CN111813057A - Energy management system of cement production plant - Google Patents
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- CN111813057A CN111813057A CN202010527156.0A CN202010527156A CN111813057A CN 111813057 A CN111813057 A CN 111813057A CN 202010527156 A CN202010527156 A CN 202010527156A CN 111813057 A CN111813057 A CN 111813057A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 113
- 239000004568 cement Substances 0.000 title claims abstract description 110
- 238000000034 method Methods 0.000 claims abstract description 70
- 230000008569 process Effects 0.000 claims abstract description 65
- 238000005265 energy consumption Methods 0.000 claims abstract description 37
- 238000005457 optimization Methods 0.000 claims abstract description 20
- 230000005540 biological transmission Effects 0.000 claims abstract description 18
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 claims abstract description 16
- 235000011114 ammonium hydroxide Nutrition 0.000 claims abstract description 16
- 238000012544 monitoring process Methods 0.000 claims abstract description 14
- 238000007726 management method Methods 0.000 claims description 132
- 239000003245 coal Substances 0.000 claims description 40
- 238000004458 analytical method Methods 0.000 claims description 34
- 239000002994 raw material Substances 0.000 claims description 32
- 230000001575 pathological effect Effects 0.000 claims description 27
- 230000002159 abnormal effect Effects 0.000 claims description 24
- 239000000428 dust Substances 0.000 claims description 24
- 238000000227 grinding Methods 0.000 claims description 18
- 238000010586 diagram Methods 0.000 claims description 14
- 238000007728 cost analysis Methods 0.000 claims description 9
- 239000000446 fuel Substances 0.000 claims description 9
- 238000010248 power generation Methods 0.000 claims description 9
- 239000002918 waste heat Substances 0.000 claims description 9
- 239000002699 waste material Substances 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 8
- 238000007405 data analysis Methods 0.000 claims description 7
- 238000009826 distribution Methods 0.000 claims description 6
- 230000007613 environmental effect Effects 0.000 claims description 6
- 238000012423 maintenance Methods 0.000 claims description 6
- 238000007619 statistical method Methods 0.000 claims description 6
- 238000003860 storage Methods 0.000 claims description 6
- 230000008859 change Effects 0.000 claims description 5
- 230000005611 electricity Effects 0.000 claims description 4
- 238000009825 accumulation Methods 0.000 claims description 3
- 238000013475 authorization Methods 0.000 claims description 3
- 238000004364 calculation method Methods 0.000 claims description 3
- 230000001186 cumulative effect Effects 0.000 claims description 3
- 238000007418 data mining Methods 0.000 claims description 3
- 238000005065 mining Methods 0.000 claims description 3
- 238000004806 packaging method and process Methods 0.000 claims description 3
- 238000012797 qualification Methods 0.000 claims description 3
- 238000012795 verification Methods 0.000 claims description 3
- 238000013461 design Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 238000009412 basement excavation Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
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- 238000012384 transportation and delivery Methods 0.000 description 1
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32368—Quality control
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P80/00—Climate change mitigation technologies for sector-wide applications
- Y02P80/10—Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention relates to an energy management system of a cement production plant, which comprises a plant energy management module, a workshop process energy management module, an equipment energy management module, a dynamic optimization module, an idling equipment monitoring module, an air compressor monitoring module, an ammonia water consumption and emission management module, a quality management module, a data transmission and input module and a system setting module, wherein the modules are mutually connected and communicated, the energy management system also comprises a mobile equipment energy management module arranged on a mobile phone, and the data of the energy management system of the cement production plant is read through the Internet. The invention closely combines the production data, the energy data, the control quality data, the equipment start-stop data and other contents, helps managers to establish a scientific and reasonable energy and production management index system, covers key performance indexes of production, quality, shutdown and the like of each process of clinker and cement production, independently realizes key performance index management on important energy consumption equipment, and finally realizes the aim of lean manufacturing management of enterprises.
Description
Technical Field
The invention relates to the technical field of industrial Internet, in particular to a cement energy management system.
Background
The industrial internet is the next main direction of industrial transformation, while the realization of an intelligent factory management system is a task being explored by most enterprises, and an energy management system is taken as a framework of one of the intelligent factory management systems, and the design of the energy management system needs to be reasonable, efficient, reliable and practical.
The cement factory belongs to a process production enterprise, and besides benefits to the market, the internal excavation and synergism are very important means. Therefore, how to design a system for cement energy management and apply the system to a production field by using modern information technology is considered by industrial information engineering. Through the high integration of the informatization technology and the industrial production process, the effective management of key performance indicators can be realized, thereby achieving the lean manufacturing management target of final enterprises.
According to the attributes of the cement factory information-based construction process, a large amount of work is mainly done, the production-to-sales period is shortened, more reliable customer delivery commitments are realized, the in-process inventory is minimized, the material utilization rate is maximized, the marginal profit is maximized, the market change is quickly responded, the visibility of production information is improved, the continuous optimization of decision support is realized, and the like.
Disclosure of Invention
The invention designs a system for managing cement energy, which integrates an informatization technology with a production field, closely combines production data, energy data, control quality data, equipment start-stop data and other contents, helps managers to establish a scientific and reasonable energy and production management index system, can automatically calculate key performance indexes, adopts a multi-dimensional data analysis method to realize decomposition and aggregation of indexes according to teams, equipment and the like, realizes real-time statistics of the key performance indexes with different periods defined as cycles, covers production, quality and shutdown processes of various processes of clinker and cement production, independently realizes key performance index management of heavy-point energy consumption equipment, and finally realizes the aim of lean manufacturing management of enterprises.
