CN112051751A - Semi-physical simulation control system for multistage series flash evaporation industrial process - Google Patents
Semi-physical simulation control system for multistage series flash evaporation industrial process Download PDFInfo
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Abstract
The invention discloses a semi-physical simulation control system of a multistage series flash evaporation industrial process, which relates to the technical field of industrial automatic control simulation and comprises a virtual object computer, a controller design computer, a process monitoring computer and a PLC (programmable logic controller). The virtual object computer is used for realizing numerical simulation of the multistage series flash industrial process, the controller design computer is used for realizing parameter identification of a controller design model, the process monitoring computer is used for realizing real-time monitoring of operation of the multistage series flash industrial process, and the PLC is used for realizing operation of a control strategy. The method can improve the control level of the multistage series flash industrial process in the Bayer process alumina production, and lays a foundation for further researching the reaction mechanism, the process characteristics and the high-performance control strategy of the multistage series flash industrial process in the Bayer process alumina production.
Description
Technical Field
The invention relates to the technical field of industrial automatic control simulation, in particular to a semi-physical simulation control system for a multistage series flash evaporation industrial process.
Background
The multistage series flash industrial process is an important component of a high-pressure dissolution process in the Bayer process alumina production process. After the ore pulp is subjected to dissolution reaction in a high-temperature high-pressure pipeline, the ore pulp enters a flash evaporator, the temperature is higher than the boiling point under the pressure due to sudden change of the pressure, the ore pulp is boiled and vaporized rapidly, the purpose of separating vapor and liquid phases is achieved, the separated exhaust steam is used for preheating the ore pulp, the purpose of saving energy and reducing consumption can be achieved, and meanwhile, the purpose of reducing the temperature and the pressure of the ore pulp is achieved. In the high-pressure digestion process of the bayer alumina production process, flash evaporators are generally used in series in multiple stages in order to reduce the pressure of the slurry to an atmospheric level.
The multistage series flash industrial process is a complex industrial production process. In the multistage series flash evaporation industrial process, the phenomena of coexistence and transformation of solid, liquid and vapor three-phase states exist, and each stage of flash evaporators are connected in series to influence each other and cause serious coupling, so that the defect that a control algorithm researched for the multistage series flash evaporation industrial process cannot be directly applied to an industrial field is caused. Therefore, in order to improve the control level of the multistage series flash industrial process in the Bayer process alumina production and better develop the research on the multistage series flash industrial process control technology, a semi-physical simulation system of the multistage series flash industrial process is particularly important, and has important significance for developing the energy-saving and consumption-reducing research of the Bayer process alumina production process.
Disclosure of Invention
The invention aims to provide a semi-physical simulation control system for a multistage series flash industrial process, which can improve the control level of the multistage series flash industrial process in Bayer process alumina production.
In order to achieve the purpose, the invention provides the following scheme:
a semi-physical simulation control system for a multistage series flash evaporation industrial process comprises a virtual object computer, a controller design computer, a process monitoring computer and a PLC (programmable logic controller);
the virtual object computer is integrated with a virtual object simulation model; the virtual object computer is used for acquiring the secondary steam flow of each stage of flash evaporator at the current moment output by the PLC, processing the secondary steam flow of each stage of flash evaporator at the current moment to acquire the steam exhaust valve opening of each stage of flash evaporator at the current moment, inputting the steam exhaust valve opening of each stage of flash evaporator at the current moment into a virtual object simulation model for simulation calculation to obtain the liquid level height of each stage of flash evaporator at the next moment, and finally sending the liquid level height of each stage of flash evaporator at the next moment into the PLC; the virtual object simulation model is used for simulating the operation of the multistage series flash evaporation industrial process; the virtual object simulation model consists of a multistage series flash evaporation industrial process mechanism model and a modeling error compensation model;
the controller design computer is used for establishing a controller design model and downloading the controller design model into the PLC to be used as an operation model in the PLC;
the PLC is used for outputting a liquid level adjusting instruction of each stage of flash evaporator according to the controller design model and the liquid level height of each stage of flash evaporator at the next moment, and sending the liquid level adjusting instruction of each stage of flash evaporator to the corresponding flash evaporator to adjust the liquid level height of the flash evaporator;
and the process monitoring computer is used for monitoring the operation process of the PLC in real time.
Optionally, the virtual object simulation model of the virtual object computer is implemented based on Matlab simulation software; the human-computer interaction interface of the virtual object computer is realized based on FactoryTalkView software; and data transmission is realized between the Matlab simulation software and the human-computer interaction interface in an OPC communication mode.
Optionally, the virtual object is computationally integrated with an object step response experiment simulation module; the object step response experiment simulation module is used for simulating and detecting the running state of the simulation object.
Optionally, the multistage series flash evaporation industrial process mechanism model is a data model between the steam exhaust valve opening and the liquid level height of each stage of flash evaporator, which is established from the viewpoints of material balance, heat balance and phase balance, based on a process reaction mechanism of the multistage series flash evaporation industrial process;
the input of the modeling error compensation model is the opening of the steam exhaust valve at the current moment and the modeling error compensation value at the previous moment, and the output of the modeling error compensation model is the modeling error compensation value at the current moment;
and the output of the virtual object simulation model is the sum of the output of the multistage series flash industrial process mechanism model and the output of the modeling error compensation model.
