阅读说明：本技术 一种加热炉低氧燃烧装置及系统 (Heating furnace low oxygen burner and system ) 是由 孙振华 刘玉环 于 2021-01-28 设计创作，主要内容包括：本发明公开了一种加热炉低氧燃烧装置及系统,包括整合模块、采集模块、工况检测模块、协同控制模块和低氧燃烧控制模块。整合模块将本装置和原有DCS集散控制系统整合,一氧化碳在线分析仪实时检测炉顶烟气中一氧化碳含量,同时通过工况检测模块对工艺介质的压力、流量、温度、燃料量、辐射室顶部负压和排烟温度等多种参数进行检测,然后协同控制模块和低氧燃烧控制模块基于以上参数,作为检测和控制对象,可将加热炉烟气氧含量长期稳定控制在1％或者1％以下,控制一氧化碳不超过100ppm,减少调节滞后的时间,减少运行波动,从而最大限度提高加热炉的热效率,解决现有手动方式控制配风会使调节滞后不及时,加热炉的运行波动变大的问题。(The invention discloses a heating furnace low-oxygen combustion device and system, which comprise an integration module, an acquisition module, a working condition detection module, a cooperative control module and a low-oxygen combustion control module. The integration module integrates the device with an original DCS distributed control system, a carbon monoxide online analyzer detects the content of carbon monoxide in furnace top smoke in real time, meanwhile, a working condition detection module detects various parameters such as pressure, flow, temperature, fuel quantity, radiation chamber top negative pressure and smoke exhaust temperature of a process medium, then the cooperative control module and the low-oxygen combustion control module are based on the parameters and used as detection and control objects, the oxygen content of the heating furnace smoke can be stably controlled to be 1% or below 1% for a long time, the carbon monoxide is controlled not to exceed 100ppm, the time of regulation lag is reduced, the running fluctuation is reduced, the heat efficiency of the heating furnace is improved to the maximum extent, and the problems that the regulation lag is not timely due to the fact that air distribution is controlled in an existing manual mode and the running fluctuation of the heating furnace is increased are solved.)

1. A low-oxygen combustion device of a heating furnace, which is characterized in that,

the system comprises an integration module, an acquisition module, a working condition detection module, a cooperative control module and a low-oxygen combustion control module, wherein the integration module, the acquisition module, the working condition detection module, the cooperative control module and the low-oxygen combustion control module are sequentially connected;

the integration module is used for being connected with a DCS (distributed control system);

the acquisition module is used for acquiring acquisition data from the DCS and the carbon monoxide analyzer;

the working condition detection module is used for acquiring the change parameters of the working conditions of the heating furnace;

the cooperative control module is used for adjusting a control strategy based on the variation parameters and the acquired data;

the hypoxic combustion control module is configured to select an optimal control route based on a control strategy.

2. The low-oxygen combustion apparatus for the heating furnace according to claim 1,

the integration module comprises a communication unit and a soft switch switching unit, the soft switch switching unit is connected with the communication unit, the communication unit is used for being connected and communicated with the DCS, and the soft switch switching unit is used for switching between an automatic optimization control state and a DCS control state.

3. The low-oxygen combustion apparatus for the heating furnace according to claim 1,

the cooperative control module comprises a combustion-supporting air valve position control unit, a flue baffle control unit and an air blower control unit, and the combustion-supporting air valve position control unit, the flue baffle control unit and the air blower control unit are respectively connected with the working condition detection module;

the combustion-supporting air valve position control unit is used for controlling the combustion-supporting air valve position;

the flue baffle control unit is used for controlling the flue baffles;

and the blower control unit is used for controlling the blower.

4. A low-oxygen combustion apparatus for a heating furnace according to claim 3,

the cooperative control module further comprises an induced draft fan control unit, the induced draft fan control unit is connected with the working condition detection module, and the induced draft fan control unit is used for controlling the induced draft fan.