According to the technical problem, the cement energy management system comprises a factory energy management module, a workshop process energy management module, an equipment energy management module, a dynamic optimization module, an idling equipment monitoring module, an air compressor monitoring module, an ammonia water consumption and emission management module, a quality management module, a data transmission and input module and a system setting module, wherein the modules are mutually connected and communicated;
the factory energy management module comprises a production and energy consumption preview window, a comprehensive performance analysis window, an inventory preview window, a raw material and product in-out preview window, a power consumption distribution diagram window, a power consumption statistical analysis window, a power consumption cost analysis window, a production statistical daily report window and a monthly performance public display window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the workshop process energy management module comprises a production and energy consumption window, a peak-valley level electricity utilization management window, an operator performance statistics window and an operator shift management window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the equipment energy management module comprises a power consumption analysis window, a heat consumption analysis window, a shutdown report window, a sick equipment management window, an operator optimization tool window and a central control operation record table window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the quality data statistical window and the quality data analysis window which are included by the quality management module are displayed through display equipment, and an operator executes corresponding operation through each window;
the data transmission window, the data input window and the data maintenance window which are arranged in the data transmission and input module are displayed through display equipment, and an operator executes corresponding operation through each window;
the system setting module comprises a safety management window and a system deployment management window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the energy management module of the mobile equipment comprises a production operation preview window, an energy consumption statistical window, a cement sale window, a production operation window, a host operation window, an abnormal data window, a user authority and login window and a message push window which are displayed through a mobile phone display screen, and an operator executes corresponding operation through each window.
Furthermore, the production and energy consumption preview window included in the factory energy management module has the functions of displaying production parameters such as key equipment operation models, machine hour yield, unit power consumption and the like through numerical values or graphic marks, displaying core performance indexes such as environmental protection data, emission data and the like and operation conditions, displaying the core performance indexes through forms when the production lines are multiple production lines, and refreshing page data every 15 minutes;
the comprehensive performance preview window has the function of displaying the data of the clinker comprehensive power consumption and energy cost, the clinker comprehensive standard coal consumption, the cement grinding power consumption, the cement comprehensive power consumption and energy cost, the ton clinker waste heat net power generation quantity, the clinker yield and sales quantity, the cement yield and sales quantity and the like in the current month;
the comprehensive performance analysis window has the functions that key energy efficiency indexes of the whole plant clinker yield, the cement yield, the clinker comprehensive power consumption, the clinker comprehensive standard coal consumption, the cement comprehensive power consumption, the ton clinker waste heat net power generation quantity, the cement clinker ratio, the clinker process power consumption and the cement process power consumption are displayed through a histogram or a curve graph, when a plurality of production lines are displayed through a parallel histogram or one graph of each production line, the upper and lower performance limit values set by an operator are displayed by red alarms, and the operator displays plant-level energy efficiency indexes by time, shift, day, month, year or self-defined set time data granularity, so that the analysis requirements of managers at different levels are met, when two production lines are used, the data is a weighted average value, and the cement clinker ratio data is acquired as the data of a batching DCS scale;
the function of the stock preview window is that an operator displays the stock condition of the raw materials, the clinker and the cement on the current date or on the specific date by inputting or automatically collecting the calculated data through a material level instrument;
the raw material and product in-out preview window has the function of summarizing and displaying the current month data or specific date of the conditions of raw fuel entering a factory, clinker leaving the factory and cement;
the power consumption distribution diagram window has the functions that data such as total purchased power outside the whole plant, real-time power consumption of each workshop or procedure and the like are displayed by using a histogram or a curve chart, and simultaneously participate in power demand side management and the like and the proposal of optimizing monthly basic power charge and the like for a power supply department, and an operator sets data by taking time, shift, day, month, year or self-defined time as granularity;
the power consumption statistical analysis window is used for displaying a high-voltage power statistical table and a low-voltage power statistical table;
the power consumption cost analysis window has the functions of automatically counting and calculating the total power consumption of the whole plant, the process and the equipment in the peak-valley period and the information of the total power consumption, and outputting a report form in an Execl or PDF format and a power consumption price trend chart of each workshop self-defined date range;
the production statistics daily report window has the functions of displaying the production yield, the machine hour and the operation data of a factory, the process energy consumption and waste heat power generation data, the in-and-out information of raw fuel and product materials and the like, and outputting an Execl or PDF format report which is counted by the current day, the current month and the current year;
the monthly performance bulletin window has the function of outputting a monthly performance bulletin table in the Execl or PDF format in a unified format for each factory of the current year or the custom query input date.
Furthermore, the workshop process energy management module comprises a production and energy consumption window function for displaying the mining process, the raw material process, the clinker process, the cement process and the loading and transporting process of the current monthly workshop, and the production operation conditions of the yield, the machine hour yield, the unit power consumption, the unit standard coal consumption, the operation rate, the reliability coefficient and the expression coefficient of the raw material mill, the coal mill, the kiln and the cement mill key equipment;
the peak-valley level power consumption management window has the functions that an operator selects a user-defined peak-valley level time period and automatically counts the peak-valley level power consumption time of a raw mill, a coal mill and a cement mill, calculates the operation rate, the peak avoiding rate, the average using rate and the valley using rate, and automatically gives a device peak avoiding condition report form in an Execl or PDF format, wherein the report form is provided with green, red or yellow marks to identify the management level of each plant;
the operator performance statistical window has the function of automatically calculating assessment reports in an Execl or PDF format and cross-shift entry condition data of each operator in each shift in a user-defined time period, and the index of the assessment reports can be defined as one of a score of 5 points, a score of percentage, a step-type score and a score according to proportion;
the operator shift-by-shift management window has the function that an operator enters production operation conditions and on-shift summary according to the assessment report, so that an assessment form of the operator in an Execl or PDF format is obtained.