Optionally, the controller design model of the controller design computer is implemented based on Matlab simulation software, and the human-computer interaction interface of the controller design computer is implemented based on FactoryTalkView software; data transmission is realized between the Matlab simulation software and the human-computer interaction interface in an OPC communication mode; the human-computer interaction interface comprises an excitation signal setting area, a modeling test process data recording area, a parameter identification area and a parameter verification area.
Optionally, the controller design model is established by using a data acquisition program, a model identification program and a model verification program in Matlab simulation software; wherein the content of the first and second substances,
the data acquisition program is used for acquiring parameter data of the controller design model; the parametric data comprises excitation signals and output signals of the virtual object simulation model under excitation of the excitation signals;
the model identification program is used for establishing a controller design model by utilizing a least square recursion algorithm according to the collected parameter data of the controller design model;
the model validation program is used to validate the controller design model.
Optionally, the software running on the process monitoring computer includes RSLogix5000 software, Factory TalkView software and RsLinx software; the RSLogix5000 software is used for writing and modifying a controller execution program; the FactoryTalkView software is used for developing and operating a human-computer interaction interface; the RsLinx software is used for realizing data communication between the PLC and the process monitoring computer; the controller execution program is an execution program of a PLC (programmable logic controller).
Optionally, the process monitoring computer is integrated with a controller comparison experiment simulation module; and the controller comparison experiment simulation module is used for simulating the operation effect of the semi-physical simulation control system under different control algorithms.
Optionally, the system further comprises a support network; data transmission is realized between the virtual object computer and the controller design computer, between the controller design computer and the PLC controller, between the process monitoring computer and the PLC controller, and between the PLC controller and the virtual object computer through the supporting network.
Optionally, a support network between the virtual object computer and the PLC controller adopts an OPC communication manner; and a supporting network between the process monitoring computer and the PLC adopts an RsLinx Enterprise communication mode.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
the invention provides a semi-physical simulation control system for a multistage series flash evaporation industrial process, which mainly comprises a virtual object computer, a controller design computer, a process monitoring computer and a PLC (programmable logic controller) actually used in an industrial field, wherein the control level of the multistage series flash evaporation industrial process in Bayer process alumina production can be improved by the mutual cooperation of the virtual object computer, the controller design computer, the process monitoring computer and the PLC.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a block diagram of a semi-physical simulation control system for a multi-stage series flash evaporation industrial process according to an embodiment of the present invention;
FIG. 2 is a block diagram of a function expansion of a semi-physical simulation control system of a second multi-stage series flash industrial process according to an embodiment of the present invention;
FIG. 3 is a schematic process diagram of a multistage tandem flash industrial process for producing alumina by Bayer process according to an embodiment of the present invention;
FIG. 4 is a diagram of a single-stage flash object model operating interface of a virtual controlled object computer according to a second embodiment of the present invention;
FIG. 5 is a schematic diagram of a controller design model operating interface of a second controller design computer according to an embodiment of the present invention;
FIG. 6 is a schematic diagram of a controller comparison experiment operation interface of a process monitoring computer according to a second embodiment of the present invention;
FIG. 7 is a schematic diagram of a human-computer interaction interface of a controller design computer according to a second embodiment of the present invention;
FIG. 8 is a schematic view of a monitoring interface of a process monitoring computer according to a second embodiment of the present invention;
fig. 9 is a comparison experimental diagram of the operation effect of different stages of flash evaporators according to the second embodiment of the present invention.
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.
The invention provides a semi-physical simulation control system of a multistage series flash industrial process, which aims at solving the problems that the multistage series flash mechanism is complex in the Bayer process alumina production process, the control strategy application research is difficult to develop directly on an industrial field and the like, can support and develop research works in different directions, and has important significance for improving the overall control technology research level of the Bayer process alumina multistage series flash industrial process.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Example one
The semi-physical simulation control system for the multistage series flash evaporation industrial process provided by the embodiment mainly comprises a support network, a virtual object computer, a controller design computer, a process monitoring computer and a PLC (programmable logic controller) used in an industrial field.
The support network mainly realizes data communication among the above parts. The support network comprises upper computer software and lower computer software, the upper computer software is monitoring software, and the upper computer software and the lower computer software are configured by means of communication software to realize communication. The communication software is installed in a virtual object computer, a controller design computer and a process monitoring computer to realize the communication among different computers, and the three computers form a local industrial Ethernet by a switch to realize data exchange; the lower computer software comprises programming software and numerical analysis software used for a virtual object computer and a controller design computer, an OPC communication mode is adopted between the numerical analysis software and the programming software, the communication software is an OPC server, the numerical analysis software is an OPC client, an OPC data access object is established in the numerical analysis software, and data interaction can be realized by configuring corresponding topic in the communication software.
The virtual object computer provides a virtual object simulation model close to a controlled object model of an actual industrial field, and the virtual object simulation model is used for simulating the operation of the multistage series flash evaporation industrial process. The virtual object simulation model consists of a multistage series flash evaporation industrial process mechanism model and a modeling error compensation model. The multistage series flash evaporation industrial process mechanism model is a data model between the steam exhaust valve opening and the liquid level height of each stage of flash evaporator, which is established from the angles of material balance, heat balance and phase balance based on the process reaction mechanism of the multistage series flash evaporation industrial process; the input of the modeling error compensation model is the opening of the steam exhaust valve at the current moment and the modeling error compensation value at the previous moment, and the output of the modeling error compensation model is the modeling error compensation value at the current moment; and the output of the virtual object simulation model is the sum of the output of the multistage series flash evaporation industrial process mechanism model and the output of the modeling error compensation model.
