硫酸盐制浆蒸煮过程的建模与控制
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摘要
全世界纸浆产量中，化学制浆约占60％，其中90％以上是由硫酸盐法所生产。蒸煮过程是硫酸盐制浆生产中的重要工段，蒸煮的质量与得率直接影响后续工序以及成纸的质量和工厂的效益。所以，研究蒸煮工艺过程，在蒸煮过程实现先进的自动控制，对稳定纸浆质量、提高产量、节约能源、降低消耗具有重要意义。另一方面，从清洁生产的角度考虑，在达到纸浆得率和质量要求的前提下，在蒸煮过程中如何尽可能地控制污染物产生，既减轻后续碱回收系统处理黑液的负荷，又最大限度地降低对环境的污染也是自动控制系统需要考虑的目标。在计算机控制系统已经或正在普及的现代化制浆造纸工业，基于这种思想的控制策略是企业减少污染排放量、实现清洁生产的可行途径之一。因此，研究蒸煮过程的先进技术，以更恰当的模型描述蒸煮过程并设计先进的控制系统非常必要。
出于上述考虑，本文作为国家自然科学基金资助项目“基于分布式智能化的建模与优化的制浆造纸清洁生产策略的研究(编号69974034)”工作的一部分，对硫酸盐法制浆中连续蒸煮过程的建模与控制进行了研究。研究的主要内容如下：(1)对蒸煮过程中有效碱的测量技术、蒸煮模型和控制系统的发展概况作了综述；(2)根据连续制浆蒸煮过程的反应机理，应用正交配置方法建立了动态模型，并进行了模型仿真；(3)根据文献中蒸煮过程经验模型产生的数据，设计了基于子空间辨识的蒸煮过程推断控制，并作了计算机仿真研究；(4)针对蒸煮过程脱木素反应的特点，设计了有效碱浓度在线软测量系统及蒸煮过程的推断控制算法；最后对工作进行了总结并指出了蒸煮过程迫切需要解决的问题以及以后的发展趋势。
Sixty percent of pulp yield is chemistry pulp in the world, and above 90% of chemistry pulp is kraft pulp. Cooking process is an important workshop section in kraft pulp. On the one hand, the quality of cooking process influence directly the following workshop section and quality and yield of paper and benefit of plant. On the other hand, in view of cleaner production, the objective in optimal control of a continuous pulp digester is to achieve maximum pulp production at a specified kappa number with a minimum of chemicals and energy input. The control strategy based on the idea is the feasible approach to reducing pollution and realizing cleaner production. Therefore, it is necessary to study a suitable model and advanced control system on a continuous pulp digester. In addition, it is urgent affairs to develop the related measurement instrument with lower cost.
Based on the above objective, as one part of the work about distributed intelligent modeling and optimization method for cleaner production of pulp and paper industry (National Science Fund, No. 69974034), the measurement technology of effective alkali, the model of continuous digester and control system are summarized in the introduction of this paper and studied deeply in the following chapters. The main content of the thesis include: (1) A dynamic model of the continuous pulp digester is developed by applying the method of orthogonal collocation and a simulation study is present showing dynamical effects of input and parameter changes. (2) Subspace identification based inferential control is applied to a continuous pulp digester. And the idea is tested on the continuous digester. (3) Based on the principle of conductance measuring liquor concentration, the online soft-measure system of effective alkali concentration is designed.
出于上述考虑，本文作为国家自然科学基金资助项目“基于分布式智能化的建模与优化的制浆造纸清洁生产策略的研究(编号69974034)”工作的一部分，对硫酸盐法制浆中连续蒸煮过程的建模与控制进行了研究。研究的主要内容如下：(1)对蒸煮过程中有效碱的测量技术、蒸煮模型和控制系统的发展概况作了综述；(2)根据连续制浆蒸煮过程的反应机理，应用正交配置方法建立了动态模型，并进行了模型仿真；(3)根据文献中蒸煮过程经验模型产生的数据，设计了基于子空间辨识的蒸煮过程推断控制，并作了计算机仿真研究；(4)针对蒸煮过程脱木素反应的特点，设计了有效碱浓度在线软测量系统及蒸煮过程的推断控制算法；最后对工作进行了总结并指出了蒸煮过程迫切需要解决的问题以及以后的发展趋势。
Sixty percent of pulp yield is chemistry pulp in the world, and above 90% of chemistry pulp is kraft pulp. Cooking process is an important workshop section in kraft pulp. On the one hand, the quality of cooking process influence directly the following workshop section and quality and yield of paper and benefit of plant. On the other hand, in view of cleaner production, the objective in optimal control of a continuous pulp digester is to achieve maximum pulp production at a specified kappa number with a minimum of chemicals and energy input. The control strategy based on the idea is the feasible approach to reducing pollution and realizing cleaner production. Therefore, it is necessary to study a suitable model and advanced control system on a continuous pulp digester. In addition, it is urgent affairs to develop the related measurement instrument with lower cost.