Furthermore, the power consumption analysis window included by the equipment energy management module is used for displaying the yield, the machine hour yield, the shutdown time, the control quality indexes, the process power consumption and the key host power consumption in any hour, shift, working day, working month and working year granularity time periods, so as to analyze the raw material mill power consumption, the coal mill power consumption, the kiln power consumption and the cement mill power consumption, and carry out color change warning through the preset upper and lower limits of the performance indexes, wherein the control quality indexes comprise the moisture and the fineness of the raw material mill, the moisture and the fineness of the coal mill, the f-CaO of the kiln, the fineness/specific surface area and the C/K ratio of the cement mill, and the key host power consumption comprises a main motor, a fan and a roller press;
the heat consumption analysis window is used for displaying energy efficiency analysis of the coal consumption of the kiln in any granularity time period of hours, shifts, working days, working months and working years, and the energy efficiency analysis comprises the hourly output, the standard coal consumption of the clinker per ton, control quality data and relevant core process parameters;
the shutdown report window has the functions of automatically recording the starting time and the ending time of key equipment of a raw mill, a coal mill, a kiln and a cement mill, automatically calculating the shutdown time and the shutdown electric quantity, and outputting a report in an Execl or PDF format in a user-defined time range, wherein the shutdown is divided into three stages from the start of shutdown to the completion of shutdown, the continuation of shutdown and the start of shutdown to the completion of startup;
the pathological equipment management window has the functions that by setting the target productivity and the pathological operation judgment standard of the equipment, the system can automatically capture the time of each pathological operation of the equipment, calculate relevant data such as the duration of the pathological operation, the yield of the pathological operation, the productivity waste ratio and the energy consumption of the pathological operation, automatically generate a pathological operation record and require an operator to fill the reasons for generating the pathological operation, wherein the productivity waste ratio comprises the yield of the pathological operation and the target yield;
the operator optimization tool window has the function that an operator adjusts parameters such as process power consumption, key host machine power consumption, core process parameters and the like of a raw material mill, a coal mill, a kiln and a cement mill according to red, yellow and green graphic prompts of the system, so that the working condition of the system is always in an energy optimization production state, the key host machine power consumption comprises a main motor, a fan, a roller press and other equipment, and the core process parameters comprise pressure, current and other parameters;
the window function of the central control operation record table is that an operator inquires key operation parameters of a raw material mill, a coal mill, a kiln and a cement mill according to dates, large production data is formed through accumulation and parameter optimization adjustment, and production, process and quality personnel can conveniently conduct data mining and comprehensive analysis and application of heat consumption and power consumption.
Furthermore, the quality data statistical window included by the quality management module is used for collecting online and offline quality data such as stock level, opening degree, temperature and the like and process key parameters through a collector;
the quality data analysis window functions to calculate and analyze various quality data by correlating the quality data with the production data.
Furthermore, the data transmission window included by the data transmission and input module has the function of transmitting data through a standard database to acquire raw fuel in-plant weight data, product out-of-plant weight data, quality result data automatically detected by a fluorescence analyzer and control quality data in a quality system to enter an energy management system;
the data input window functions in that an operator manually enters data required by system standards;
the data maintenance window has the function of giving information such as qualification rate judgment, performance index benchmarking, early warning, completion degree calculation and the like through the system and helping an operator to maintain relevant indexes.
Further, the system setting module comprises a security management window function for setting security levels and operation authorities based on definition of individual users and group users so as to execute different operation management;
the system deployment management window has the functions of collecting different types of data in real time, storing a historical database and transmitting the integrated automatic system data to a service logic layer of the energy management system.
Furthermore, the production operation preview window included by the mobile equipment energy management module has the function that an operator views comprehensive information such as each energy consumption proportion diagram of each enterprise, each enterprise cement sales histogram, each enterprise production operation condition, each enterprise host equipment operation condition, abnormal data statistics and the like;
the energy consumption statistical window has the functions of displaying the consumption proportion of each enterprise to each energy under the group by taking the type of energy consumed in production as a reference, and checking the daily consumption of the energy of the selected enterprise;
the cement sale window has the functions of displaying a comparison graph of the cement sale amount of each enterprise by a histogram, and checking the daily sale amount, the monthly accumulated sale amount and the current storage capacity ratio of various types of cement of the selected enterprise;
the production operation window has the functions of checking main clinker, cement products, varieties and daily output, monthly cumulative amount and the like of each enterprise and the machine hour output of a certain product in each host system;
the host operation window has the function of displaying the comparison of the number of times of the fault shutdown and the planned shutdown of each enterprise on the same day and the information of the number of times of the shutdown, the operation duration, the operation rate and the like of each host system of the selected enterprise such as a raw material mill, a rotary kiln, a cement mill and the like by using a histogram;
the abnormal data window has the functions of displaying the total number of all levels of abnormal conditions, each abnormal type and the respective abnormal number of the month by a histogram, and setting the notification of the push message according to the abnormal level of the abnormal data prompt or the prompt condition appointed by the operator;
the user authority and login window function is to establish the authorization authority of the user, the type and each module of the mobile equipment at the PC terminal, and to set the user name and password verification of the login interface of the user of the mobile equipment;
the message pushing window has the function of pushing messages set aiming at energy consumption early warning, alarming, stopping and the like to a user side of the mobile equipment, and the message pushing window is used for enabling an operator to set different message pushing ranges and alarming levels in the system.