The virtual object simulation model of the virtual object computer is realized based on Matlab simulation software; the human-computer interaction interface of the virtual object computer is realized based on FactoryTalkView software; and data transmission is realized between the Matlab simulation software and the human-computer interaction interface in an OPC communication mode.
The virtual object computer is connected with the PLC through a support network; the virtual object computer is used for acquiring the secondary steam flow of each stage of flash evaporator at the current moment output by the PLC, processing the secondary steam flow of each stage of flash evaporator at the current moment to acquire the steam exhaust valve opening of each stage of flash evaporator at the current moment, then inputting the steam exhaust valve opening of each stage of flash evaporator at the current moment into the virtual object simulation model for simulation calculation to obtain the liquid level height of each stage of flash evaporator at the next moment, and finally sending the liquid level height of each stage of flash evaporator at the next moment into the PLC.
An object step response experiment simulation module is integrated on the virtual object calculation; the object step response experiment simulation module is used for simulating and detecting the running state of the simulation object.
The controller design computer is used for establishing a controller design model and mainly comprises an identification data acquisition function, a model parameter identification function and a model effect verification function. The controller design computer obtains process technological parameters from the PLC, then realizes the calculation of the parameters of the controller design model according to the control target set by the user to obtain the controller design model, and transmits the controller design model to the PLC to realize the adjustment of the control effect of the multistage series flash evaporation industrial process.
The controller design model of the controller design computer is realized based on Matlab simulation software, and the human-computer interaction interface of the controller design computer is realized based on FactoryTalkView software; data transmission is realized between Matlab simulation software and a human-computer interaction interface in an OPC communication mode; the human-computer interaction interface comprises an excitation signal setting area, a modeling test process data recording area, a parameter identification area and a parameter verification area.
The controller design model is established by utilizing a data acquisition program, a model identification program and a model verification program in Matlab simulation software; the data acquisition program is used for acquiring parameter data of the controller design model; the parameter data comprises an excitation signal and an output signal of the virtual object simulation model under the excitation of the excitation signal; the model identification program is used for establishing a controller design model by utilizing a least square recursion algorithm according to the collected parameter data of the controller design model; the model validation program is used to validate the controller design model.
The process monitoring computer comprises loop control software and upper computer monitoring software, and is mainly used for realizing the compiling of the controller execution program and the development of the monitoring picture, and can also carry out the comparison experiment of different control algorithms. The process monitoring computer is used for monitoring the operation process of the PLC in real time, receiving the operation setting of a user on the multistage series flash evaporation industrial process, outputting the operation result of the PLC to a monitoring picture and helping the user to realize the real-time monitoring of the operation condition of the technological process; the controller execution program is an execution program of the PLC.
The software running on the process monitoring computer comprises RSLogox 5000 software, FactoryTalkView software and RsLinx software; RSLogox 5000 software is used for writing and modifying a controller execution program; the FactoryTalkView software is used for developing and operating a human-computer interaction interface; the RsLinx software is used for realizing data communication between the PLC and the process monitoring computer.
The process monitoring computer is integrated with a controller comparison experiment simulation module; and the controller comparison experiment simulation module is used for simulating the operation effect of the semi-physical simulation control system under different control algorithms.
The PLC controller comprises a power supply, a CPU, an Ethernet communication module, and a corresponding AI module, AO module, DI module and DO module; the PLC is connected with the process monitoring computer through the Ethernet communication module to realize the downloading and running of the program. The PLC is used for realizing the real-time operation of the execution program of the controller. The PLC is used for outputting a liquid level adjusting instruction of each stage of flash evaporator according to the design model of the controller and the liquid level height of each stage of flash evaporator at the next moment, and sending the liquid level adjusting instruction of each stage of flash evaporator to the corresponding flash evaporator so as to adjust the liquid level height of the flash evaporator.
Example two
Each part of the semi-physical simulation control system for the multistage series flash evaporation industrial process provided by the embodiment is specifically introduced as follows:
1. supporting the network: data communication between each part in the semi-physical simulation control system is mainly realized, such as data communication between a virtual object computer and a controller design computer, data communication between a process monitoring computer and a PLC controller, data communication between the PLC controller and the virtual object computer, and the like. According to the different positions of the network, different communication modes are adopted, for example, the support network between the virtual object computer and the PLC adopts an OPC communication mode, and the support network between the process monitoring computer and the PLC adopts an RsLinx Enterprise communication mode.
2. Virtual object computer: the method is mainly used for operating a virtual object simulation model in a semi-physical simulation control system, and the virtual object simulation model is used for simulating the operation of an actual multistage series flash evaporation industrial process. The virtual object simulation model consists of a multistage series flash evaporation industrial process mechanism model and a modeling error compensation model. Based on the process reaction mechanism of the multistage series flash evaporation industrial process, a data model between the opening degree of a dead steam valve and the liquid level height of each stage of flash evaporator is established from the viewpoints of material balance, heat balance and phase balance, and the data model is called as a multistage series flash evaporation industrial process mechanism model; because a certain deviation exists between the process operation mechanism of the multistage series flash evaporation industrial process and the actual industrial operation process of the multistage series flash evaporation, a modeling error compensation model is introduced to make up for the modeling error caused by the deviation. The input of the modeling error compensation model is the opening degree of the steam exhaust valve at the current moment and the modeling error compensation value at the previous moment, and the output is the modeling error compensation value at the current moment; the modeling error compensation model is constructed according to historical data and a neural network technology; the historical data comprises historical steam exhaust valve opening and historical moment modeling error compensation values.
