality product " are allowed to continue to produce like product.This just can improve product quality more timely, and, by solidification, production operation parameter is set, decrease the human intervention to production run, both avoided the product quality problem that mistake causes, and can enhance productivity again, the consistency level of product can also have been ensured better.
As the preferred embodiments of the present invention, shown in Figure 3, above-mentioned condition monitoring step S201 can be refined as step S2011 and step S2012:
Step S2011, batch production optimization system D102 are from the driving state of chemical production device D101 Real-time Obtaining chemical production device D101;
Step S2012, judges: if chemical production device D101 is in normal driving state, then continue to perform and produce and detect data acquisition step; If chemical production device D101 is in improper driving state, then batch production optimization system D102 obtains the driving state of chemical production device D101 again from chemical production device D101.
Shown in Fig. 3 ~ Fig. 5, in production with detect in data acquisition step, batch production optimization system D102 (in data acquisition and memory module D202) obtains and stores the production operation data of chemical production device D101 when production product from chemical production device D101; Quality detection module D301 in quality detecting system D103 detects the product producing gained, and in product quality database D 302 quality test results of record product.
Shown in Fig. 3 ~ Fig. 5, in multilevel iudge step 303, quality detecting system D103, according to the quality test results of product, obtains product that quality test results meets quality requirements most as most high-quality product by the multilevel iudge module D303 in quality detecting system D103.
Shown in Fig. 3 ~ Fig. 5, in operating parameter obtaining step, batch production optimization system D102 obtains production batch and the production time information of most high-quality product from the product quality database D 302 of quality detecting system D103, and crucial production operation data when producing most high-quality product according to this production batch and production time information (in the data acquisition and memory module D202 of batch production optimization system D102) inquiry.
Shown in Fig. 3 ~ Fig. 5, in operating parameter curing schedule S205, obtained crucial production operation data are solidificated in the control system of chemical production device D101 as setting value by batch production optimization system D102, and chemical production device D101 is produced according to these crucial production operation data.
The present invention solidify crucial production operation data time, both these data directly can be solidified into chemical production device, make device according to this optimum configurations produce; Also this data write can be entered an automatic control module, control described chemical production device by this automatic control module and produce.
Therefore, on the basis of above each preferred embodiment, after operating parameter curing schedule S205, automatic production control step S206 can also be comprised, obtained crucial production operation data are stored in batch production optimization system D102 as setting value by batch production optimization system D102, and produce according to crucial production operation data automatic control work process units D101, this mode causes automatically based on the crucial production operation data realization response producing most high-quality product, achieve the automatic control to chemical production device better, optimize chemical industry batch production method of operating further, be conducive to guaranteeing product quality, enhance productivity.
The present invention is after the solidification completing once crucial production operation data is arranged, and the continuous surveillance of the checking and product quality that cyclically can also carry out production operation parameter improves, and further ensure that product quality.The method that above-described Optimization of Chemical batch production operates, its each embodiment and combination in any thereof can circulate and carry out, and single cycle can comprise the following steps that order performs: condition monitoring step, production and detection data acquisition step, multilevel iudge step, operating parameter obtaining step, operating parameter curing schedule.The automatic production control step performed after can also being included in operating parameter curing schedule in single cycle.The preferred embodiment of each step is all applicable to circulation implementation above.Benefit is: after avoiding manual intervention, realizing control automatically, after continuation tracking chemical production device realizes robotization, whether the quality test results of new production product meets the requirement of high-quality product quality indicator, the key operating parameters needing to continue Optimization of Chemical process units is judged whether according to comparing result, thus to chemical plant installations high-quality, stable operation generation directive function that intermittence is produced.
When circulation performs, chemical production device D101 produces according to the crucial production operation data of setting, and the quality detection module D301 that the product produced sends into quality detecting system D103 detects; Multilevel iudge module D303 by the quality test results of the product of new production compared with the quality test results of " most high-quality product ", quality test results is more met the product of quality requirements as new " most high-quality product ", thus the crucial production operation data of Continuous optimization chemical production device on this basis, thus guarantee product quality.
As second aspect of the present invention, provide a kind of chemical industry batch production operating system, comprise chemical production device D101 and quality detecting system D103, especially, this chemical industry batch production operating system also comprises the batch production optimization system D102 carrying out bidirectional data exchange with chemical production device D101 and quality detecting system D103 respectively, see Fig. 2 ~ Fig. 5.This batch production optimization system D102 comprises with lower module:
Condition monitoring module D201, for the running state information of Real-time Obtaining chemical production device D101;
Data acquisition and memory module D202, for obtaining and storing the production operation data of chemical production device D101 when producing product, and for the production batch that obtains most high-quality product and production time information;
Data inquiry module D203, for inquiring about crucial production operation data when producing most high-quality product in data acquisition and memory module D202 according to production batch and production time information;
Data write module D204, for obtained crucial production operation data being solidified as setting value, makes chemical production device D101 produce according to these crucial production operation data.
