CN114942619A - Automatic production control method for lime rotary kiln - Google Patents

Automatic production control method for lime rotary kiln Download PDF

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Publication number
CN114942619A
CN114942619A CN202210541032.7A CN202210541032A CN114942619A CN 114942619 A CN114942619 A CN 114942619A CN 202210541032 A CN202210541032 A CN 202210541032A CN 114942619 A CN114942619 A CN 114942619A
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fuel
air
unit
lime
amount
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Inventor
张国武
孙全利
王泽�
郭晓军
杨斌
梁建忠
杨林
贾延龙
陈戈
常红
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Shanxi Taigang Engineering Technology Co ltd
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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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2/00—Lime, magnesia or dolomite
    • C04B2/10—Preheating, burning calcining or cooling
    • 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
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31359—Object oriented model for fault, quality control
    • 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
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/40—Production or processing of lime, e.g. limestone regeneration of lime in pulp and sugar mills

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Ceramic Engineering (AREA)
  • Quality & Reliability (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Thermal Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

The invention relates to the technical field of lime rotary kiln production, in particular to an automatic production control method of a lime rotary kiln. An automatic production control method of a lime rotary kiln comprises the following steps: the method comprises the following steps: setting the yield of lime; step two: setting production heat consumption; step three: the air factor is set. By the method provided by the invention, the complex regulation and control of the lime rotary kiln can be simplified into automatic control of materials, fuel and air according to the yield. The operator is presented with the adjustment of three key parameters of yield, heat consumption and air coefficient, and the heat consumption and the air coefficient only need to be finely adjusted, so that the production operation is greatly simplified.