Based on the above objective, as one part of the work about distributed intelligent modeling and optimization method for cleaner production of pulp and paper industry (National Science Fund, No. 69974034), the measurement technology of effective alkali, the model of continuous digester and control system are summarized in the introduction of this paper and studied deeply in the following chapters. The main content of the thesis include: (1) A dynamic model of the continuous pulp digester is developed by applying the method of orthogonal collocation and a simulation study is present showing dynamical effects of input and parameter changes. (2) Subspace identification based inferential control is applied to a continuous pulp digester. And the idea is tested on the continuous digester. (3) Based on the principle of conductance measuring liquor concentration, the online soft-measure system of effective alkali concentration is designed.
引文
[1](加拿大)G．A．斯穆克著．曹邦威译．制浆造纸工程大全[M]．[M]北京：中国轻工业出版社．
2001年5月
[2]吴福骞．纸浆技术新发展及科研动向[J]．北方造纸．1997(3)：13-19
[3]吴福骞．纸浆技术新发展及科研动向(续)[J]．北方造纸．1997(4)：20-24
[4]姚光裕．21世纪的木材硫酸盐制浆新技术[J]．林业科技通讯．1995(11)：8-10
[5]黄成希，王广维．化学制浆新工艺—低能耗间歇蒸煮技术[J]．天津造纸．1992(3)：1-8
[6]胡受祖．蒸煮技术的飞跃——连续蒸煮设备及工艺的发展[J]．纸和造纸．1998(3)：5-6
[7]颜文俊，孙优贤．化学制浆过程控制的现状和发展趋势研究[A]．工业过程建模与控制会议论文集，1994：12-19
[8]汪仲熙．低能耗间歇蒸煮技术及其特点[J]．纸和造纸．1996(1)：11-12
[9]许向阳，于玲等．间歇蒸煮过程计算机优化控制系统[J]．中国造纸学报．2000．15：98-102
[10]王慧，肖兰等．面向清洁生产的制浆过程建模与优化方法[J]．中国造纸学报．2000．15：88-92
[11]陈嘉翔．硫酸盐纸浆的RDH蒸煮与低毒性／无毒性漂白的进展[J]．中国造纸．1992．Vol．11(2)：54-58
[12]陈嘉翔．MCC与EMCC蒸煮技术[J]．中国造纸．1993．12(4)：51-54
[13]Walbum, H.H. On-line Measurements of Processes and Products in The Pulp & Paper Industry--Survey Paper[A], IFAC PRP4. Automation 4[C]. Ghent, Belgiums. 1980:505-532
[14]Farrar, D..Effective Alkali Measurement Improves Continuos Digester Performance[R]: 131-134
[15]Cleveland, C.. On-line Analysis of Pulping Liquor with a Process Titrator[J], Tappi.,Nov. 1990: 157-161
[16]Cole, R., et al..Southeastern Kraft Mill Uses On-line Sensor to Improve Alkali Monitoring[J]. pulp & Paper. Nov. 1991:75-77
[17]管永刚主编．碱法蒸煮实用技术[M]．天津：天津大学出版社．1992
[18]罗琪，刘焕彬．硫酸盐间歇蒸煮过程中有效碱浓度数学模型的研究[J]．广东造纸．1997(3)：1-4
[19]Smith, C.C. and Williams, T.J.. A Kinetic Model of Kraft Pulping Reactions: Modeling and Control of Kraft Production Systems[A]. Proc. of ISA. [C] Symposium. Millwaukee. Oct. 1975: 7-20
[20]Gustafson, et al,.Theoretical Model of the Kraft Pulping Process[J]. Ind. Eng. Chem. Proc. Des. Dev. 1983.22(1):87