As a preferred embodiment, above-mentioned batch production optimization system can further include automatic control module D205, see Fig. 6, this automatic control module D205 for storing obtained crucial production operation data, and produces according to crucial production operation data automatic control work process units D101.Automatic control module D205 can according to set crucial production operation data, the topworks corresponding to automatically opening or closing, thus realize the manufacture automatic control based on optimal operation parameter.This mode causes automatically based on the crucial production operation data realization response producing most high-quality product, achieves the automatic control to chemical production device better, is conducive to guaranteeing product quality, enhance productivity.
In above-mentioned chemical industry batch production operating system, quality detecting system D103 may further include quality detection module D301, product quality database D 302 and multilevel iudge module D303, shown in Figure 5.Wherein, quality detection module D301 produces the product of gained for detecting, obtain the quality test results of this product; Product quality database D 302 is for recording the quality test results of all products; Multilevel iudge module D303 is used for the quality test results according to record in product quality database D 302, compares the product that met quality requirements most as most high-quality product.
Above-mentioned quality detection module D301 can according to the quality testing instrument needing to select to be suitable for, and between product, database D 302 can continue to use Laboratory Information Management System of the prior art.
As a preferred embodiment, above-mentioned data acquisition and memory module D202 also can be further used for obtaining from chemical production device D101 and store the production operation data of chemical production device D101 when producing product, and for the production batch that obtains most high-quality product from quality detecting system D103 and production time information.
As the 3rd aspect of the present invention, when carrying out batch (-type) batch production control, after often completing the production of batch, each embodiment of the method that Optimization of Chemical batch production provided by the present invention can be adopted to operate carries out acquisition and the solidification of crucial production operation data.Namely, after completing the production of batch, entire block is performed to said production and detection data acquisition step, multilevel iudge step, operating parameter obtaining step, operating parameter curing schedule (with automatic production control step) in the method for above-mentioned Optimization of Chemical batch production operation.Benefit is: for batch production control system taking batch operation as characteristic, by a batch management, after the optimal operation parameter being solidificated in the control system of chemical production device searching out " gold batch " by finding " most high-quality product " realizes automatically controlling, can not drop into or help enterprise to enhance productivity under few prerequisite dropped into, whether the real-time data base allowing data acquisition and memory module and data inquiry module be combined into helps each production link of enterprise statistics efficient according to the requirement of production schedules, guarantee the quality, guarantor finishes the work with measuring, thus reach the effect of enhancing production capacities, guarantee while planned production task completes smoothly to be that enterprise increases availability.
The target of batch (-type) batch production control is by corresponding with the production operation data of each batch for the product quality of the identical trade mark, different batches detection data, thus the operating parameter (best practices) found under product quality optimal conditions, and by basic reason that Data Comparison finds current product quality to fluctuate from production operation aspect.The present invention is carried out in actual production apply and after realizing the automatic initiation operation of interval reflection process, identical trade mark product quality is obviously improved, and fluctuation range obviously reduces, thus reaches the object optimized and produce, ensure product quality.
Those skilled in the art will also understand is that, may be implemented as electronic hardware, computer software or both combinations in conjunction with various illustrative logical blocks, unit, circuit and the algorithm steps described by disclosure herein.In order to this interchangeability of hardware and software is clearly described, the function with regard to various exemplary components, square, unit, circuit and step has carried out general description to it.This function is implemented as software or is implemented as hardware and depends on embody rule and be applied to the design constraint of whole system.Those skilled in the art can realize described function in every way for often kind of embody rule, but this realization determines should not be interpreted as causing departing from the scope of the present invention.
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 (13)
1. a method for Optimization of Chemical batch production operation, is characterized in that,
The method includes the steps of:
Condition monitoring step, the running state information of Real-time Obtaining chemical production device;
Produce and detect data acquisition step, obtain and store the production operation data of described chemical production device when producing product; Detect the described product producing gained, and record the quality test results of described product;
Multilevel iudge step, according to the described quality test results of described product, obtains described quality test results by multilevel iudge and meets the product of quality requirements most as most high-quality product;
Operating parameter obtaining step, the production batch of most high-quality product described in acquisition and production time information, and the crucial production operation data described in producing according to this production batch and production time information inquiry during most high-quality product;
Obtained described crucial production operation data are solidified as setting value by operating parameter curing schedule, and described chemical production device is produced according to these crucial production operation data.
2., according to the method for Optimization of Chemical batch production operation according to claim 1, it is characterized in that:
In described condition monitoring step, batch production optimization system from the driving state of described chemical production device Real-time Obtaining chemical production device, and judges:
If described chemical production device is in normal driving state, then continue perform described production and detect data acquisition step;
If described chemical production device is in improper driving state, then described batch production optimization system obtains the driving state of described chemical production device again from described chemical production device.