The virtual object simulation model of the virtual object computer is realized based on Matlab simulation software, namely the Matlab simulation software is used for realizing the operation of the virtual object simulation model; the human-computer interaction interface of the virtual object computer adopts FactoryTalkView software, and the human-computer interaction interface is used for realizing the visualization of a virtual object simulation model; data communication between Matlab simulation software and a human-computer interaction interface is realized by adopting an OPC communication mode, so that a virtual object computer is formed, and numerical simulation of a multistage series flash evaporation industrial process is realized.
3. Controller design computer: the method is mainly used for establishing a controller design model. Before the controller design model is established, a modeling test needs to be performed on a controlled object, a specific excitation signal, such as a step signal, a pulse signal and the like, is used as input data of the controlled object, the controlled object is sufficiently excited, and meanwhile output data of the controlled object is recorded. And forming a data matrix by using the recorded input data and output data of the controlled object, and establishing a controller design model of the controlled object by adopting a corresponding modeling algorithm (such as a least square recursion algorithm). And after the controller design model is obtained, the input data in the obtained industrial field data of the controlled object is used as the input data of the controller design model, the output data corresponding to the controller design model is recorded, then the error between the output data of the controller design model and the actual output data of the industrial field is calculated, and whether the obtained controller design model can meet the controller design requirement is judged according to the error evaluation index. Only the controller design model that achieves satisfactory verification results can be used for subsequent controller design.
When the controller design model is established, firstly, the structure of the controller design model (the number of controller orders and controller parameters) is determined according to the indexes of the controller design model (such as the minimum control error variance) and the characteristics of the controller design model, so as to obtain the mathematical expression of the controller design model, then the obtained mathematical expression of the controller design model is substituted into a controlled object, so as to obtain a closed-loop equation of the controlled object, then, the controller orders and the controller parameters are updated according to the principle that the root of the closed-loop equation is positioned on the left half plane of a coordinate system, so as to obtain a final controller design model, and finally, the controller design model is downloaded into a PLC (programmable logic controller).
The controller design model of the controller design computer is realized based on Matlab simulation software, and the controller design computer is used for operating a controller design algorithm of the multistage series flash evaporation industrial process; the human-computer interaction interface of the controller design computer adopts FactoryTalkView software, the human-computer interaction interface is used for realizing the visualization of the design process of the multi-stage series flash industrial process controller, and the human-computer interaction interface mainly comprises excitation signal setting, modeling test process data recording, parameter identification, parameter verification and the like; and the data communication between the Matlab simulation software and the human-computer interaction interface is realized by adopting an OPC communication mode.
4. The process monitoring computer: the real-time operation monitoring of the multistage series flash industrial process and the writing and modification of the controller execution program are mainly realized. The software running on the process monitoring computer comprises RSLogix5000 software, Factory TalkView software and RsLinx software, wherein the RSLogix5000 software is mainly used for compiling and modifying a controller execution program; the Factory TalkView software is used for developing and operating a human-computer interaction interface, and realizes real-time monitoring of operation parameters of the multistage series flash evaporation industrial process, equipment state monitoring and operation, real-time adjustment of a process operation process and the like; the RsLinx software is used for realizing data communication between the PLC and the process monitoring computer.
5. Industrial process controller (i.e. PLC controller): a control Logix series product of Rockwell company is adopted as an industrial process controller, mainly comprises a main control module, an I/O module, a power supply module and an Ethernet communication module, and is used for running a controller to execute a program. The human-computer interaction interface is realized by a process monitoring computer.
In the semi-physical simulation control system of the multistage series flash evaporation industrial process consisting of the five parts, the virtual object computer is used for realizing numerical simulation of the Bayer process alumina production multistage series flash evaporation industrial process, the controller design computer is used for realizing data acquisition and controller design model parameter identification, the process monitoring computer is used for realizing real-time monitoring of the Bayer process alumina production multistage series flash evaporation industrial process operation, the industrial process controller is used for realizing control strategy operation, the support network provides support for data communication among the parts, thus, a semi-physical simulation control system of the Bayer process aluminum oxide production multistage series flash industrial process integrating modeling and control is formed, and a foundation is laid for further researching the reaction mechanism, the process characteristics and the high-performance control strategy of the Bayer process aluminum oxide production multistage series flash industrial process.
The function extension module of the semi-physical simulation control system for the multistage series flash evaporation industrial process provided by the embodiment is shown in fig. 2, and the simulation method is as follows:
first, a virtual object system in a virtual object computer is established. The virtual object system includes a virtual object simulation model, a virtual sensor model, and a virtual actuator model.
The virtual execution mechanism model is used for simulating an execution mechanism of an industrial field, mainly refers to a variable frequency pump and a regulating valve, refers to a regulating valve at the top of a flash evaporator in a multistage series flash evaporation industrial process, is a valve dynamic characteristic mechanism model, is input into a process loop controller (namely a PLC (programmable logic controller) which is integrated in a process monitoring computer), namely a control variable u and secondary steam flow, and is established according to a valve response curve (obtained by drawing data of valve opening and secondary steam flow in an actual field to obtain a fitting relation between the valve opening and the secondary steam flow, namely steam exhaust valve opening).