[21]吴诗欣．硫酸盐法蒸煮脱木素的动力学—数学模型及其应用[J]．中国造纸．1983．3(4)：11-t6
[22]Vroom, K.E.. The H- Factor: A Means of Expressing Cooking Times and Temperatures as a Single Variable[J]. Pulp & Paper Mag. Can.. 1957:58(3): 228-231
[23]Jonas Funkquist. A Dynamic Model of the Continuous Digester Suitable for System Identification[Z].http://www.s3.kth.se/s3/control/ftp/reports/1994/IR.S3-REG-9403/
[24]Francis,J.Doyle Ⅲ, Ferhan, Kayihan. Reaction Profile Control of the Continuous Pulp Digester[J]. Chemical Engineering Science 1999.54:2679-2688
[25]Hatton, J.V. The Potential of Process Control in Kraft Pulping of Hardwoods Relative to Softwoods[J]. Tappi., 1976. 59(8): 48-50
[26]李向阳，朱学峰．硫酸盐蒸煮过程Kappa值预测模型的研究与应用[J]．广东造纸．2000(5)：23-27
[27]Chari, N.C.S. Integrated Control System for Batch Digester Control[J]. Tappi., 1973.56(7): 65-68
[28]管永刚．木浆蒸煮经验数学模型的建立[J]．中国造纸．2000．19(4)：53-55
[29]于玲，祝和云．神经元网络用于纸浆的高锰酸钾值(P值)的软测量．自动化理论、技术与应用(第四卷)[A]．1997：379-382
[30]罗琪，刘焕彬．人工神经网络在硫酸盐间歇蒸煮过程纸浆硬度建模中的应用[J]．广东造纸．1997(5-6)：94-96，114
[31]Helena, Cristina, Aguiar,Rubens. and Maciel, Filho. Neural Network and Hybrid Model: a Discussion about Different Modeling Techniques to Predict Pulping Degree with Industrial Data[J]. Chemical Engineering Science 2001.56:565-570
[32]Maciel Filho, R., Aguiar, H.C. Modelling and Analysis of A Continuous Industrial Kraft Pulping Digester[Z]. 50th Canadian Chemical Engineering. Conference, Montreal, October 15-18, 2000. http://www.csche 2000.ca/Abstracts/abstractss123.pdf
[33]管永刚．关于硫酸盐法蒸煮数学模型的若干问题[J]．中国造纸．1997．16(2)：55-58
[34]罗琪，刘焕彬等．木片硫酸盐法蒸煮过程的建模[J]．中国学术期刊文摘．1998(1)
[35]罗琪，刘焕彬等．由硫酸盐法蒸煮脱木素反应动力学推导出的纸浆Kappa值数学模型[J]．广东造纸．1997(4)：1-3，42
[36]罗琪，刘焕彬．Lo—Solids~(TM)蒸煮过程纸浆Kappa值数学模型的建立[J]．广东造纸．1998(3)：11-13
[37]莫芳灿主编．制浆造纸工业自动化[M]．北京：轻工业出版社．1981
[38]管永刚．硫酸盐法蒸煮质量控制的新策略[J]．中华纸业．1999．20(4)：21-23
[39]张健，刘焕彬等．制浆蒸煮过程终点预报系统的开发[J]．广东造纸．2000(2)：5-7
[40]Parthasarathy Kesavan,Jay H.Lee etc. Partial Least Squares (PLS) Based Monitoring and Control of Batch Digesters[J].Journal of Process Control 10(2000):.229-236
[41]Measurex公司．Measurex 2002蒸煮控制系统技术资料[R]
[42]Bill. Gough, John. T. Kay. Kraft Continuous Digester Effective Alkali Control[Z].下载于下述网页：http://www.udl.com/library/p46.html
[43]Bill. Gough, John.T.Kay. Predictive Adaptive Control Aids Pulp Digestion[J]. Control Engineering November, 1997,或下载于网站http://www.brainwave.com/pdf/a70.pdf
[44]Dumont, G. A. Application of Advanced Controls Methods in the Pulp and Paper Industry—A Survey[J]. Automatica. 1986.22(2): 143-153.
