铝电解槽焙烧控制系统设计与研究
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摘要
当前铝电解的生产流程主要分为焙烧、启动和正常生产三个阶段,而焙烧阶段尤为重要,焙烧质量的好坏直接影响到以后铝电解的正常生产。目前国内众多铝厂多采用具有竞争力的焦炭床焙烧方法,整个焙烧过程仍然采用工人手工焊接和拆除分流器,焙烧过程中产生的大量数据采用人工记录,这样不仅操作繁杂、控制精度低,而且数据记录准确度难以保证,不利于以后分析处理。本论文针对中国铝业贵州分公司的焙烧现状,提出并设计了一套电解槽焙烧分流装置及其控制系统。
论文首先分析总结了国内外铝厂电解槽的焙烧控制方法,结合贵州铝厂是采用焦炭床焙烧方法的实际状况以及焙烧质量的评价标准,设计了整套焙烧分流控制系统的硬件,在分析了硬件的操作性和可靠性之后实现了硬件的选型以及具体实现功能,为之后的系统软件部分开发缩短周期奠定了基础,并设计给出了系统硬件的接线图。
其次在结合控制系统硬件功能之后实现了系统软件的功能,包括上位机监控系统——采用西门子公司WinCC组态软件开发,并详述了其具体开发流程及具体实现功能；下位机PLC程序采用Step7开发设计,使用梯形图和语句表设计了功能程序和错误诊断程序,并利用仿真模拟器测试了软件功能。
最后,针对焙烧控制电解槽温度这个核心控制变量,建立了温度控制算法。对铝电解槽这个大惯性大滞后的控制对象,采用实验法确定了其控制模型；并采用PID控制方法整定控制模型的特性参数,通过在MATLAB/Simulink建模仿真中最终确定采用PI控制器,结合温度分区算法和负荷均匀算法实现了铝电解槽焙烧温度控制。
At present, the production process of electrolytic aluminum is divided into three stages, baking, starting up and regular production, thus baking stage is particularly important, because baking quality directly affects regular production of electrolytic aluminum. Now lots of domestic aluminum industries adopt competitive methods of coke-bed roasting, still using welding and dismounted the shunts by hand during the whole process of baking, and manual recording large amounts of data, which is not only complicated in operation, low exact in control, but also difficult to ensure accuracy of recording data and not favored to analysis and processing afterwards. Aiming at the present baking situation in Chalco Guizhou Branch, this paper proposed and designed a set of baking shunts device and its control system in aluminum reduction cells.
Firstly, this paper analyzes and summarizes method of baking control in aluminum industry at home and abroad, together with actual baking situation in Chalco Guizhou Branch as well as evaluation criteria of baking quality, devising the hardware of the whole baking control system, realizing hardware selection and concrete function after analyzing operability and reliability. These are laid foundation for shorter development period of software, and designing and providing wiring diagram of system hardware.
Secondly, this paper provides software selection and function after reference to the function of control system hardware, including monitoring system of the upper machine, which is developed with Siemens WinCC configuration software, and PLC program of lower machine which developed with Step7. Paper describes development process and function in detail, functional programs and fault diagnosis procedures are designed with ladder and statement table. Meanwhile, the function of software is tested by the simulator.
Finally, focusing on the core control variable of temperature in aluminum reduction cell, this paper provides the establishment of temperature control algorithm. The control model of cell is based on experiments in terms to the big inertia of electrolytic cell control target. Characteristic parameters of control model are settled according to PID control method, PI controller is adopted through model simulation in MATLAB/Simulink, ultimately achieving baking temperature control after combined with temperature zoning algorithm and load equalization algorithm.