3., according to the method for Optimization of Chemical batch production operation according to claim 1, it is characterized in that:
Described production and detecting in data acquisition step, described batch production optimization system obtains and stores the production operation data of described chemical production device when production product from described chemical production device; Quality detection module in quality detecting system detects the described product producing gained, and in product quality database, record the quality test results of described product.
4., according to the method for Optimization of Chemical batch production operation according to claim 1, it is characterized in that:
In described multilevel iudge step, described quality detecting system, according to the described quality test results of described product, obtains described quality test results by the multilevel iudge module in described quality detecting system and meets the product of quality requirements most as most high-quality product.
According to the method for Optimization of Chemical batch production operation according to claim 1, it is characterized in that:
In described operating parameter obtaining step, the production batch of most high-quality product described in described batch production optimization system obtains from the described product quality database of described quality detecting system and production time information, and the crucial production operation data described in producing according to this production batch and production time information inquiry during most high-quality product.
5., according to the method for Optimization of Chemical batch production operation according to claim 1, it is characterized in that:
In described operating parameter curing schedule, obtained described crucial production operation data are solidificated in the control system of described chemical production device as setting value by described batch production optimization system, and described chemical production device is produced according to these crucial production operation data.
6., according to the method for arbitrary described Optimization of Chemical batch production operation of claim 1 ~ 6, it is characterized in that:
After described operating parameter curing schedule, also comprise:
Automatic production control step, obtained described crucial production operation data are stored in described batch production optimization system as setting value by described batch production optimization system, and automatically control described chemical production device according to described crucial production operation data and produce.
7., according to the method for arbitrary described Optimization of Chemical batch production operation of claim 1 ~ 6, it is characterized in that:
The method is capable of circulation carries out, and single cycle comprises the following steps that order performs:
Described condition monitoring step;
Described production and detection data acquisition step;
Described multilevel iudge step;
Described operating parameter obtaining step;
Described operating parameter curing schedule.
8., according to the method for Optimization of Chemical batch production operation according to claim 8, it is characterized in that:
The following steps that described single cycle performs after being also included in described operating parameter curing schedule:
Obtained described crucial production operation data are stored in described batch production optimization system as setting value by automatic production control step, and automatically control described chemical production device according to described crucial production operation data and produce.
9. a chemical industry batch production operating system, comprises chemical production device and quality detecting system, it is characterized in that:
This chemical industry batch production operating system also comprises the batch production optimization system of carrying out bidirectional data exchange with described chemical production device and described quality detecting system respectively;
Described batch production optimization system comprises with lower module: condition monitoring module, for the running state information of chemical production device described in Real-time Obtaining;
Data acquisition and memory module, for obtaining and storing the production operation data of described chemical production device when producing product, and for the production batch that obtains most high-quality product and production time information;
Data inquiry module, for inquire about in described data acquisition and memory module according to described production batch and production time information produce described in most high-quality product time crucial production operation data;
Data write module, for obtained described crucial production operation data being solidified as setting value, makes described chemical production device produce according to these crucial production operation data.
10. according to chemical industry batch production operating system according to claim 10, it is characterized in that: described batch production optimization system also comprises with lower module:
Automatic control module, for storing obtained described crucial production operation data, and automatically controls described chemical production device according to described crucial production operation data and produces.
11., according to the chemical industry batch production operating system described in claim 10 or 11, is characterized in that:
Described quality detecting system comprises quality detection module, product quality database and multilevel iudge module,
Described quality detection module, for detecting the product producing gained, obtains the quality test results of this product;
Described product quality database, for recording the described quality test results of all products;
Described multilevel iudge module, for according to the described quality test results recorded in described product quality database, compare met quality requirements most product as most high-quality product.
12., according to chemical industry batch production operating system according to claim 12, is characterized in that:
Described data acquisition and memory module, for obtaining from described chemical production device and storing the production operation data of described chemical production device when producing product, and for the production batch that obtains most high-quality product from described quality detecting system and production time information.
13. 1 kinds of batch (-type) batch production control method, is characterized in that:
After often completing the production of batch, the method for arbitrary described Optimization of Chemical batch production operation of claim 1 ~ 9 is adopted to carry out acquisition and the solidification of crucial production operation data.
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Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105527837A (en) * | 2015-12-22 | 2016-04-27 | 蓝星（北京）技术中心有限公司 | Chemical production device control loop parameter setting test method and device |
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| CN108803315A (en) * | 2017-12-13 | 2018-11-13 | 杭州电子科技大学 | A kind of intelligent-tracking control method of Chemical Batch Process |
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| CN113126582A (en) * | 2021-04-20 | 2021-07-16 | 万华化学集团股份有限公司 | Intermittent process production time control method, storage medium and system |
| CN113126582B (en) * | 2021-04-20 | 2022-07-12 | 万华化学集团股份有限公司 | Intermittent process production time control method, storage medium and system |
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