[45]沈文浩，刘焕彬．化学制浆蒸煮过程控制[J]．上海造纸．1999．30(4)：8-9，12
[46]Raja Amirthalingam, Jay H. Lee. Subspace Identification Based Inferential Control Applied to a Continuous Pulp Digester[J]. Journal of Process Control 1999(9): 397-406
[47]Philip A.Wisnewski, Francis J.Doyle Ⅲ. A Reduced Model Approach to Estimation and Control of a Kamyr Digester[J]. Computers Chem..Engng. 1996. 20(Suppl):1053-1058
[48]K.Belarbi,K.Bettou etc. Fuzzy Neural Networks for Estimation and Fuzzy Controller Design Simulation Study for a Pulp Batch Digester[J]. Journal of Process Control 10 (2000): 35-41
[49]H.D.Truett. Optimizing the Control of a Batch Digester House with Integrated Distributed Control System[J]. Tappi,.Feb., 1991: 133-140
2001年5月
[2]吴福骞．纸浆技术新发展及科研动向[J]．北方造纸．1997(3)：13-19
[3]吴福骞．纸浆技术新发展及科研动向(续)[J]．北方造纸．1997(4)：20-24
[4]姚光裕．21世纪的木材硫酸盐制浆新技术[J]．林业科技通讯．1995(11)：8-10
[5]黄成希，王广维．化学制浆新工艺—低能耗间歇蒸煮技术[J]．天津造纸．1992(3)：1-8
[6]胡受祖．蒸煮技术的飞跃——连续蒸煮设备及工艺的发展[J]．纸和造纸．1998(3)：5-6
[7]颜文俊，孙优贤．化学制浆过程控制的现状和发展趋势研究[A]．工业过程建模与控制会议论文集，1994：12-19
[8]汪仲熙．低能耗间歇蒸煮技术及其特点[J]．纸和造纸．1996(1)：11-12
[9]许向阳，于玲等．间歇蒸煮过程计算机优化控制系统[J]．中国造纸学报．2000．15：98-102
[10]王慧，肖兰等．面向清洁生产的制浆过程建模与优化方法[J]．中国造纸学报．2000．15：88-92
[11]陈嘉翔．硫酸盐纸浆的RDH蒸煮与低毒性／无毒性漂白的进展[J]．中国造纸．1992．Vol．11(2)：54-58
[12]陈嘉翔．MCC与EMCC蒸煮技术[J]．中国造纸．1993．12(4)：51-54
[13]Walbum, H.H. On-line Measurements of Processes and Products in The Pulp & Paper Industry--Survey Paper[A], IFAC PRP4. Automation 4[C]. Ghent, Belgiums. 1980:505-532
[14]Farrar, D..Effective Alkali Measurement Improves Continuos Digester Performance[R]: 131-134
[15]Cleveland, C.. On-line Analysis of Pulping Liquor with a Process Titrator[J], Tappi.,Nov. 1990: 157-161
[16]Cole, R., et al..Southeastern Kraft Mill Uses On-line Sensor to Improve Alkali Monitoring[J]. pulp & Paper. Nov. 1991:75-77
[17]管永刚主编．碱法蒸煮实用技术[M]．天津：天津大学出版社．1992
[18]罗琪，刘焕彬．硫酸盐间歇蒸煮过程中有效碱浓度数学模型的研究[J]．广东造纸．1997(3)：1-4
[19]Smith, C.C. and Williams, T.J.. A Kinetic Model of Kraft Pulping Reactions: Modeling and Control of Kraft Production Systems[A]. Proc. of ISA. [C] Symposium. Millwaukee. Oct. 1975: 7-20
[20]Gustafson, et al,.Theoretical Model of the Kraft Pulping Process[J]. Ind. Eng. Chem. Proc. Des. Dev. 1983.22(1):87
[21]吴诗欣．硫酸盐法蒸煮脱木素的动力学—数学模型及其应用[J]．中国造纸．1983．3(4)：11-t6
[22]Vroom, K.E.. The H- Factor: A Means of Expressing Cooking Times and Temperatures as a Single Variable[J]. Pulp & Paper Mag. Can.. 1957:58(3): 228-231
[23]Jonas Funkquist. A Dynamic Model of the Continuous Digester Suitable for System Identification[Z].http://www.s3.kth.se/s3/control/ftp/reports/1994/IR.S3-REG-9403/
[24]Francis,J.Doyle Ⅲ, Ferhan, Kayihan. Reaction Profile Control of the Continuous Pulp Digester[J]. Chemical Engineering Science 1999.54:2679-2688