论文首先分析总结了国内外铝厂电解槽的焙烧控制方法,结合贵州铝厂是采用焦炭床焙烧方法的实际状况以及焙烧质量的评价标准,设计了整套焙烧分流控制系统的硬件,在分析了硬件的操作性和可靠性之后实现了硬件的选型以及具体实现功能,为之后的系统软件部分开发缩短周期奠定了基础,并设计给出了系统硬件的接线图。
其次在结合控制系统硬件功能之后实现了系统软件的功能,包括上位机监控系统——采用西门子公司WinCC组态软件开发,并详述了其具体开发流程及具体实现功能；下位机PLC程序采用Step7开发设计,使用梯形图和语句表设计了功能程序和错误诊断程序,并利用仿真模拟器测试了软件功能。
最后,针对焙烧控制电解槽温度这个核心控制变量,建立了温度控制算法。对铝电解槽这个大惯性大滞后的控制对象,采用实验法确定了其控制模型；并采用PID控制方法整定控制模型的特性参数,通过在MATLAB/Simulink建模仿真中最终确定采用PI控制器,结合温度分区算法和负荷均匀算法实现了铝电解槽焙烧温度控制。
At present, the production process of electrolytic aluminum is divided into three stages, baking, starting up and regular production, thus baking stage is particularly important, because baking quality directly affects regular production of electrolytic aluminum. Now lots of domestic aluminum industries adopt competitive methods of coke-bed roasting, still using welding and dismounted the shunts by hand during the whole process of baking, and manual recording large amounts of data, which is not only complicated in operation, low exact in control, but also difficult to ensure accuracy of recording data and not favored to analysis and processing afterwards. Aiming at the present baking situation in Chalco Guizhou Branch, this paper proposed and designed a set of baking shunts device and its control system in aluminum reduction cells.
Firstly, this paper analyzes and summarizes method of baking control in aluminum industry at home and abroad, together with actual baking situation in Chalco Guizhou Branch as well as evaluation criteria of baking quality, devising the hardware of the whole baking control system, realizing hardware selection and concrete function after analyzing operability and reliability. These are laid foundation for shorter development period of software, and designing and providing wiring diagram of system hardware.
Secondly, this paper provides software selection and function after reference to the function of control system hardware, including monitoring system of the upper machine, which is developed with Siemens WinCC configuration software, and PLC program of lower machine which developed with Step7. Paper describes development process and function in detail, functional programs and fault diagnosis procedures are designed with ladder and statement table. Meanwhile, the function of software is tested by the simulator.