Furthermore, the dynamic optimization module has the function of applying the optimal central control operation record table to production according to the parameters of the branch result, the operable parameter and the control variable, so that the energy consumption is minimized;
the idle equipment monitoring module has the function of finding energy waste in three areas such as a workshop belt conveying system, a raw material conveying system, a cement mill front conveying system and the like which run idle or in half load in each shift;
the air compressor monitoring module is used for performing combined analysis on unit power consumption, output, power consumption and outlet pressure parameters of the air compressor at any time interval to obtain an optimal statistical report and a curve graph of outlet compressed air volume and air pressure of the air compressor, and control indexes of inlet and outlet air volume of compressed air storage tanks with the length of more than 1m each, air pressure and air volume of collected dust of a host machine are counted into cost analysis, wherein the host machine dust collection comprises kiln tail bag dust collection, kiln head bag dust collection, coal grinding bag dust collection, high-concentration cement grinding dust collection, cement grinding air discharge dust collection, packaging workshop section dust collection and the like;
the ammonia water consumption and emission management module has the function of acquiring the ammonia water usage amount and NO in any granularity time period of hours, shifts, working days, working months and working years from the acquisition endX、SO2And (4) waiting for the environmental emission data, calculating the unit clinker ammonia water usage, checking the emission data, the ammonia water usage data and a curve graph, and finding the optimal operation parameters and control indexes.
The energy management system has the advantages that the energy management system of the cement production plant covers important energy consumption data such as coal, electricity and the like and production data acquired by an equipment end, and a flattening mode information system for centralized data acquisition, management and analysis is realized; by means of a lean management platform, reliable operation of production plant equipment is realized through data information fusion of production, mechanical, electrical, process and quality, production cost is reduced in an optimized mode, and the aim of green development is fulfilled.
Moreover, the functions of all application modules in the energy management system of the cement production plant are relatively independent, so that the stability and the maintainability of the energy management system of the cement production plant are improved; according to project requirements and basic principles of platformization, information interaction is carried out among all components through a unified system platform interface, and the whole system cannot be influenced by local change of the system; enterprise terminal users can upgrade and expand the functionality or scope of the original functional components at any time according to the development requirements so as to meet the requirements of specific work.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1: the structural schematic diagram of the energy management system of the cement production plant;
FIG. 2: a schematic diagram of a plant energy management module structure;
FIG. 3: a workshop process energy management module indicates;
FIG. 4: a schematic diagram of an equipment energy management module;
FIG. 5: a mobile device energy management module schematic diagram;
FIG. 6: a schematic diagram of a quality management module;
FIG. 7: a schematic diagram of a data transmission and input module;
FIG. 8: and the system setting module is schematic.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
With reference to fig. 1, the cement energy management system comprises a factory energy management module, a workshop process energy management module, an equipment energy management module, a dynamic optimization module, an idling equipment monitoring module, an air compressor monitoring module, an ammonia water consumption and discharge management module, a quality management module, a data transmission and input module and a system setting module, wherein the modules are mutually connected and communicated, and the cement energy management system also comprises a mobile equipment energy management module arranged on a mobile phone, and reads the data of the cement production factory energy management system through the internet;
the factory energy management module comprises a production and energy consumption preview window, a comprehensive performance analysis window, an inventory preview window, a raw material and product in-out preview window, a power consumption distribution diagram window, a power consumption statistical analysis window, a power consumption cost analysis window, a production statistical daily report window and a monthly performance public display window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the workshop process energy management module comprises a production and energy consumption window, a peak-valley level electricity utilization management window, an operator performance statistics window and an operator shift management window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the equipment energy management module comprises a power consumption analysis window, a heat consumption analysis window, a shutdown report window, a sick equipment management window, an operator optimization tool window and a central control operation record table window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the quality data statistical window and the quality data analysis window which are included by the quality management module are displayed through display equipment, and an operator executes corresponding operation through each window;
the data transmission window, the data input window and the data maintenance window which are arranged in the data transmission and input module are displayed through display equipment, and an operator executes corresponding operation through each window;
the system setting module comprises a safety management window and a system deployment management window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the energy management module of the mobile equipment comprises a production operation preview window, an energy consumption statistical window, a cement sale window, a production operation window, a host operation window, an abnormal data window, a user authority and login window and a message push window which are displayed through a mobile phone display screen, and an operator executes corresponding operation through each window.
With reference to fig. 2, the production and energy consumption preview window included in the plant energy management module is used for displaying production parameters such as the operation model of key equipment, the machine hour yield, the unit power consumption and the like through numerical values or graphic marks, and simultaneously displaying core performance indexes such as environmental protection data, emission data and the like and operation conditions, and when the production lines are a plurality of production lines, the production and energy consumption preview window is displayed through a table, and page data is refreshed every 15 minutes;
the comprehensive performance preview window has the function of displaying the data of the clinker comprehensive power consumption and energy cost, the clinker comprehensive standard coal consumption, the cement grinding power consumption, the cement comprehensive power consumption and energy cost, the ton clinker waste heat net power generation quantity, the clinker yield and sales quantity, the cement yield and sales quantity and the like in the current month;
the comprehensive performance analysis window has the functions that key energy efficiency indexes of the whole plant clinker yield, the cement yield, the clinker comprehensive power consumption, the clinker comprehensive standard coal consumption, the cement comprehensive power consumption, the ton clinker waste heat net power generation quantity, the cement clinker ratio, the clinker process power consumption and the cement process power consumption are displayed through a histogram or a curve graph, when a plurality of production lines are displayed through a parallel histogram or one graph of each production line, the upper and lower performance limit values set by an operator are displayed by red alarms, and the operator displays plant-level energy efficiency indexes by time, shift, day, month, year or self-defined set time data granularity, so that the analysis requirements of managers at different levels are met, when two production lines are used, the data is a weighted average value, and the cement clinker ratio data is acquired as the data of a batching DCS scale;
the function of the stock preview window is that an operator displays the stock condition of the raw materials, the clinker and the cement on the current date or on the specific date by inputting or automatically collecting the calculated data through a material level instrument;
the raw material and product in-out preview window has the function of summarizing and displaying the current month data or specific date of the conditions of raw fuel entering a factory, clinker leaving the factory and cement;
the power consumption distribution diagram window has the functions that data such as total purchased power outside the whole plant, real-time power consumption of each workshop or procedure and the like are displayed by using a histogram or a curve chart, and simultaneously participate in power demand side management and the like and the proposal of optimizing monthly basic power charge and the like for a power supply department, and an operator sets data by taking time, shift, day, month, year or self-defined time as granularity;
the power consumption statistical analysis window is used for displaying a high-voltage power statistical table and a low-voltage power statistical table;
the power consumption cost analysis window has the functions of automatically counting and calculating the total power consumption of the whole plant, the process and the equipment in the peak-valley period and the information of the total power consumption, and outputting a report form in an Execl or PDF format and a power consumption price trend chart of each workshop self-defined date range;
the production statistics daily report window has the functions of displaying the production yield, the machine hour and the operation data of a factory, the process energy consumption and waste heat power generation data, the in-and-out information of raw fuel and product materials and the like, and outputting an Execl or PDF format report which is counted by the current day, the current month and the current year;
the monthly performance bulletin window has the function of outputting a monthly performance bulletin table in the Execl or PDF format in a unified format for each factory of the current year or the custom query input date.