The single-stage flash evaporator mechanism model is established by MATLAB simulation software in a virtual object computer according to material balance, heat balance and phase balance, the input of the single-stage flash evaporator mechanism model is the exhaust steam valve opening degree output by the virtual execution mechanism model, and the output is controlled variables (such as liquid level, pressure and the like) required to be controlled. And then acquiring secondary steam flow data and controlled variable (liquid level, pressure and the like) data of an actual site, processing the secondary steam flow data by a virtual execution mechanism model to obtain the opening degree of a steam exhaust valve, and then performing error learning by using an RBF neural network to obtain a data-driven modeling error compensation model of the single-stage flash evaporator. After the single-stage flash evaporator mechanism model and the modeling error compensation model are established, the theoretical output of the single-stage flash evaporator mechanism model is superposed with the error output of the modeling error compensation model, so that the output of the virtual object simulation model is obtained and is used as the output value of the whole virtual object system.
After the virtual object simulation model of the single-stage flash evaporator is completed, the virtual object simulation model of the multi-stage serial flash evaporator can be established, and because the stages are directly connected, the parameters of the output materials of the previous stage are used as the input parameters of the next stage, and the virtual object simulation models of the single-stage flash evaporators are connected one by one, so that the virtual object simulation model of the multi-stage serial flash evaporator is formed.
The virtual sensor model is used for simulating a detection instrument of an industrial field and transmitting the value of the controlled variable parameter calculated and output by the virtual object simulation model to the process loop controller, so that the purpose of detection is realized.
And secondly, developing a visual object interface. In order to make the created virtual object system more intuitive and vivid, an operation interface of a single-stage flash evaporation object model is developed in a virtual object computer by using FactoryTalkView Studio software, as shown in FIG. 4, the operation interface comprises parameters (flow, temperature and density) of input ore pulp and output ore pulp, and parameters such as temperature, pressure and liquid level of a flash evaporator and secondary steam. An object mechanism model is displayed on the left lower portion of an operation interface, operation trend monitoring (liquid level, pressure, temperature and outlet density) of some important parameters is performed on the right side of the operation interface, and a model parameter module in the operation interface displays first-stage (first-stage) inlet slurry parameters of multi-stage series flash evaporation and is initialized for a virtual object system. All data in the run interface is from the tag value in the actual process loop controller.
And thirdly, identifying the design model parameters of the controller. The identification of the parameters of the controller design model is the basis for the operation of the process loop controller in the process monitoring computer, and the identification of the parameters of the controller design model needs to be completed before the process loop controller is designed. In a controller design computer, parameter identification of a controller design model is realized by utilizing a data acquisition program, a model identification program and a model verification program of Matlab simulation software.
The data acquisition program is used for acquiring parameter data for identifying a controller design model, and the parameter data comprises an excitation signal and an output signal y of a virtual object system under the condition that the excitation signal is fully excited, the excitation signal of the model is the opening degree of a steam exhaust valve, and the excitation signal adopts white noise in order to fully reflect the dynamic characteristic of the model. On a controller design interface, not only are the mean value, the variance and the amplitude of an excitation signal set, but also the total group number of acquired data and the data group number for identifying and verifying a controller design model are set, then the excitation signal is transmitted to a virtual object computer through communication to be used as the input of a virtual object system (the opening value of a continuously-changing exhaust steam valve), the output y (controlled variable values, liquid level, pressure and the like) of the virtual object system is continuously acquired, and thus, a data acquisition program is completed.
In the model identification program, parameters of the controller design model are identified and obtained by utilizing a least square recurrence algorithm according to the collected input data and output data of the virtual object system.
In order to verify the quality of the parameters identified by the controller design model, a model verification program is required to be used for verification (verification is to take the controller design model as an object, use verification data u as the input of the controller design model, and compare the output of the controller design model with the collected data y). When the fitting effect is good, the parameters can be used for controller design to obtain a controller design model, and the controller design model can be sent to a process loop controller for loop control by clicking and downloading.
And fourthly, designing a computer monitoring picture by the development controller. In order to make the identification process of the controller design model intuitive and easy to operate, a controller design picture is developed in a controller design computer by utilizing FactoryTalkView Studio software, a model structure needing to be identified is displayed in the upper left area of the picture, the excitation signal parameter setting and the identification result display area are arranged in the lower left area of the picture, and the convergence curve of parameters in the identification process and the fitting condition of the model when the model is verified are respectively displayed in the right area of the picture.
And step five, the process loop controller executes program development. After the development of the relevant programs on the virtual object computer and the controller design computer is completed, the development of the relevant programs on the process monitoring computer is carried out.