Finally, focusing on the core control variable of temperature in aluminum reduction cell, this paper provides the establishment of temperature control algorithm. The control model of cell is based on experiments in terms to the big inertia of electrolytic cell control target. Characteristic parameters of control model are settled according to PID control method, PI controller is adopted through model simulation in MATLAB/Simulink, ultimately achieving baking temperature control after combined with temperature zoning algorithm and load equalization algorithm.
引文
[1]董春明.国内外铝工业发展简况[R].2005：pp1-5
[2]干益人.铝电解槽焦粒焙烧的技术关键和实施方法[J].轻金属,2001
[3]刘永刚,唐骞,梁韬.铝电解槽大型预焙槽四种焙烧方法的比较.轻金属,2000(4)：pp33-35
[4]廖贤安,张明凯.铝电解槽焙烧启动方法和发展动向[EB/OL].中国铝电解网,2010-12
[5]吴庆刚,等.大型预焙铝电解槽焙烧启动的过程控制与方法[EB/OL].中国铝电解网,2010-12
[6]彭其润,等.基于PLC与专家控制器的电解槽预焙烧燃烧控制系统[D].计算机测量与控制,2004,20(4)：pp3-8
[7]伍成波.铝电解槽高温烟气焙烧技术的理论与实践[D].重庆：重庆大学,2004
[8]苏昆哲.深入浅出西门子WinCCV6[M].北京：北京航空航天大学出版社,2004
[9]冯乃祥.铝电解[M].化学工业出版社,2006
[10]史洪尧.230kA铝电解槽开发与生产应用综合技术研究[J].辽宁：东北大学,2006
[11]高守传.精通SQL结构化查询语言详解[M].北京：人民邮电出版社,2007
[12]黄东,罗飞,赵少华,冯炳枢.基于VBScript实现WinCC过程数据归档[J].微计算机信息,2008,24：pp275-276
[13]Shaher A.Mohamed, M.M.Megahed, H.Hashem, M.El-Ghonimy. Development of Coke-bed Preheating Method for 200kA cells. Light Metals 2006, pp676-680
[14]Zhao Qun, Xie Yanli, Qiu Zhuxian, Zhao Wuwei. Coke power bake preheat start-up of 280kA alumina electrolysis cells in China. Light Metals 2006
[15]Zeng Shuiping, Li Jinhong, Lan Tao, Analysis of the Start-Up of Q-350 Prebaked Aluminum Reduction Cells, light metal 2006, pp271-273
[16]Marc Dupuis.Usage of full 3D transient thermo-electric F.E.Model to study the thermal gradient generated in the lining during a coke preheat[J]. Light Metals,2001:pp757-762
[17]Marc Dupuis. Computation of aluminum reduction cell energy balance using ANSYS finite element models[J].Light Metals,1998:pp409-417
[18]华桂林,邵勇.230kA大型预焙槽焙烧启动技术方案探讨[J].轻金属,2004(8)：pp39-40
[19]邵勇,李俊,曹继明,许庆.230kA铝电解槽的“最佳”操作与实践[J].轻金属,2010(5)：pp35-36
[20]海云,王正荣,郭有斌.240kA大型电解槽焦粒焙烧启动的技术与实践[A].全国铝电解槽生产技术与操作技术学术报告和经验交流会论文集[C],2007
[21]崔坚.西门子S7可编程控制器—STEP7编程指南[M].北京：机械工业出版社,2007
[22]严爱军,张亚庭,高学金.过程控制系统[M].北京：北京工业大学出版社,2010
[23]李颖.Simulink动态系统建模与仿真[M].西安：西安电子科技大学出版社,2009
[24]北京南山高科技有限公司.一种碳素阳极焙烧生产系统的控制方法[P].中国专利数据库,CN200410102603.9,2005-08-10
[25]康定军,覃海棠,袁志刚.焦粒焙烧启动对电解槽寿命的影响[J].铝镁通讯,2009(3)：ppl5-17
[26]杨鹏程.350kA铝电解槽焦床焙烧温度控制浅析[J].轻金属,2009(7)：pp28-29
[27]单保禄.铝电解监控系统[J].轻金属,2009(4)：pp69-70
[28]李民军,李劫,李欣峰,等.预焙铝电解槽智能模糊控制系统监控软件.中国有色金属学报,1998.8：pp506-512
[29]邹忠,张文根,周诗国,李劫,叶绍龙,等.32位预焙铝电解槽控制系统上位机监控软件开发[J].2001,32(3)：pp256-258
[30]毛联杰.S7-300系列PLC与组态软件WinCC实现通信的方法[J].电气时代,2006(9)：pp106-107
[31]刘海石.延长大型铝电解槽寿命的研究[D].东北大学,2006
