石灰炉热工过程的在线仿真与智能集成控制
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摘要
石灰炉是目前工业上生产石灰和获得二氧化碳气体的常用设备，但由于石灰烧成的各项工艺参数难以获得，致使生产过程中普遍存在着石灰炉内生产状况难以准确掌握，生产自动控制无法进行等问题。本文在此背景下，针对石灰炉的具体情况，研究了利用热工仿真技术，使用新的智能集成控制的思想，解决石灰炉燃烧控制的难题。
本文根据炉内热平衡和物料平衡原理，建立了焦炭燃烧和石灰石分解的理论模型；对混合料预热过程及石灰冷却过程进行了研究和理论分析。基于对石灰炉内的燃烧等工艺过程的热工分析，建立了石灰炉内反应与传热的数值仿真模型。并以此为基础，利用现场检测和测定的各种参数，对石灰炉内预热带、煅烧带和冷却带的高度以及烧成状况、分解率等工艺过程进行计算机仿真，研究各参数对石灰石煅烧的影响。
根据仿真结果，在已有的自动检测系统基础上，通过增加必要的在线检测手段，收集石灰炉生产过程的在线信息，实现了石灰炉的全息检测；综合运用炉窑热工和反应动力学原理，总结现场操作经验和工艺要求，研究石灰炉控制模型，建立了专家知识库，开发了石灰炉炉况在线诊断模型和软件；根据石灰石煅烧分解率、炉内温度分布以及石灰炉运行状况的在线计算和诊断结果，采用模糊控制和专家控制系统相结合，运用模糊智能控制器，集成基于数学模型的控制技术和基于经验知识的控制技术，进行炉况控制决策，从而获得了过去难以达到的控制效果。
本系统投入生产实践中后，石灰质量、CO_2浓度及产能都有明显提高，石灰炉高效稳定运行，实现了增产降耗的目标。
At present shaft furnace is widely used to product lime and obtain carbon dioxide in
industry. As it is difficult to determine some importan technical parameters and operating
condition of lime sintering, production processes can not be understood accurately and
cofltrOlled automatically. According to the actual condition of lime fumace, in this thesis
numerical simulation technology and new intelligent integration control idea are used to
solve the problem of combustion control in lime furnace.
According to the theory of heat and materials balance, the theoretic model of coke
combustion and lime decomposition was established. The pre-heating process of mixed feed
and cooling process of hot lime were investigated and theoretically analyzed. On the basis of
thermal analysis of the technical processes, a numerical model of reaction and heat transfer
in lime fumace was developed. Based on various parameters monitored and measured on
site, compllter simulation is carried ollt to find ollt the height of preheating zone,
calcinations zone, cooling zone, and calcining status, decomposition ratio .etc. The impact of
parameters on lime stOne calcining has been studied.
By adding new instruments and integrating the results of numerical simulation and
measurements, the online information of production process in lime furnace was sufficiently
collected. By using thermal and reaction dynamics principles and fully collecting operation
experience, the control model of lime furnace was studied and expert repository was
estab1ished. Online diagnosing model and software of operation conditions of lime furnace
were aIso developed. According to the decomposition rate, temperature distribution, and
online diagnosing resultS of operating statUs, control strategy of fiJrnace operation was
decided.
Based on computer simulation and parameter measurements fuZZy and expert control
systems were adopted, and funy intelligent controller was developed to integrate
mathematical model and experience of operators into control techniques to realize high-level control, which was difficult to attain before.
After the control system was put into practice, the quality of lime, CO2 concentration and productivity were distinctly increased as a result of effective and steady operation of lime furnace, and thus, the target of increasing production and decreasing expense was realized.
本文根据炉内热平衡和物料平衡原理，建立了焦炭燃烧和石灰石分解的理论模型；对混合料预热过程及石灰冷却过程进行了研究和理论分析。基于对石灰炉内的燃烧等工艺过程的热工分析，建立了石灰炉内反应与传热的数值仿真模型。并以此为基础，利用现场检测和测定的各种参数，对石灰炉内预热带、煅烧带和冷却带的高度以及烧成状况、分解率等工艺过程进行计算机仿真，研究各参数对石灰石煅烧的影响。
根据仿真结果，在已有的自动检测系统基础上，通过增加必要的在线检测手段，收集石灰炉生产过程的在线信息，实现了石灰炉的全息检测；综合运用炉窑热工和反应动力学原理，总结现场操作经验和工艺要求，研究石灰炉控制模型，建立了专家知识库，开发了石灰炉炉况在线诊断模型和软件；根据石灰石煅烧分解率、炉内温度分布以及石灰炉运行状况的在线计算和诊断结果，采用模糊控制和专家控制系统相结合，运用模糊智能控制器，集成基于数学模型的控制技术和基于经验知识的控制技术，进行炉况控制决策，从而获得了过去难以达到的控制效果。
本系统投入生产实践中后，石灰质量、CO_2浓度及产能都有明显提高，石灰炉高效稳定运行，实现了增产降耗的目标。
At present shaft furnace is widely used to product lime and obtain carbon dioxide in
industry. As it is difficult to determine some importan technical parameters and operating
condition of lime sintering, production processes can not be understood accurately and
cofltrOlled automatically. According to the actual condition of lime fumace, in this thesis
numerical simulation technology and new intelligent integration control idea are used to
solve the problem of combustion control in lime furnace.