Description

Automatic production control method for lime rotary kiln
Technical Field
The invention relates to the technical field of lime rotary kiln production, in particular to an automatic production control method of a lime rotary kiln.
Background
The difference of the production control levels of domestic lime rotary kilns is large, and most of the control levels are not high. Basically, the production is carried out through manual operation of computer pictures, feeding amount, fuel amount, primary air, secondary air, air conveying and conveying, discharging amount and air inducing amount are respectively adjusted and controlled by an operator, the kiln head pressure, the kiln tail pressure, the kiln head temperature, the kiln tail temperature, the flue gas temperature and the like of the kiln are checked, and finally the lime production operation is finished.
For such a large number of parameter variation controls, it generally requires extremely high operation experience and attention to perform parameter adjustment and response well, and achieve good production. In practical production application, generally, few continuous personnel with extremely high operation experience are available, and continuous extremely high concentration degree is more difficult to achieve, so that various condition changes can be hardly reflected continuously in time, and the problems of large product yield and quality fluctuation, large kiln condition fluctuation and large production energy consumption are caused.
For the multivariable control, an expert system, a model predictive analysis system and the like formed by adopting various technical schemes are also available, but the realization cost is particularly high, the realization effect is not ideal, and the function commissioning rate is low.
Disclosure of Invention
The invention aims to solve the problems and provides an automatic production control method of a lime rotary kiln.
The purpose of the invention is realized by the following steps: an automatic production control method of a lime rotary kiln comprises the following steps: the method comprises the following steps: setting the yield of lime, wherein the unit of the set yield is ton per day, calculating the required limestone amount according to the set yield, calculating the pushing time unit second of the preheater, and circularly controlling the pushing action according to the calculated time period, so that the limestone is added into the rotary kiln according to the requirement; step two: setting production heat consumption, wherein each kilogram of KCal is a unit, namely, the consumed comprehensive heat required by producing 1 kilogram of lime, automatically calculating the required fuel quantity through the production heat consumption, the lime yield and the fuel heat value, and transmitting the calculated fuel quantity as a set value to the conventional high-precision fuel supply system to realize the precise control of the fuel; step three: setting an air coefficient, calculating the required combustion air amount according to the fuel amount and the air coefficient, wherein for the lime kiln taking pulverized coal as fuel, the air fed into the kiln for combustion comprises primary air, secondary air and spray gun air delivery, and the primary air and the delivery air do not need to be frequently adjusted, so that the control of the air amount is the control of the secondary air amount, and the accurate control of the air amount can be realized by controlling the rotating speed of a secondary fan.
The calculation method in the step one is
Figure 918099DEST_PATH_IMAGE001
，
Figure 561570DEST_PATH_IMAGE002
The lime coefficient: the proportion of lime and limestone is obtained through limestone assay, and the material pushing amount is as follows: 14-20 push heads are uniformly and annularly configured on the vertical preheater, limestone is added into the kiln through sequential actions of the push heads, the stroke of each push head action is fixed, the limestone volume pushed into the kiln is the same, and the amount of the pushed limestone in each action, namely unit Kg, can be calculated according to the fixed stroke and the uniform volume of the limestone pushed into the kiln.
The calculation method in the step two is a fuel quantity calculation formula:
Figure 975365DEST_PATH_IMAGE003
，
fuel quantity: the unit is Kg/hour, which is the unit when the fuel is pulverized coal, and when the fuel is fuel gas fuel, the unit of fuel quantity is converted into standard cubic per hour;
setting heat consumption: the unit is KCal/Kg, which is the unit when the fuel is coal powder, and when the fuel is gas fuel, the unit is KCal/NM 3;
fuel calorific value: the unit is KCal/Kg, the test data is obtained, and when the fuel is gas fuel, the unit is KCal/NM 3.
The calculation method of the third step is
Figure 969866DEST_PATH_IMAGE004
；
Figure 48681DEST_PATH_IMAGE005
，
Initial air amount: the theoretical amount of air required to completely burn a unit of fuel, unit NM3, can be obtained from theoretical calculations, as a fixed value, which varies from fuel to fuel;
the air amount of primary air: the unit NM3 is measured by a flowmeter arranged on a primary air pipeline or calculates theoretical air quantity according to the rotating speed of a fan, and changes in real time;
conveying air volume of pulverized coal: the unit NM3 is measured by a flowmeter arranged on a pulverized coal conveying air pipeline or calculates theoretical air quantity according to the rotating speed of a fan, and changes in real time;
air factor: the unit is not needed, the value of 1.00-2.00 is taken, and the amount of the inlet air volume can be adjusted by adjusting the value.
The invention has the beneficial effects that: by the method provided by the invention, the complex regulation and control of the lime rotary kiln can be simplified into automatic control of materials, fuel and air according to the yield. The operator is only presented with the adjustment of three key parameters of yield, heat consumption and air coefficient, and the heat consumption and the air coefficient only need to be finely adjusted, so that the production operation is greatly simplified.
The method provided by the invention fundamentally realizes lean production of the rotary kiln, the produced product has stable quality and stable kiln condition, the heat consumption of the rotary kiln is greatly reduced, and the production safety is essentially ensured.