[32]Mohamed Sh. A, "Coke Bed Preheating of Aluminum Reduction Cell", M Sc. Thesis, Minia University, Egypt,1999, pp20-53
[33]Zangiacomi C, et al, "Preheating Study of Smelting Cells", Light Metals 2005, pp333-336
[34]Marcos Marga, Calvo Isidro, et al. Object-oriented modeling for remote monitoring of manufacturing processes. IEEE Symposium on Emerging Technologies and Factory Automation, ETFA,2001, 1:pp287-293
[35]V.K.Mann. Cryolite Ratio and Bath Temperature Stabilization Problem in Aluminum Reduction cell, Light Metals,1998:pp371-376
[36]Tikasz L and Horvath J. Expert System-based Consulting Toolkit for Aluminum Electrolysis. Recent Metallurgical Advances in Light Metals Industries,1995, pp271-281
[37]Zhou Juan, Liu Xiang, Zuo Dongsheng, Zhu Xiaopei, "The Monitoring system based on WinCC of Aluminum Reduction Cells," Metallurgical Industry Automation 2004
[38]Li Jie. An intelligent controller for aluminum smelter potlines. Chinese Journal of Nonferrous Metals, v8,n3,Sept.1998,pp557-560
[39]Gao Shouchuan, "Proficient in Structured Query Language," beijing: POSTS&TELECOM PRESS 2007
[40]Li Yang, Yueheng Li, Zhi Yu, "Operating User-defined SQL Database based on VBS Script of WinCC V6.2," Industrial Control Computer 2010
[41]陶永华,尹怡欣,葛芦生.新型PID控制及其应用[M].机械工业出版社,1998
[42]廖常初.西门子工业通信网络组态编程与故障诊断[M].北京：机械工业出版社,2009
[43]杨勇,张大波.铝电解槽阳极电流监测系统的研究与实现[J].中国科技论文在线,2009.11：ppl-3
[44]丁心耿,吴敏.智能控制技术在200kA铝电解过程中应用[J].计算机技术与自动化,2002,21(4)：pp98-100
[45]赵显寓.国外铝电解计算机控制技术的发展动态[J].冶金自动化,1991,15(2)：pp8-10
[2]干益人.铝电解槽焦粒焙烧的技术关键和实施方法[J].轻金属,2001
[3]刘永刚,唐骞,梁韬.铝电解槽大型预焙槽四种焙烧方法的比较.轻金属,2000(4)：pp33-35
[4]廖贤安,张明凯.铝电解槽焙烧启动方法和发展动向[EB/OL].中国铝电解网,2010-12
[5]吴庆刚,等.大型预焙铝电解槽焙烧启动的过程控制与方法[EB/OL].中国铝电解网,2010-12
[6]彭其润,等.基于PLC与专家控制器的电解槽预焙烧燃烧控制系统[D].计算机测量与控制,2004,20(4)：pp3-8
[7]伍成波.铝电解槽高温烟气焙烧技术的理论与实践[D].重庆：重庆大学,2004
[8]苏昆哲.深入浅出西门子WinCCV6[M].北京：北京航空航天大学出版社,2004
[9]冯乃祥.铝电解[M].化学工业出版社,2006
[10]史洪尧.230kA铝电解槽开发与生产应用综合技术研究[J].辽宁：东北大学,2006
[11]高守传.精通SQL结构化查询语言详解[M].北京：人民邮电出版社,2007
[12]黄东,罗飞,赵少华,冯炳枢.基于VBScript实现WinCC过程数据归档[J].微计算机信息,2008,24：pp275-276
[13]Shaher A.Mohamed, M.M.Megahed, H.Hashem, M.El-Ghonimy. Development of Coke-bed Preheating Method for 200kA cells. Light Metals 2006, pp676-680
[14]Zhao Qun, Xie Yanli, Qiu Zhuxian, Zhao Wuwei. Coke power bake preheat start-up of 280kA alumina electrolysis cells in China. Light Metals 2006
[15]Zeng Shuiping, Li Jinhong, Lan Tao, Analysis of the Start-Up of Q-350 Prebaked Aluminum Reduction Cells, light metal 2006, pp271-273
[16]Marc Dupuis.Usage of full 3D transient thermo-electric F.E.Model to study the thermal gradient generated in the lining during a coke preheat[J]. Light Metals,2001:pp757-762