The first is the development of the executive program of the process loop controller, whether a simple PID control program or a more advanced control algorithm, is developed here. In the actual industrial production field, the most widely used is still a DCS system or a PLC controller, so the execution program of the process loop controller is in the form of a ladder diagram in Studio 5000 software. The input of the process loop controller is a real-time detection value of a controlled variable, the input of the process loop controller in the simulation control system of this embodiment is a controlled variable value (liquid level, pressure, etc.) output by a virtual sensor model in a virtual object computer, the output of the process loop controller is a controlled variable regulation value, and the secondary steam flow output by each stage of flash evaporator after being regulated by the controlled variable regulation value acts on a virtual execution mechanism model in the virtual object computer through communication. To this end, the process loop controller in the process monitoring computer is linked to the virtual object system in the virtual object computer to form a complete closed control loop. However, in the actual alumina production process, the parameters of the flash evaporation process model are always in dynamic change, so that the controller design model in the process loop controller needs to be periodically corrected by using the controller design computer, when the control effect is poor, the program in the controller design computer is re-run, data is re-acquired, the controller design model is identified, and the new controller design model is obtained and then downloaded to the process loop controller, so that the correction of the controller design model in the process loop controller is realized.
And sixthly, developing a production process operation monitoring picture. The production process running monitoring picture in the process monitoring computer is a monitoring picture used in an actual industrial field, the monitoring picture is developed according to an actual process flow and production requirements, and the full flow of the multistage series flash evaporation can be monitored in real time on the monitoring picture and is close to industrial field production.
The software interface of the semi-physical simulation control system for the multistage series flash evaporation industrial process provided in this embodiment mainly includes three parts, which are a single-stage flash evaporation object model operation interface running on a virtual object computer, as shown in fig. 4, a controller design model operation interface running on a controller design computer, as shown in fig. 5, and a controller comparison experiment operation interface running on a process monitoring computer, as shown in fig. 6.
The single-stage flash evaporation object model operation interface is mainly used for monitoring operation parameters of a single-stage flash evaporation industrial process in real time, the operation interface mainly comprises a single-stage flash evaporation industrial process schematic diagram, a mechanism model expression, model parameters and an important parameter operation trend, and the bottom of the operation interface is a picture switching navigation button.
The controller design model operation interface is mainly used for assisting in identifying the controller design model and mainly comprises the controller design model, least square identification algorithm parameter setting, identification result display, identification result verification and the like.
The controller comparison experiment operation interface is mainly used for comparing the operation performance of control strategies of different controllers, and comprises a structural schematic diagram of an unmodeled dynamic controller, a model operation fluctuation parameter, the display of tracking operation effects of different controllers and the evaluation index of the controller performance.
The semi-physical simulation control system for the multistage series flash industrial process provided in this embodiment is a semi-physical simulation control system designed and developed for the multistage series flash industrial process in the dissolution process of the actual alumina production industrial process, and as shown in fig. 3, describes relevant conditions of specific equipment, material input and output, and the like involved in the multistage series flash industrial process. As can be seen from fig. 3, the multistage serial flash evaporation industrial process is formed by connecting multistage flash evaporators end to end, the feed of the first-stage flash evaporator (i.e. the feed of the multistage serial flash evaporation industrial process) is ore pulp (a high-temperature and high-pressure mixture with coexistent gas-liquid-solid three phases) dissolved out at high pressure, the discharge of the first-stage flash evaporator is used as the feed of the second-stage flash evaporator, the ore pulp is sequentially connected in series, and after the temperature and pressure of the 11-stage flash evaporator are reduced, the dissolved-out ore pulp finally enters a dilution tank and is used. However, for the single-stage flash evaporator, the feeding material is high-temperature and high-pressure ore pulp, after entering the flash evaporator, with the sudden increase of the volume, the flash evaporation phenomenon occurs, a large amount of secondary steam exhaust flow (or called secondary steam flow) is released, the secondary steam exhaust flow is used for preheating the ore pulp in the dissolution pipeline, the ore pulp after temperature reduction and pressure reduction enters the next-stage flash evaporator, and the temperature reduction and pressure reduction are carried out again until the ore pulp is reduced to normal pressure and normal temperature (lower than 80 ℃).
For the semi-physical simulation control system of the multistage series flash evaporation industrial process provided by this embodiment, a simple description is made below on how to operate and use related functions, and the specific steps are as follows:
step 1: and (5) initializing the system. Checking the work of the virtual object computer, the controller design computer and the process monitoring computer, checking whether the starting self-checking of the support network and each part of the PLC controller is normal, if all the parts are normal, performing the step 2, and if not, re-initializing.
Step 2: a virtual object simulation model (MATLAB program model _ duo jiszmodel v1.m) on a virtual object computer is opened and run, then a numerical analysis software program which is written in advance is run, then factor ytalk view interface editing software is opened, a single-stage flash object model client is run, and the running effect of the single-stage flash object model client is shown in fig. 4.
And step 3: a step response experiment (shown in fig. 4) was performed on the subject to ensure that the virtual subject ran properly.
Step 3.1: initializing the single-stage flash object model client, and inputting corresponding material parameters (such as feeding flow, feeding density, feeding temperature) and equipment parameter information (here, default parameters are initialized by a program) on a parameter column (shown as 1 in fig. 3) of an operation interface of the single-stage flash object model client.
Step 3.2: and opening a valve operation panel, setting an initial opening value of the steam exhaust valve (shown in a position 2 in the figure 3), displaying a real-time value of an operation signal on an operation interface of the client side of the single-stage flash evaporation object model, observing a parameter operation trend on the right side of the operation interface (shown in a position 3 in the figure 3), and gradually enabling the operation of the single-stage flash evaporation object model to enter a steady state.
Step 3.3: step signals are input into the valve, the opening value of the steam exhaust valve is adjusted, and the single-stage flash object model client side operation interface displays that the process enters another new steady state process from one steady state.