The method provided by the invention has the advantages of low implementation cost, easy realization and high commissioning rate.
Drawings
FIG. 1 is a flow chart of the present invention.
Detailed Description
Aiming at the situations, the invention provides a technical scheme for controlling the automatic production of the lime rotary kiln, and the simple method can be used for better solving the multivariable complex control problem, and has the advantages of good realization effect, stable production, low realization cost and high commissioning rate.
Technical scheme
1. The lime rotary kiln generally comprises a waste gas draught fan, a waste gas dust remover, a vertical preheater, a rotary kiln, a vertical cooler, a discharge apron conveyor, a fuel supply system and other main equipment and a complete process production line of a matched motor, a fan and an instrument.
2. The lime rotary kiln also comprises a matched controller (PLC or DCS), a computer and a development tool.
3. Setting the yield of lime, wherein the unit of the set yield is ton per day, automatically calculating the required limestone amount according to the set yield, then calculating the pushing time (unit second) of the preheater, and circularly controlling the pushing action according to the calculated time period, thereby adding limestone into the rotary kiln according to the requirement.
The calculation method comprises the following steps:
Figure 625287DEST_PATH_IMAGE006
，
Figure 537879DEST_PATH_IMAGE007
。
description of the calculation data
Lime coefficient: the ratio of lime to limestone can be obtained by limestone assay.
Material pushing amount: the vertical preheater is uniformly and annularly provided with a plurality of pushing heads, limestone is added into the kiln through the sequential actions of the pushing heads, the stroke of each pushing head action is fixed, the limestone pushed into the kiln has the same volume, and the pushed limestone quantity of each action, namely unit Kg, can be roughly calculated according to the fixed stroke.
4. The production heat consumption is set, the unit KCal per kilogram, namely the consumed comprehensive heat required by producing 1 kilogram of lime, and the required fuel quantity can be automatically calculated through the production heat consumption, the lime yield and the fuel heat value. The calculated fuel amount is transmitted to the high-precision fuel supply system as a set value, and the precise control of the fuel can be easily realized.
Fuel quantity calculation formula:
Figure 488517DEST_PATH_IMAGE008
。
description of the calculation data
Fuel quantity: the unit is Kg/hour, which is the unit when the fuel is pulverized coal, and when the fuel is gas fuel, the unit of the fuel quantity is converted into standard cubic per hour;
setting heat consumption: the unit is KCal/Kg, which is the unit when the fuel is coal powder, and the unit is KCal/NM3 when the fuel is fuel gas;
fuel calorific value: the unit is KCal/Kg, the test data is obtained, and when the fuel is gas fuel, the unit is KCal/NM 3.
5. An air coefficient is set, and a required combustion air amount is automatically calculated based on the fuel amount and the air coefficient. For a lime kiln using pulverized coal as fuel, air entering the lime kiln for combustion comprises primary air, secondary air and spray gun air delivery, and considering that the primary air is mainly used for forming pulverized coal into longer combustion flame, and the air delivery is mainly used for ensuring a certain solid-gas ratio, the primary air and the air delivery do not need to be frequently adjusted under normal conditions, so that the control of air volume is simplified to control the secondary air volume. The accurate control of the air quantity can be realized by controlling the rotating speed of the secondary fan.
By limiting the minimum value of the air coefficient, certain excess air can be ensured, so that the combustion safety is fundamentally ensured.
The total combustion air amount calculation formula is as follows:
Figure 698919DEST_PATH_IMAGE009
；
Figure 333294DEST_PATH_IMAGE010
。
description of the calculation data
Initial air amount: the amount of air theoretically required for complete combustion of a unit of fuel, unit NM3, is a fixed value that varies from fuel to fuel;
the air amount of primary air: the unit NM3 is measured by a flowmeter arranged on a primary air pipeline or calculates theoretical air quantity according to the rotating speed of a fan, and changes in real time;
conveying air volume of pulverized coal: the unit NM3 is measured by a flowmeter arranged on a pulverized coal conveying air pipeline or calculates theoretical air quantity according to the rotating speed of a fan, and changes in real time;
air factor: the air volume can be adjusted by adjusting the value, which is a value greater than 1.00.
6. By using the methods of the 3 rd, 4 th and 5 th steps, the core factors (materials, fuel and air) of the combustion control of the rotary kiln can be simply decomposed into a series of definite control logics: the material quantity and the fuel quantity are obtained from the yield, and the air quantity is obtained from the fuel quantity, so that the material, the fuel and the air are automatically controlled according to the yield. By using the method, multi-target and multi-parameter decoupling control is realized to a certain extent.
7. When the method of the steps 3, 4 and 5 is used, the kiln head of the rotary kiln is kept at a proper negative pressure, so that safe and environment-friendly production is realized. The flue gas after the rotary kiln combustion is discharged by a waste gas induced draft fan after passing through an environment-friendly dust remover, the rotation speed of the waste gas induced draft fan is controlled by a conventional PID (proportion integration differentiation) to ensure that the pressure of the kiln head can be automatically kept within a set negative pressure range, and the negative pressure set value (-5 to-50 Pa) does not need to be changed generally.
When the air coefficient is changed, the change of the air input inevitably reflects the negative pressure of the kiln head, so that the kiln head negative pressure controller can respond and adjust the rotating speed of the waste gas draught fan in time, and the negative pressure is controlled within a set range.