[17]Marc Dupuis. Computation of aluminum reduction cell energy balance using ANSYS finite element models[J].Light Metals,1998:pp409-417
[18]华桂林,邵勇.230kA大型预焙槽焙烧启动技术方案探讨[J].轻金属,2004(8)：pp39-40
[19]邵勇,李俊,曹继明,许庆.230kA铝电解槽的“最佳”操作与实践[J].轻金属,2010(5)：pp35-36
[20]海云,王正荣,郭有斌.240kA大型电解槽焦粒焙烧启动的技术与实践[A].全国铝电解槽生产技术与操作技术学术报告和经验交流会论文集[C],2007
[21]崔坚.西门子S7可编程控制器—STEP7编程指南[M].北京：机械工业出版社,2007
[22]严爱军,张亚庭,高学金.过程控制系统[M].北京：北京工业大学出版社,2010
[23]李颖.Simulink动态系统建模与仿真[M].西安：西安电子科技大学出版社,2009
[24]北京南山高科技有限公司.一种碳素阳极焙烧生产系统的控制方法[P].中国专利数据库,CN200410102603.9,2005-08-10
[25]康定军,覃海棠,袁志刚.焦粒焙烧启动对电解槽寿命的影响[J].铝镁通讯,2009(3)：ppl5-17
[26]杨鹏程.350kA铝电解槽焦床焙烧温度控制浅析[J].轻金属,2009(7)：pp28-29
[27]单保禄.铝电解监控系统[J].轻金属,2009(4)：pp69-70
[28]李民军,李劫,李欣峰,等.预焙铝电解槽智能模糊控制系统监控软件.中国有色金属学报,1998.8：pp506-512
[29]邹忠,张文根,周诗国,李劫,叶绍龙,等.32位预焙铝电解槽控制系统上位机监控软件开发[J].2001,32(3)：pp256-258
[30]毛联杰.S7-300系列PLC与组态软件WinCC实现通信的方法[J].电气时代,2006(9)：pp106-107
[31]刘海石.延长大型铝电解槽寿命的研究[D].东北大学,2006
[32]Mohamed Sh. A, "Coke Bed Preheating of Aluminum Reduction Cell", M Sc. Thesis, Minia University, Egypt,1999, pp20-53
[33]Zangiacomi C, et al, "Preheating Study of Smelting Cells", Light Metals 2005, pp333-336
[34]Marcos Marga, Calvo Isidro, et al. Object-oriented modeling for remote monitoring of manufacturing processes. IEEE Symposium on Emerging Technologies and Factory Automation, ETFA,2001, 1:pp287-293
[35]V.K.Mann. Cryolite Ratio and Bath Temperature Stabilization Problem in Aluminum Reduction cell, Light Metals,1998:pp371-376
[36]Tikasz L and Horvath J. Expert System-based Consulting Toolkit for Aluminum Electrolysis. Recent Metallurgical Advances in Light Metals Industries,1995, pp271-281
[37]Zhou Juan, Liu Xiang, Zuo Dongsheng, Zhu Xiaopei, "The Monitoring system based on WinCC of Aluminum Reduction Cells," Metallurgical Industry Automation 2004
[38]Li Jie. An intelligent controller for aluminum smelter potlines. Chinese Journal of Nonferrous Metals, v8,n3,Sept.1998,pp557-560
[39]Gao Shouchuan, "Proficient in Structured Query Language," beijing: POSTS&TELECOM PRESS 2007
[40]Li Yang, Yueheng Li, Zhi Yu, "Operating User-defined SQL Database based on VBS Script of WinCC V6.2," Industrial Control Computer 2010
[41]陶永华,尹怡欣,葛芦生.新型PID控制及其应用[M].机械工业出版社,1998
[42]廖常初.西门子工业通信网络组态编程与故障诊断[M].北京：机械工业出版社,2009
[43]杨勇,张大波.铝电解槽阳极电流监测系统的研究与实现[J].中国科技论文在线,2009.11：ppl-3
[44]丁心耿,吴敏.智能控制技术在200kA铝电解过程中应用[J].计算机技术与自动化,2002,21(4)：pp98-100
[45]赵显寓.国外铝电解计算机控制技术的发展动态[J].冶金自动化,1991,15(2)：pp8-10