And 4, step 4: and after the step response experiment of the single-stage flash object model is completed, clicking a navigation button at the bottom of the operation interface of the client of the single-stage flash object model, switching to the operation interface of the client of the multi-stage flash object model used in the actual field, and performing the related experiment of the multi-stage flash object. Taking fig. 7 as an example, the operation interface shows the first three stages (NT108, NT109, NT110) of the cascade flash evaporation process, the three trend pictures are the liquid level heights of the three flash evaporators respectively, the steam exhaust valve opening degrees (as shown in 1 in fig. 7) of 8#, 9#, and 10# above each flash evaporator in fig. 7 can be adjusted, the liquid level variation trend of each flash evaporator is observed, and as can be seen from fig. 7, the virtual object simulation model can approximately simulate the operation condition of an actual site. Fig. 7 shows a computer human-computer interface designed for the controller, through which a user can not only independently perform a step response experiment for each stage of flash evaporator, but also perform a step response experiment for the multiple stages of flash evaporators.
And 5: after the step 4 is completed, the simulation object can be ensured to run normally, and the controller design computer is run below. Opening Matlab simulation software on a controller design computer, sequentially inputting control _ bianshiuuju.m, control _ bianshitrain.m and control _ bianshitest.m in a Matlab running environment, then opening FactoryTalkView interface editing software, and running a controller design model client as shown in FIG. 5.
Step 6: the parameters related to the excitation signal u (equivalent to the input of the step response experiment) are set in the identification related parameter setting column of the controller design model client operation interface (as shown in fig. 5 at 1), where the mean value is set to 40, the amplitude value is set to 5, the variance is set to 1, the number of the sampling data sets is 5000, the number of the training data sets is 2500, the number of the test data sets is 500, then the "start sampling" button is clicked, the set excitation signal u (k) is used as the input of the virtual object simulation model in the virtual object computer, the corresponding output signal y (k) is returned after the calculation of the virtual object simulation model, and y (k) in the experiment is the liquid level height of the flash evaporator, so that the data acquisition work is completed.
And 7: after data collection is completed, a controller design model parameter identification experiment is performed, an identification starting button on the right side of an operation interface of a controller design model client is clicked, an identification program is started, the operation interface (shown as 2 in fig. 5) and a bottom identification parameter table (shown as 3 in fig. 5) can display the final identification result, the 2 in fig. 5 shows the convergence trend of identification parameters, the 3 in fig. 5 shows the final parameter identification value, and at the moment, the collected test data can be used for verifying the verification effect (shown as 4 in fig. 5) of the identification controller design model on a test data set and is displayed on the lower right of the operation interface.
And 8: after the identification of the design model parameters of the controller is completed, the design of the control strategy is started, and the simulation control system takes a simple PID control experiment and a PID control experiment with unmodeled dynamic compensation as examples to demonstrate how to carry out the research and comparison experiments of the control strategy. Firstly, opening a process monitoring computer, opening RSLogox 5000 software, downloading a PLC program of K02 to an actual Rockwell PLC controller, opening FactoryTalkView interface editing software, operating a client, and switching to an operation interface as shown in FIG. 8.
And step 9: first, a simple PID control experiment is performed, taking LT110 liquid level control as an example, in a manual mode, after a virtual object runs stably, a target liquid level value is set to 1.9 (as shown in 1 in fig. 8), after a PID parameter is set, an automatic mode is put into operation, a tracking effect is observed (as shown in 2 in fig. 8), and the PID parameter is adjusted according to the effect, as shown in fig. 8. Fig. 8 is a schematic view of a monitoring interface of the process monitoring computer, wherein a PID tracking control experiment is performed on one stage Nt109, a liquid level target value SP is set on a panel, the loop is automatically put into operation, and a control tracking effect can be improved by adjusting PID control parameters.
Step 10: after the simple PID control experiment is completed, a control effect comparison experiment is performed, and the control is switched to a controller comparison experiment operation interface, as shown in fig. 6, the operation effect comparison results of the simple PID control experiment (as shown in 1 in fig. 6) and the PID control experiment with unmodeled dynamic compensation (as shown in 2 in fig. 6) are respectively displayed on the controller comparison experiment operation interface, a tracking effect graph and a control signal are displayed on the right side of the controller comparison experiment operation interface, a liquid level setting value SP and a liquid level detection value PV of the loop are displayed in a first trend graph at 1 in fig. 6, wherein a light color line is a liquid level setting value SP, a dark color line is a tracking detection value PV, a second trend graph at 1 in fig. 6 is a control signal, namely an operation set value of a valve position, and are the same at 2 in fig. 6. The lowest end (shown at 3 in fig. 6) was measured for effect using IAE and MSE.
Fig. 9 is a comparative experiment chart of the operation effect of different control algorithms respectively adopted for different stages of flash evaporators. The verification result proves that the Bayer process aluminum oxide production multistage series flash industrial process semi-physical simulation system can carry out comparison experiment research on different control algorithms.