With reference to fig. 3, the workshop process energy management module includes the production and energy consumption window functions of displaying the mining process, raw material process, clinker process, cement process and shipping process of the current monthly workshop, and the production operation conditions of the yield, machine hour yield, unit power consumption, unit standard coal consumption, operation rate, reliability coefficient and performance coefficient of the raw mill, coal mill, kiln and cement mill key equipment;
the peak-valley level power consumption management window has the functions that an operator selects a user-defined peak-valley level time period and automatically counts the peak-valley level power consumption time of a raw mill, a coal mill and a cement mill, calculates the operation rate, the peak avoiding rate, the average using rate and the valley using rate, and automatically gives a device peak avoiding condition report form in an Execl or PDF format, wherein the report form is provided with green, red or yellow marks to identify the management level of each plant;
the operator performance statistical window has the function of automatically calculating assessment reports in an Execl or PDF format and cross-shift entry condition data of each operator in each shift in a user-defined time period, and the index of the assessment reports can be defined as one of a score of 5 points, a score of percentage, a step-type score and a score according to proportion;
the operator shift-by-shift management window has the function that an operator enters production operation conditions and on-shift summary according to the assessment report, so that an assessment form of the operator in an Execl or PDF format is obtained.
With reference to fig. 4, the power consumption analysis window included in the equipment energy management module is used for displaying the yield, the machine hour yield, the shutdown time, the control quality indexes, the process power consumption and the key host power consumption in any time period of granularity, such as any hour, shift, working day, working month and working year, so as to analyze the raw material mill power consumption, the coal mill power consumption, the kiln power consumption and the cement mill power consumption, and perform color change warning through preset upper and lower limits of performance indexes, wherein the control quality indexes include the moisture and fineness of the raw material mill, the moisture and fineness of the coal mill, the f-CaO of the kiln, the fineness/specific surface area and the C/K ratio of the cement mill, and the key host power consumption includes a main motor, a fan and a roller press;
the heat consumption analysis window is used for displaying energy efficiency analysis of the coal consumption of the kiln in any granularity time period of hours, shifts, working days, working months and working years, and the energy efficiency analysis comprises the hourly output, the standard coal consumption of the clinker per ton, control quality data and relevant core process parameters;
the shutdown report window has the functions of automatically recording the starting time and the ending time of key equipment of a raw mill, a coal mill, a kiln and a cement mill, automatically calculating the shutdown time and the shutdown electric quantity, and outputting a report in an Execl or PDF format in a user-defined time range, wherein the shutdown is divided into three stages from the start of shutdown to the completion of shutdown, the continuation of shutdown and the start of shutdown to the completion of startup;
the pathological equipment management window has the functions that by setting the target productivity and the pathological operation judgment standard of the equipment, the system can automatically capture the time of each pathological operation of the equipment, calculate relevant data such as the duration of the pathological operation, the yield of the pathological operation, the productivity waste ratio and the energy consumption of the pathological operation, automatically generate a pathological operation record and require an operator to fill the reasons for generating the pathological operation, wherein the productivity waste ratio comprises the yield of the pathological operation and the target yield;
the operator optimization tool window has the function that an operator adjusts parameters such as process power consumption, key host machine power consumption, core process parameters and the like of a raw material mill, a coal mill, a kiln and a cement mill according to red, yellow and green graphic prompts of the system, so that the working condition of the system is always in an energy optimization production state, the key host machine power consumption comprises a main motor, a fan, a roller press and other equipment, and the core process parameters comprise pressure, current and other parameters;
the window function of the central control operation record table is that an operator inquires key operation parameters of a raw material mill, a coal mill, a kiln and a cement mill according to dates, large production data is formed through accumulation and parameter optimization adjustment, and production, process and quality personnel can conveniently conduct data mining and comprehensive analysis and application of heat consumption and power consumption.