8. When the method of the steps 3, 4 and 5 is used, when the raw materials are stable, the lime coefficient and the pushing amount can be regarded as constants; when the fuel is stable, the fuel heating value may be considered constant. Thus, the complex regulation control of the lime rotary kiln presents to the operator only the adjustment of three key parameters of yield, heat consumption and air coefficient.
After the yield is set, the production can be completed stably and reliably only by fine adjustment of heat consumption and air coefficient.
9. The lime rotary kiln also comprises the control of the discharge amount, and the discharge is completed through a vertical cooler. The material level detection is designed on the cooler, and the material level of the cooler is controlled at a certain material level by controlling the vibration frequency change of a plurality of dumpers on the vertical cooler, so that the discharge amount control is completed. These controls can all be done by classical PID.
The process of the invention is illustrated by an example:
1. a1000 t/d active lime rotary kiln production line is provided with a variable frequency control waste gas draught fan, a set of cloth bag waste gas dust remover, a vertical preheater (18 chambers), a rotary kiln with the diameter of phi 4.88 multiplied by 70m, a vertical cooler, a discharge apron conveyor, a set of fuel supply system and other main equipment, and is matched with related motors, fans, instruments and the like.
2. The matched controller adopts Siemens 1500 series PLC, a plurality of computers are configured, and Siemens Bombycis and WINCC software are adopted as development tools.
3. The yield of lime is set, the yield is set to be 1000 tons per day, the coefficient of lime can be obtained to be 0.52 through limestone assay, and the required amount of limestone is automatically calculated according to the set yield.
Limestone quantity =1000/0.52=1923 tons.
Roughly calculating the amount of the limestone pushed in each action, namely 423 kg of pushing amount.
Then, the head pushing time (unit second) of the preheater is calculated.
Push-head time = (86400 × 423)/(1923 × 1000) =19 seconds.
The circulation control of 18 pushing heads according to the calculated time period is easily realized through a PLC program, so that the limestone is added into the rotary kiln as required.
4. The heat rate of production was set to 980KCal per Kg, the fuel used in this example was pulverized coal, the average calorific value of the pulverized coal obtained from the test data was 6750KCal/Kg, and the amount of fuel required was calculated.
Fuel quantity = (980 x 1000)/(6750 x 24) =6049 kg.
The calculated fuel quantity is used as a set value and is transmitted to the high-precision rotor scale equipment of the embodiment through PLC communication, the rotor scale can accurately control the coal feeding quantity through a self frequency converter, and pulverized coal is blown into the rotary kiln head for combustion by utilizing a conveying fan and a pulverized coal spray gun.
5. An air coefficient is set, in this example, the air coefficient is set to 1.12, the required combustion air amount is automatically calculated according to the fuel amount and the air coefficient, and the initial air amount is measured by 8 standard cubes.
Total air =6049 × 1.12 × 8 =54199 standard cubic.
At this time, the air quantity of primary air entering the kiln is 2530 standard cubes, the conveying air quantity of pulverized coal entering the kiln is 2520 standard cubes, and the required secondary air quantity is calculated.
Secondary air volume = 54199-.
The air quantity is used as a set value for controlling the secondary fan, and the variable frequency rotating speed of the secondary fan is controlled through conventional PID control logic, so that the control of the secondary air quantity is realized.
6. The core factors (material, fuel and air) of the combustion control of the rotary kiln are simplified and decomposed into a series of definite control logics through the methods of the 3 rd, the 4 th and the 5 th steps: the material quantity and the fuel quantity are obtained from the yield, and the air quantity is obtained from the fuel quantity, so that the material, the fuel and the air are automatically controlled according to the yield.
After the core control logic of the rotary kiln is completed, other controls such as kiln head negative pressure and charge level control are simply realized by adopting a conventional PID controller.
In the example, the negative pressure of the kiln head is set to be-30 Pa, and a conventional PID controller is arranged in a PLC program to control the rotating speed of a variable-frequency exhaust gas induced draft fan so as to automatically keep the pressure of the kiln head within a set negative pressure range. Designing radar material level detection on the cooler, controlling the material level of the cooler to be at a certain material level by controlling the vibration frequency change of the discharger, and thus finishing the control of the discharge amount.
By the method provided by the invention, the complex regulation and control of the lime rotary kiln can be simplified into automatic control of materials, fuel and air according to the yield. The operator is presented with the adjustment of three key parameters of yield, heat consumption and air coefficient, and the heat consumption and the air coefficient only need to be finely adjusted, so that the production operation is greatly simplified.
The method provided by the invention fundamentally realizes lean production of the rotary kiln, the produced product has stable quality and stable kiln condition, the heat consumption of the rotary kiln is greatly reduced, and the production safety is essentially guaranteed. The method provided by the invention has the advantages of low implementation cost, easy realization and high commissioning rate.
The above description is only an embodiment of the present invention, but the structural features of the present invention are not limited thereto, and any changes or modifications within the scope of the present invention by those skilled in the art are covered by the present invention.