[25]Hatton, J.V. The Potential of Process Control in Kraft Pulping of Hardwoods Relative to Softwoods[J]. Tappi., 1976. 59(8): 48-50
[26]李向阳，朱学峰．硫酸盐蒸煮过程Kappa值预测模型的研究与应用[J]．广东造纸．2000(5)：23-27
[27]Chari, N.C.S. Integrated Control System for Batch Digester Control[J]. Tappi., 1973.56(7): 65-68
[28]管永刚．木浆蒸煮经验数学模型的建立[J]．中国造纸．2000．19(4)：53-55
[29]于玲，祝和云．神经元网络用于纸浆的高锰酸钾值(P值)的软测量．自动化理论、技术与应用(第四卷)[A]．1997：379-382
[30]罗琪，刘焕彬．人工神经网络在硫酸盐间歇蒸煮过程纸浆硬度建模中的应用[J]．广东造纸．1997(5-6)：94-96，114
[31]Helena, Cristina, Aguiar,Rubens. and Maciel, Filho. Neural Network and Hybrid Model: a Discussion about Different Modeling Techniques to Predict Pulping Degree with Industrial Data[J]. Chemical Engineering Science 2001.56:565-570
[32]Maciel Filho, R., Aguiar, H.C. Modelling and Analysis of A Continuous Industrial Kraft Pulping Digester[Z]. 50th Canadian Chemical Engineering. Conference, Montreal, October 15-18, 2000. http://www.csche 2000.ca/Abstracts/abstractss123.pdf
[33]管永刚．关于硫酸盐法蒸煮数学模型的若干问题[J]．中国造纸．1997．16(2)：55-58
[34]罗琪，刘焕彬等．木片硫酸盐法蒸煮过程的建模[J]．中国学术期刊文摘．1998(1)
[35]罗琪，刘焕彬等．由硫酸盐法蒸煮脱木素反应动力学推导出的纸浆Kappa值数学模型[J]．广东造纸．1997(4)：1-3，42
[36]罗琪，刘焕彬．Lo—Solids~(TM)蒸煮过程纸浆Kappa值数学模型的建立[J]．广东造纸．1998(3)：11-13
[37]莫芳灿主编．制浆造纸工业自动化[M]．北京：轻工业出版社．1981
[38]管永刚．硫酸盐法蒸煮质量控制的新策略[J]．中华纸业．1999．20(4)：21-23
[39]张健，刘焕彬等．制浆蒸煮过程终点预报系统的开发[J]．广东造纸．2000(2)：5-7
[40]Parthasarathy Kesavan,Jay H.Lee etc. Partial Least Squares (PLS) Based Monitoring and Control of Batch Digesters[J].Journal of Process Control 10(2000):.229-236
[41]Measurex公司．Measurex 2002蒸煮控制系统技术资料[R]
[42]Bill. Gough, John. T. Kay. Kraft Continuous Digester Effective Alkali Control[Z].下载于下述网页：http://www.udl.com/library/p46.html
[43]Bill. Gough, John.T.Kay. Predictive Adaptive Control Aids Pulp Digestion[J]. Control Engineering November, 1997,或下载于网站http://www.brainwave.com/pdf/a70.pdf
[44]Dumont, G. A. Application of Advanced Controls Methods in the Pulp and Paper Industry—A Survey[J]. Automatica. 1986.22(2): 143-153.
[45]沈文浩，刘焕彬．化学制浆蒸煮过程控制[J]．上海造纸．1999．30(4)：8-9，12
[46]Raja Amirthalingam, Jay H. Lee. Subspace Identification Based Inferential Control Applied to a Continuous Pulp Digester[J]. Journal of Process Control 1999(9): 397-406
[47]Philip A.Wisnewski, Francis J.Doyle Ⅲ. A Reduced Model Approach to Estimation and Control of a Kamyr Digester[J]. Computers Chem..Engng. 1996. 20(Suppl):1053-1058
[48]K.Belarbi,K.Bettou etc. Fuzzy Neural Networks for Estimation and Fuzzy Controller Design Simulation Study for a Pulp Batch Digester[J]. Journal of Process Control 10 (2000): 35-41
[49]H.D.Truett. Optimizing the Control of a Batch Digester House with Integrated Distributed Control System[J]. Tappi,.Feb., 1991: 133-140