5. The low-oxygen combustion apparatus for the heating furnace according to claim 4,

the cooperative control module further comprises a valve control unit, the valve control unit is connected with the working condition detection module, and the valve control unit is used for controlling the valve.

6. A low-oxygen combustion apparatus for a heating furnace according to claim 5,

the cooperative control module further comprises a deep learning unit, the deep learning unit is connected with the combustion-supporting air valve position control unit, the flue baffle control unit, the blower control unit, the draught fan control unit and the valve control unit, and the deep learning unit is used for right the combustion-supporting air valve position control unit, the flue baffle control unit, the blower control unit, the draught fan control unit and the valve control unit perform data collection and learning.

7. The low-oxygen combustion apparatus for the heating furnace according to claim 1,

the low-oxygen combustion control module comprises a time control unit, a consumption control unit, an air supply control unit and a hearth pressure control unit, wherein the time control unit, the consumption control unit, the air supply control unit and the hearth pressure control unit are sequentially connected, and the time control unit is used for calculating based on parameters to obtain the shortest response time; the control system comprises a consumption control unit, an air supply control unit and a hearth pressure control unit, wherein the consumption control unit is used for calculating based on parameters to obtain minimum fuel consumption control, the air supply control unit is used for optimizing according to the fuel gas amount of a heating furnace to obtain the hot air supply amount and the smoke discharge amount, and the hearth pressure control unit is used for automatically correcting the hearth pressure setting by combining working condition parameters.

8. A heating furnace low-oxygen combustion system, comprising a heating furnace low-oxygen combustion device according to any one of claims 1 to 7, characterized by further comprising a display and a memory bank, wherein the display and the memory bank are respectively connected with the heating furnace low-oxygen combustion device.

Technical Field

The invention relates to the technical field of heating furnace control, in particular to a low-oxygen combustion device and system of a heating furnace.

Background

The adoption of the automatic control technology is an effective way for improving the uniform heating efficiency of the heating furnace in the whole operation period, and is also a necessary trend of the development of a modern production process control system and the continuous progress of the technological level. The control of two most main loops which mainly affect the thermal efficiency of the heating furnace, namely the control of hot air supply volume and flue gas induced air volume, in the production process control of the heating furnace, most devices still stay in a lagging state depending on manual operation adjustment.

Because a single-loop PID regulation control mode of a conventional instrument is adopted in the DCS, the method cannot adapt to the complexity of the operation process of the heating furnace, and an ideal control effect is difficult to achieve under the conditions that various disturbance factors and working condition changes frequently occur. The automatic control of the heating furnace basically stays at the original level, and the automatic regulation control and use effects of the hot air and flue gas loop of the DCS automatic control system are not ideal. Most devices still rely on manual control of air distribution, adjustment lag is not timely, and operation fluctuation of the heating furnace is large. The average thermal efficiency of the furnace over the entire operating cycle is lower than that obtained at the periodic inspection and review.

Disclosure of Invention

The invention aims to provide a heating furnace low-oxygen combustion device and system, and aims to solve the problems that the regulation is delayed and not in time and the operation fluctuation of a heating furnace is increased due to the fact that air distribution is controlled manually in the prior art.

In order to achieve the above object, in a first aspect, the present invention provides a low-oxygen combustion device for a heating furnace, including an integration module, an acquisition module, a working condition detection module, a cooperative control module and a low-oxygen combustion control module, where the integration module, the acquisition module, the working condition detection module, the cooperative control module and the low-oxygen combustion control module are connected in sequence; the integration module is used for being connected with a DCS (distributed control system); the acquisition module is used for acquiring acquisition data from the DCS and the carbon monoxide analyzer; the working condition detection module is used for acquiring the change parameters of the working conditions of the heating furnace; the cooperative control module is used for adjusting a control strategy based on the variation parameters and the acquired data; the hypoxic combustion control module is configured to select an optimal control route based on a control strategy.