Claims (4)

1. The automatic production control method of the lime rotary kiln is characterized by comprising the following steps: the method comprises the following steps: the method comprises the following steps: setting the yield of lime, wherein the unit of the set yield is ton per day, calculating the required limestone amount according to the set yield, then calculating the unit second of the head pushing time of the preheater, and circularly controlling the head pushing action according to the calculated time period, so that the limestone is added into the rotary kiln according to the requirement;
step two: setting production heat consumption, namely, the consumed comprehensive heat required by producing 1 kilogram of lime per kilogram of KCal, automatically calculating the required fuel quantity through the production heat consumption, the lime yield and the fuel heat value, and transmitting the calculated fuel quantity as a set value to the existing high-precision fuel supply system to realize the precise control of the fuel;
step three: setting an air coefficient, calculating the required combustion air amount according to the fuel amount and the air coefficient, wherein for the lime kiln taking pulverized coal as fuel, the air fed into the kiln for combustion comprises primary air, secondary air and spray gun air delivery, and the primary air and the delivery air do not need to be frequently adjusted, so that the control of the air amount is the control of the secondary air amount, and the accurate control of the air amount can be realized by controlling the rotating speed of a secondary fan.
2. The automatic production control method of the lime rotary kiln as claimed in claim 1, wherein: the calculation method in the step one is
Figure 385186DEST_PATH_IMAGE001
，
Figure 370591DEST_PATH_IMAGE002
The lime coefficient: the proportion of lime and limestone is obtained through limestone assay, and the material pushing amount is as follows: 14-20 push heads are uniformly and annularly arranged on the vertical preheater, limestone is added into the kiln through sequential actions of the push heads, the stroke of each push head action is fixed, the limestone volume pushed into the kiln is the same, and the amount of the pushed limestone in each action, namely unit Kg, can be calculated according to the fixed stroke and the same volume of the limestone pushed into the kiln.
3. The automatic production control method of the lime rotary kiln as claimed in claim 1, wherein: the calculation method in the second step is a fuel quantity calculation formula:
Figure 791208DEST_PATH_IMAGE003
，
fuel quantity: the unit is Kg/hour, which is the unit when the fuel is pulverized coal, and when the fuel is gas fuel, the unit of the fuel quantity is converted into standard cubic per hour;
setting heat consumption: the unit is KCal/Kg, which is the unit when the fuel is coal powder, and the unit is KCal/NM3 when the fuel is fuel gas;
fuel calorific value: the unit KCal/Kg, the test data obtained, in the case of gas-type fuel, is KCal/NM 3.
4. The automatic production control method of the lime rotary kiln as claimed in claim 1, characterized in that: the calculation method of the third step is
Figure 60515DEST_PATH_IMAGE004
；
Figure 173965DEST_PATH_IMAGE005
，
Initial air amount: the theoretical air quantity required for complete combustion of a unit of fuel, unit NM3, can be obtained from theoretical calculations, being a fixed value, which varies from fuel to fuel;
the air amount of primary air: the unit NM3 is measured by a flowmeter arranged on a primary air pipeline or calculates theoretical air quantity according to the rotating speed of a fan, and changes in real time;
conveying air volume of pulverized coal: the unit NM3 is measured by a flowmeter arranged on a pulverized coal conveying air pipeline or calculates theoretical air quantity according to the rotating speed of a fan, and changes in real time;
air factor: the unit is not needed, the value of 1.00-2.00 is taken, and the amount of the inlet air volume can be adjusted by adjusting the value.
CN202210541032.7A 2022-05-19 2022-05-19 Automatic production control method for lime rotary kiln Pending CN114942619A (en)

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