According to the theory of heat and materials balance, the theoretic model of coke
combustion and lime decomposition was established. The pre-heating process of mixed feed
and cooling process of hot lime were investigated and theoretically analyzed. On the basis of
thermal analysis of the technical processes, a numerical model of reaction and heat transfer
in lime fumace was developed. Based on various parameters monitored and measured on
site, compllter simulation is carried ollt to find ollt the height of preheating zone,
calcinations zone, cooling zone, and calcining status, decomposition ratio .etc. The impact of
parameters on lime stOne calcining has been studied.
By adding new instruments and integrating the results of numerical simulation and
measurements, the online information of production process in lime furnace was sufficiently
collected. By using thermal and reaction dynamics principles and fully collecting operation
experience, the control model of lime furnace was studied and expert repository was
estab1ished. Online diagnosing model and software of operation conditions of lime furnace
were aIso developed. According to the decomposition rate, temperature distribution, and
online diagnosing resultS of operating statUs, control strategy of fiJrnace operation was
decided.
Based on computer simulation and parameter measurements fuZZy and expert control
systems were adopted, and funy intelligent controller was developed to integrate
mathematical model and experience of operators into control techniques to realize high-level control, which was difficult to attain before.
After the control system was put into practice, the quality of lime, CO2 concentration and productivity were distinctly increased as a result of effective and steady operation of lime furnace, and thus, the target of increasing production and decreasing expense was realized.
引文
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2．н.и叶列明编，王延明译．氧化铝生产过程与设备[M]．冶金工业出版社，1987．
3．毕诗文．铝土矿的拜耳法溶出[M]．冶金工业出版社，1997．
4．靳古功．烧结法生产氧化铝生料配置过程的优化控制[M]．氧化铝生产文集，1999．
5．陈金清，等．石灰炉煅烧质量与氧化铝质量的关系，矿冶工程，2000(6)
6．张如先，等．石灰炉配料控制算法[J]．洛阳工学院学报，2000，21(2)：70-72．
7．游自强，等．PLC在大型活性石灰成套设备中的应用[J]．冶金自动化，2000(2)：49-51．
8．苑莉，现代石灰竖窑与PLC自动控制[J]．河北冶金，1998(1)：53-55．
9．阮学彬，等．三明钢铁厂气烧石灰窑计算机控制系统[J]．冶金自动化，2000(4)：63-64．
10．肖师荣，等．自校正控制在石灰竖窑控制系统中的应用[J]．福州大学学报，1999，27(4)：62-64．
11．周孑民，等．石灰窑窑内热工分析与操作优化[J]．工业加热，2000(4)．
12．孙剑峰．石灰炉烧白煤操作探讨[J]．科技与管理，1999增刊．
13．c 苑安民．石灰窑各区高度优化研究．上海冶金高等专科学校学报[J]，1999，20(1)：24-29．
14．(?)义胜，等．竖炉石灰窑气体流动数学模型研究．包头钢铁学院学报[J]，1997，16(2)：110-115．
15．陈英，张宇．用风口燃烧温度判断高炉热状态的可行性研究[J]．鞍钢技术，2000(11)：6-8．
16．麦雪凤．柳钢2#高炉大修工程仪控系统配置及特点[J]．冶金自动化[J]，2000(6)：62-63．
17．吴胜利，等．基于模糊数学的高炉炉况预测模型[J]．钢铁，2001，36(3)：12-14．
18．包宏，杨章远．高炉人工智能炉况监控系统的研制及应用．中国有色金属学报，1997(7)．
19．苑安民．石灰窑各区高度优化研究，上海冶金高等专科学校学报，1999，20(1)：24-29。
20．周乃君，易正明等．石灰炉煅烧分解率在线监测模型研究．化工学报，2001．；52(7)：612-615．
21．周乃君，易正明等．石灰炉炉内过程数值仿真．中南工业大学学报，2000：31(5)．
22．[苏]н.п.塔邦希科夫编，甄文彬译．石灰的生产[M]．中国建筑工业出版社，1982．
23．[日]鞭岩，森山昭编，蔡志鹏译．冶金反应工程学[M]．科学出版社，1981．
24．中国纯碱工业协会．纯碱工学[M]．化学工业出版社，1990．
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27．[法]洛杰．路瓦松编，王福成译．焦炭[M]．冶金工业出版社，1981．
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