The semi-physical simulation control system for the multistage series flash industrial process can be used for carrying out simulation research on multistage series flash industrial process control on an actual industrial field, can be used for carrying out real-time simulation on the operation condition of the multistage flash industrial process on the basis, can be used for carrying out complex control strategy research, and can also be used for carrying out comparison experiment research on various controllers. For the actual industrial process of multistage series flash evaporation in Bayer process alumina production in industry, the invention can carry out process simulation of the industrial process of multistage series flash evaporation, carry out research of different high-performance control algorithms, and further improve the control effect of the flash evaporation process and even the whole dissolution process, which has important significance for improving the automation level of the dissolution process in Bayer process alumina production.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (10)
1. A semi-physical simulation control system of a multistage series flash evaporation industrial process is characterized by comprising a virtual object computer, a controller design computer, a process monitoring computer and a PLC (programmable logic controller);
the virtual object computer is integrated with a virtual object simulation model; the virtual object computer is used for acquiring the secondary steam flow of each stage of flash evaporator at the current moment output by the PLC, processing the secondary steam flow of each stage of flash evaporator at the current moment to acquire the steam exhaust valve opening of each stage of flash evaporator at the current moment, inputting the steam exhaust valve opening of each stage of flash evaporator at the current moment into a virtual object simulation model for simulation calculation to obtain the liquid level height of each stage of flash evaporator at the next moment, and finally sending the liquid level height of each stage of flash evaporator at the next moment into the PLC; the virtual object simulation model is used for simulating the operation of the multistage series flash evaporation industrial process; the virtual object simulation model consists of a multistage series flash evaporation industrial process mechanism model and a modeling error compensation model;
the controller design computer is used for establishing a controller design model and downloading the controller design model into the PLC to be used as an operation model in the PLC;
the PLC is used for outputting a liquid level adjusting instruction of each stage of flash evaporator according to the controller design model and the liquid level height of each stage of flash evaporator at the next moment, and sending the liquid level adjusting instruction of each stage of flash evaporator to the corresponding flash evaporator to adjust the liquid level height of the flash evaporator;
and the process monitoring computer is used for monitoring the operation process of the PLC in real time.
2. The semi-physical simulation control system of a multistage series flash evaporation industrial process according to claim 1, wherein the virtual object simulation model of the virtual object computer is implemented based on Matlab simulation software; the human-computer interaction interface of the virtual object computer is realized based on Factory TalkView software; and data transmission is realized between the Matlab simulation software and the human-computer interaction interface in an OPC communication mode.
3. The semi-physical simulation control system of a multistage series flash industrial process according to claim 1, wherein the virtual object is computationally integrated with an object step response experimental simulation module; the object step response experiment simulation module is used for simulating and detecting the running state of the simulation object.
4. The semi-physical simulation control system of the multistage series flash evaporation industrial process according to claim 1, wherein the multistage series flash evaporation industrial process mechanism model is a data model between the steam exhaust valve opening and the liquid level height of each stage of flash evaporator, which is established from the viewpoint of material balance, heat balance and phase balance, based on the process reaction mechanism of the multistage series flash evaporation industrial process;
the input of the modeling error compensation model is the opening of the steam exhaust valve at the current moment and the modeling error compensation value at the previous moment, and the output of the modeling error compensation model is the modeling error compensation value at the current moment;
and the output of the virtual object simulation model is the sum of the output of the multistage series flash industrial process mechanism model and the output of the modeling error compensation model.
5. The semi-physical simulation control system of the multistage series flash evaporation industrial process, according to claim 1, wherein the controller design model of the controller design computer is implemented based on Matlab simulation software, and the human-computer interaction interface of the controller design computer is implemented based on Factory TalkView software; data transmission is realized between the Matlab simulation software and the human-computer interaction interface in an OPC communication mode; the human-computer interaction interface comprises an excitation signal setting area, a modeling test process data recording area, a parameter identification area and a parameter verification area.
6. The semi-physical simulation control system of the multistage series flash evaporation industrial process according to claim 5, wherein the controller design model is established by using a data acquisition program, a model identification program and a model verification program in Matlab simulation software; wherein the content of the first and second substances,
the data acquisition program is used for acquiring parameter data of the controller design model; the parametric data comprises excitation signals and output signals of the virtual object simulation model under excitation of the excitation signals;
the model identification program is used for establishing a controller design model by utilizing a least square recursion algorithm according to the collected parameter data of the controller design model;
the model validation program is used to validate the controller design model.
7. The semi-physical simulation control system of the multistage series flash evaporation industrial process as claimed in claim 1, wherein the software running on the process monitoring computer is RSLogix5000 software, Factory talk view software and RsLinx software; the RSLogix5000 software is used for writing and modifying a controller execution program; the FactoryTalkView software is used for developing and operating a human-computer interaction interface; the RsLinx software is used for realizing data communication between the PLC and the process monitoring computer; the controller execution program is an execution program of a PLC (programmable logic controller).
8. The semi-physical simulation control system of the multistage series flash evaporation industrial process as claimed in claim 1, wherein the process monitoring computer is integrated with a controller contrast experiment simulation module; and the controller comparison experiment simulation module is used for simulating the operation effect of the semi-physical simulation control system under different control algorithms.
9. The semi-physical simulation control system of a multi-stage series flash industrial process according to claim 1, further comprising a support network; data transmission is realized between the virtual object computer and the controller design computer, between the controller design computer and the PLC controller, between the process monitoring computer and the PLC controller, and between the PLC controller and the virtual object computer through the supporting network.
10. The semi-physical simulation control system of a multistage series flash evaporation industrial process according to claim 9, wherein a support network between the virtual object computer and the PLC controller employs an OPC communication method; and a supporting network between the process monitoring computer and the PLC adopts an RsLinx Enterprise communication mode.
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