The integration module comprises a communication unit and a soft switch switching unit, the soft switch switching unit is connected with the communication unit, the communication unit is used for being connected and communicated with a DCS system, and the soft switch switching unit is used for switching between an automatic optimization control state and a DCS control state.

The cooperative control module comprises a combustion-supporting air valve position control unit, a flue baffle control unit and an air blower control unit, wherein the combustion-supporting air valve position control unit, the flue baffle control unit and the air blower control unit are respectively connected with the working condition detection module;

the combustion-supporting air valve position control unit is used for controlling the combustion-supporting air valve position;

the flue baffle control unit is used for controlling the flue baffles;

and the blower control unit is used for controlling the blower.

The cooperative control module further comprises an induced draft fan control unit, the induced draft fan control unit is connected with the working condition detection module, and the induced draft fan control unit is used for controlling the induced draft fan.

The cooperative control module further comprises a valve control unit, the valve control unit is connected with the working condition detection module, and the valve control unit is used for controlling the valve.

Wherein, the cooperative control module still includes degree of depth learning unit, degree of depth learning unit with combustion-supporting wind valve position control unit flue baffle the control unit blower the control unit draught fan the control unit valve the control unit connects, degree of depth learning unit, it is right to be used for combustion-supporting wind valve position control unit flue baffle the control unit blower the control unit draught fan the control unit with valve the control unit carries out data acquisition and study.

The low-oxygen combustion control module comprises a time control unit, a consumption control unit, an air supply control unit and a hearth pressure control unit, wherein the time control unit, the consumption control unit, the air supply control unit and the hearth pressure control unit are sequentially connected, and the time control unit is used for calculating based on parameters to obtain the shortest response time; the control system comprises a consumption control unit, an air supply control unit and a hearth pressure control unit, wherein the consumption control unit is used for calculating based on parameters to obtain minimum fuel consumption control, the air supply control unit is used for optimizing according to the fuel gas amount of a heating furnace to obtain the hot air supply amount and the smoke discharge amount, and the hearth pressure control unit is used for automatically correcting the hearth pressure setting by combining working condition parameters.

In a second aspect, the invention further provides a heating furnace low-oxygen combustion system, which comprises a heating furnace low-oxygen combustion device, a display and a memory bank, wherein the display and the memory bank are respectively connected with the heating furnace low-oxygen combustion device.

According to the heating furnace low-oxygen combustion device and the heating furnace low-oxygen combustion system, the original DCS distributed control system of the device and the production device can be organically integrated through the integration module, and an architecture mode which is very convenient to operate is formed, the mode utilizes the extensible communication function of an industrial control computer and the DCS distributed control system, and the heating furnace low-oxygen combustion device and the heating furnace low-oxygen combustion system have high reliability and safety and lowest cost investment. The laser carbon monoxide on-line analyzer detects the content of carbon monoxide in furnace top flue gas in real time, and simultaneously detects various parameters such as pressure, flow, temperature, fuel quantity, radiation chamber top negative pressure, exhaust gas temperature and the like of a process medium through the working condition detection module, then the cooperative control module and the low-oxygen combustion control module are used as detection and control objects based on the parameters, so that the oxygen content of the flue gas of the heating furnace can be stably controlled to be below 1% or 1% for a long time, the carbon monoxide is controlled not to exceed 100ppm, the lag time of regulation is reduced, the running fluctuation is reduced, the heat efficiency of the heating furnace is improved to the maximum, and the problems that the lag of regulation is not timely and the running fluctuation of the heating furnace is increased due to the fact that air distribution is controlled in.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.

FIG. 1 is a block diagram of a furnace hypoxic combustion system of the present invention;

FIG. 2 is a block diagram of an integration module of the present invention;

FIG. 3 is a block diagram of a coordinated control module of the present invention;

FIG. 4 is a block diagram of the hypoxic combustion control module of the present invention;

fig. 5 is a control schematic diagram of a low oxygen burner system of a heating furnace according to the present invention.