With reference to fig. 5, the production operation preview window included in the mobile device energy management module is used for an operator to view comprehensive information such as each energy consumption proportion graph of each enterprise, each enterprise cement sales histogram, each enterprise production operation condition, each enterprise host device operation condition, abnormal data statistics and the like;
the energy consumption statistical window has the functions of displaying the consumption proportion of each enterprise to each energy under the group by taking the type of energy consumed in production as a reference, and checking the daily consumption of the energy of the selected enterprise;
the cement sale window has the functions of displaying a comparison graph of the cement sale amount of each enterprise by a histogram, and checking the daily sale amount, the monthly accumulated sale amount and the current storage capacity ratio of various types of cement of the selected enterprise;
the production operation window has the functions of checking main clinker, cement products, varieties and daily output, monthly cumulative amount and the like of each enterprise and the machine hour output of a certain product in each host system;
the host operation window has the function of displaying the comparison of the number of times of the fault shutdown and the planned shutdown of each enterprise on the same day and the information of the number of times of the shutdown, the operation duration, the operation rate and the like of each host system of the selected enterprise such as a raw material mill, a rotary kiln, a cement mill and the like by using a histogram;
the abnormal data window has the functions of displaying the total number of all levels of abnormal conditions, each abnormal type and the respective abnormal number of the month by a histogram, and setting the notification of the push message according to the abnormal level of the abnormal data prompt or the prompt condition appointed by the operator;
the user authority and login window function is to establish the authorization authority of the user, the type and each module of the mobile equipment at the PC terminal, and to set the user name and password verification of the login interface of the user of the mobile equipment;
the message pushing window has the function of pushing messages set aiming at energy consumption early warning, alarming, stopping and the like to a user side of the mobile equipment, and the message pushing window is used for enabling an operator to set different message pushing ranges and alarming levels in the system.
With reference to fig. 6, the quality data statistical window included in the quality management module is used for collecting online and offline quality data such as stock level, opening degree, temperature and the like and process key parameters through a collector;
the quality data analysis window functions to calculate and analyze various quality data by correlating the quality data with the production data.
With reference to fig. 7, the data transmission window included in the data transmission and input module is used for transmitting data through the standard database to acquire raw fuel in-plant weight data, product out-of-plant weight data, quality result data automatically inspected by the fluorescence analyzer, and control quality data in the quality system, and entering the data into the energy management system;
the data input window functions in that an operator manually enters data required by system standards;
the data maintenance window has the function of giving information such as qualification rate judgment, performance index benchmarking, early warning, completion degree calculation and the like through the system and helping an operator to maintain relevant indexes.
With reference to fig. 8, the system setup module includes the security management window function to set security levels and operation rights based on the definition of individual users and groups of users, so as to perform different operation management;
the system deployment management window has the functions of collecting different types of data in real time, storing a historical database and transmitting the integrated automatic system data to a service logic layer of the energy management system.
In the other modules combined with fig. 1, the function of the dynamic optimization module is to apply the optimal central control operation record table to production according to the parameters of the branch results, the operational parameters and the control variables, so as to minimize energy consumption;
the idle equipment monitoring module has the function of finding energy waste in three areas such as a workshop belt conveying system, a raw material conveying system, a cement mill front conveying system and the like which run idle or in half load in each shift;
the air compressor monitoring module is used for performing combined analysis on unit power consumption, output, power consumption and outlet pressure parameters of the air compressor at any time interval to obtain an optimal statistical report and a curve graph of outlet compressed air volume and air pressure of the air compressor, and control indexes of inlet and outlet air volume of compressed air storage tanks with the length of more than 1m each, air pressure and air volume of collected dust of a host machine are counted into cost analysis, wherein the host machine dust collection comprises kiln tail bag dust collection, kiln head bag dust collection, coal grinding bag dust collection, high-concentration cement grinding dust collection, cement grinding air discharge dust collection, packaging workshop section dust collection and the like;
the ammonia water consumption and emission management module has the function of acquiring the ammonia water usage amount and NO in any granularity time period of hours, shifts, working days, working months and working years from the acquisition endX、SO2And (4) waiting for the environmental emission data, calculating the unit clinker ammonia water usage, checking the emission data, the ammonia water usage data and a curve graph, and finding the optimal operation parameters and control indexes.
Through the setting of the detailed module and each window, the information management scheme of the CEMOS system in the cement industry is realized, and the use requirements of different users are facilitated.
Claims (9)
1. The energy management system of the cement production plant is characterized by comprising a plant energy management module, a workshop process energy management module, an equipment energy management module, a dynamic optimization module, an idling equipment monitoring module, an air compressor monitoring module, an ammonia water consumption and emission management module, a quality management module, a data transmission and input module and a system setting module, wherein the modules are mutually connected and communicated;
the factory energy management module comprises a production and energy consumption preview window, a comprehensive performance analysis window, an inventory preview window, a raw material and product in-out preview window, a power consumption distribution diagram window, a power consumption statistical analysis window, a power consumption cost analysis window, a production statistical daily report window and a monthly performance public display window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the workshop process energy management module comprises a production and energy consumption window, a peak-valley level electricity utilization management window, an operator performance statistics window and an operator shift management window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the equipment energy management module comprises a power consumption analysis window, a heat consumption analysis window, a shutdown report window, a sick equipment management window, an operator optimization tool window and a central control operation record table window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the quality data statistical window and the quality data analysis window which are included by the quality management module are displayed through display equipment, and an operator executes corresponding operation through each window;
the data transmission window, the data input window and the data maintenance window which are arranged in the data transmission and input module are displayed through display equipment, and an operator executes corresponding operation through each window;
the system setting module comprises a safety management window and a system deployment management window which are displayed through display equipment, and an operator executes corresponding operation through each window;
the energy management module of the mobile equipment comprises a production operation preview window, an energy consumption statistical window, a cement sale window, a production operation window, a host operation window, an abnormal data window, a user authority and login window and a message push window which are displayed through a mobile phone display screen, and an operator executes corresponding operation through each window.
2. The energy management system of a cement manufacturing plant according to claim 1, said plant energy management module characterized by:
the production and energy consumption preview window has the functions of displaying production parameters such as the operation model of key equipment, the output per hour, the unit power consumption and the like through numerical values or graphic marks, simultaneously displaying core performance indexes such as environmental protection data, emission data and the like and operation conditions, displaying the core performance indexes through a table when the production lines are a plurality of production lines, and refreshing page data every 15 minutes;
the comprehensive performance preview window has the function of displaying the data of the clinker comprehensive power consumption and energy cost, the clinker comprehensive standard coal consumption, the cement grinding power consumption, the cement comprehensive power consumption and energy cost, the ton clinker waste heat net power generation quantity, the clinker yield and sales quantity, the cement yield and sales quantity and the like in the current month;
the comprehensive performance analysis window has the functions that key energy efficiency indexes of the whole plant clinker yield, the cement yield, the clinker comprehensive power consumption, the clinker comprehensive standard coal consumption, the cement comprehensive power consumption, the ton clinker waste heat net power generation quantity, the cement clinker ratio, the clinker process power consumption and the cement process power consumption are displayed through a histogram or a curve graph, when a plurality of production lines are displayed through a parallel histogram or one graph of each production line, the upper and lower performance limit values set by an operator are displayed by red alarms, and the operator displays plant-level energy efficiency indexes by time, shift, day, month, year or self-defined set time data granularity, so that the analysis requirements of managers at different levels are met, when two production lines are used, the data is a weighted average value, and the cement clinker ratio data is acquired as the data of a batching DCS scale;
the function of the stock preview window is that an operator displays the stock condition of the raw materials, the clinker and the cement on the current date or on the specific date by inputting or automatically collecting the calculated data through a material level instrument;
the raw material and product in-out preview window has the function of summarizing and displaying the current month data or specific date of the conditions of raw fuel entering a factory, clinker leaving the factory and cement;
the power consumption distribution diagram window has the functions that data such as total purchased power outside the whole plant, real-time power consumption of each workshop or procedure and the like are displayed by using a histogram or a curve chart, and simultaneously participate in power demand side management and the like and the proposal of optimizing monthly basic power charge and the like for a power supply department, and an operator sets data by taking time, shift, day, month, year or self-defined time as granularity;
the power consumption statistical analysis window is used for displaying a high-voltage power statistical table and a low-voltage power statistical table;
the power consumption cost analysis window has the functions of automatically counting and calculating the total power consumption of the whole plant, the process and the equipment in the peak-valley period and the information of the total power consumption, and outputting a report form in an Execl or PDF format and a power consumption price trend chart of each workshop self-defined date range;
the production statistics daily report window has the functions of displaying the production yield, the machine hour and the operation data of a factory, the process energy consumption and waste heat power generation data, the in-and-out information of raw fuel and product materials and the like, and outputting an Execl or PDF format report which is counted by the current day, the current month and the current year;
the monthly performance bulletin window has the function of outputting a monthly performance bulletin table in the Execl or PDF format in a unified format for each factory of the current year or the custom query input date.
3. The energy management system of cement manufacturing plant according to claim 1, wherein said plant process energy management module is characterized by:
the production and energy consumption window has the functions of displaying the mining process, the raw material process, the clinker process, the cement process and the loading and transporting process of the current monthly workshop, and the production operation conditions of the yield, the machine hour yield, the unit power consumption, the unit standard coal consumption, the operation rate, the reliability coefficient and the expression coefficient of the raw material mill, the coal mill, the kiln and the cement mill key equipment;
the peak-valley level power consumption management window has the functions that an operator selects a user-defined peak-valley level time period and automatically counts the peak-valley level power consumption time of a raw mill, a coal mill and a cement mill, calculates the operation rate, the peak avoiding rate, the average using rate and the valley using rate, and automatically gives a device peak avoiding condition report form in an Execl or PDF format, wherein the report form is provided with green, red or yellow marks to identify the management level of each plant;
the operator performance statistical window has the function of automatically calculating assessment reports in an Execl or PDF format and cross-shift entry condition data of each operator in each shift in a user-defined time period, and the index of the assessment reports can be defined as one of a score of 5 points, a score of percentage, a step-type score and a score according to proportion;
the operator shift-by-shift management window has the function that an operator enters production operation conditions and on-shift summary according to the assessment report, so that an assessment form of the operator in an Execl or PDF format is obtained.
4. The energy management system of a cement manufacturing plant according to claim 1, wherein said equipment energy management module is characterized by:
the power consumption analysis window has the functions of displaying the yield, the machine hour yield, the shutdown time, the control quality indexes, the process power consumption and the key host power consumption in any granularity time period of hours, shifts, working days, working months and working years, so that the raw material grinding power consumption, the coal grinding power consumption, the kiln power consumption and the cement grinding power consumption are analyzed, color change warning is carried out through the preset upper and lower limits of the performance indexes, the control quality indexes comprise the moisture and the fineness of the raw material grinding, the moisture and the fineness of the coal grinding, the f-CaO of the kiln, the fineness/specific surface area and the C/K ratio of the cement grinding, and the key host power consumption comprises a main motor, a fan and a roller press;
the heat consumption analysis window is used for displaying energy efficiency analysis of the coal consumption of the kiln in any granularity time period of hours, shifts, working days, working months and working years, and the energy efficiency analysis comprises the hourly output, the standard coal consumption of the clinker per ton, control quality data and relevant core process parameters;
the shutdown report window has the functions of automatically recording the starting time and the ending time of key equipment of a raw mill, a coal mill, a kiln and a cement mill, automatically calculating the shutdown time and the shutdown electric quantity, and outputting a report in an Execl or PDF format in a user-defined time range, wherein the shutdown is divided into three stages from the start of shutdown to the completion of shutdown, the continuation of shutdown and the start of shutdown to the completion of startup;
the pathological equipment management window has the functions that by setting the target productivity and the pathological operation judgment standard of the equipment, the system can automatically capture the time of each pathological operation of the equipment, calculate relevant data such as the duration of the pathological operation, the yield of the pathological operation, the productivity waste ratio and the energy consumption of the pathological operation, automatically generate a pathological operation record and require an operator to fill the reasons for generating the pathological operation, wherein the productivity waste ratio comprises the yield of the pathological operation and the target yield;
the operator optimization tool window has the function that an operator adjusts parameters such as process power consumption, key host machine power consumption, core process parameters and the like of a raw material mill, a coal mill, a kiln and a cement mill according to red, yellow and green graphic prompts of the system, so that the working condition of the system is always in an energy optimization production state, the key host machine power consumption comprises a main motor, a fan, a roller press and other equipment, and the core process parameters comprise pressure, current and other parameters;
the window function of the central control operation record table is that an operator inquires key operation parameters of a raw material mill, a coal mill, a kiln and a cement mill according to dates, large production data is formed through accumulation and parameter optimization adjustment, and production, process and quality personnel can conveniently conduct data mining and comprehensive analysis and application of heat consumption and power consumption.
5. The energy management system of a cement manufacturing plant according to claim 1, wherein said quality management module is characterized by:
the quality data statistical window is used for collecting on-line and off-line quality data such as warehouse material level, opening degree, temperature and the like and process key parameters through a collector;
the quality data analysis window functions to calculate and analyze various quality data by correlating the quality data with the production data.
6. The energy management system of claim 1, wherein the data transmission and input module is characterized by:
the data transmission window has the function that the data transmission through the standard database requires the collection of raw fuel in-plant weight data, product out-of-plant weight data, quality result data automatically detected by the fluorescence analyzer and control quality data in the quality system to enter the energy management system;
the data input window functions in that an operator manually enters data required by system standards;
the data maintenance window has the function of giving information such as qualification rate judgment, performance index benchmarking, early warning, completion degree calculation and the like through the system and helping an operator to maintain relevant indexes.
7. The energy management system for cement manufacturing plant according to claim 1, said system setup module characterized by:
the safety management window is used for setting safety levels and operation authorities based on definition of individual users and group users so as to execute different operation management;
the system deployment management window has the functions of collecting different types of data in real time, storing a historical database and transmitting the integrated automatic system data to a service logic layer of the energy management system.
8. The energy management system of claim 1, wherein the mobile energy management module is further configured to:
the production operation preview window has the function that an operator checks comprehensive information such as each energy consumption proportion diagram of each enterprise, a cement sales histogram of each enterprise, production operation conditions of each enterprise, operation conditions of host equipment of each enterprise, abnormal data statistics and the like;
the energy consumption statistical window has the functions of displaying the consumption proportion of each enterprise to each energy under the group by taking the type of energy consumed in production as a reference, and checking the daily consumption of the energy of the selected enterprise;
the cement sale window has the functions of displaying a comparison graph of the cement sale amount of each enterprise by a histogram, and checking the daily sale amount, the monthly accumulated sale amount and the current storage capacity ratio of various types of cement of the selected enterprise;
the production operation window has the functions of checking main clinker, cement products, varieties and daily output, monthly cumulative amount and the like of each enterprise and the machine hour output of a certain product in each host system;
the host operation window has the function of displaying the comparison of the number of times of the fault shutdown and the planned shutdown of each enterprise on the same day and the information of the number of times of the shutdown, the operation duration, the operation rate and the like of each host system of the selected enterprise such as a raw material mill, a rotary kiln, a cement mill and the like by using a histogram;
the abnormal data window has the functions of displaying the total number of all levels of abnormal conditions, each abnormal type and the respective abnormal number of the month by a histogram, and setting the notification of the push message according to the abnormal level of the abnormal data prompt or the prompt condition appointed by the operator;
the user authority and login window function is to establish the authorization authority of the user, the type and each module of the mobile equipment at the PC terminal, and to set the user name and password verification of the login interface of the user of the mobile equipment;
the message pushing window has the function of pushing messages set aiming at energy consumption early warning, alarming, stopping and the like to a user side of the mobile equipment, and the message pushing window is used for enabling an operator to set different message pushing ranges and alarming levels in the system.
9. The energy management system of any one of claims 1 to 8, wherein:
the dynamic optimization module has the function of applying the optimal central control operation record table to production according to the parameters of the branch result, the operational parameter and the control variable, so that the energy consumption is minimized;
the idle equipment monitoring module has the function of finding energy waste in three areas such as a workshop belt conveying system, a raw material conveying system, a cement mill front conveying system and the like which run idle or in half load in each shift;
the air compressor monitoring module is used for performing combined analysis on unit power consumption, output, power consumption and outlet pressure parameters of the air compressor at any time interval to obtain an optimal statistical report and a curve graph of outlet compressed air volume and air pressure of the air compressor, and control indexes of inlet and outlet air volume of compressed air storage tanks with the length of more than 1m each, air pressure and air volume of collected dust of a host machine are counted into cost analysis, wherein the host machine dust collection comprises kiln tail bag dust collection, kiln head bag dust collection, coal grinding bag dust collection, high-concentration cement grinding dust collection, cement grinding air discharge dust collection, packaging workshop section dust collection and the like;
the ammonia water consumption and emission management module has the function of acquiring the ammonia water usage amount and NO in any granularity time period of hours, shifts, working days, working months and working years from the acquisition endX、SO2And (4) waiting for the environmental emission data, calculating the unit clinker ammonia water usage, checking the emission data, the ammonia water usage data and a curve graph, and finding the optimal operation parameters and control indexes.
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Application publication date: 20201023 |