1-integration module, 2-acquisition module, 3-working condition detection module, 4-cooperative control module, 5-low oxygen combustion control module, 6-display, 7-memory bank, 11-communication unit, 12-soft switch switching unit, 41-combustion-supporting air valve position control unit, 42-flue baffle control unit, 43-blower control unit, 44-induced draft fan control unit, 45-valve control unit, 46-deep learning unit, 51-time control unit, 52-consumption control unit, 53-air supply control unit, 54-furnace pressure control unit, 511-first data acquirer, 512-time controller, 513-first fuzzy logic processor, 521-second data acquirer, and, 522-consumption controller, 523-second fuzzy logic processor.

Detailed Description

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.

In the description of the present invention, it is to be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on the orientations or positional relationships illustrated in the drawings, and are used merely for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed in a particular orientation, and be operated, and thus, are not to be construed as limiting the present invention. Further, in the description of the present invention, "a plurality" means two or more unless specifically defined otherwise.

Referring to fig. 1 to 5, the present invention provides a low oxygen combustion apparatus for a heating furnace, comprising:

the system comprises an integration module 1, an acquisition module 2, a working condition detection module 3, a cooperative control module 4 and a low-oxygen combustion control module 5, wherein the integration module 1, the acquisition module 2, the working condition detection module 3, the cooperative control module 4 and the low-oxygen combustion control module 5 are connected in sequence;

the integration module 1 is used for connecting with a DCS system;

the acquisition module 2 is used for acquiring acquisition data from a DCS (distributed control system) and a carbon monoxide analyzer;

the working condition detection module 3 is used for acquiring the variation parameters of the working conditions of the heating furnace;

the cooperative control module 4 is used for adjusting a control strategy based on the variation parameters and the acquired data;

the hypoxic combustion control module 5 is configured to select an optimal control route based on a control strategy.

In the embodiment, the integration module 1 can organically integrate the device and the original DCS distributed control system of the production device, and form an architecture mode very convenient for operation, which utilizes the extensible communication functions of the industrial control computer and the DCS distributed control system, thereby having high reliability, safety and lowest cost investment. The laser carbon monoxide on-line analyzer detects the content of carbon monoxide in furnace top smoke in real time, and simultaneously detects various parameters such as pressure, flow, temperature, fuel quantity, radiation chamber top negative pressure, smoke exhaust temperature and the like of a process medium through the working condition detection module 3, then the cooperative control module 4 and the low-oxygen combustion control module 5 serve as detection and control objects based on the parameters, can stably control the oxygen content of the heating furnace smoke to be below 1% or 1% for a long time, controls the carbon monoxide not to exceed 100ppm, reduces the time of regulation lag, reduces the operation fluctuation, improves the heat efficiency of the heating furnace to the maximum extent, and solves the problems that the existing manual mode controls air distribution to lead the regulation lag to be untimely and the operation fluctuation of the heating furnace to be large.

Further, the integration module 1 includes a communication unit 11 and a soft switch switching unit 12, the soft switch switching unit 12 is connected to the communication unit 11, the communication unit 11 is configured to communicate with a DCS system, and the soft switch switching unit 12 is configured to switch between an automatic optimization control state and a DCS control state.

In this embodiment, the MODBUS communication protocol is a completely reliable industrial standard, the automatic optimization control system receives the DCS data reliably, and in view of system safety, the valve position control signal output by the automatic optimization control system is not directly sent to the field execution mechanism, but is determined by the soft switch switching unit 12 newly added in the DCS interface. Similarly, when the system is switched back to the DCS after running under automatic optimization control, the DCS is already in a manual state, and the set value of the DCS always tracks the valve position on the spot. The system is a bumpless handoff regardless of the handoff.

Further, the cooperative control module 4 includes a combustion-supporting air valve position control unit 41, a flue damper control unit 42 and an air blower control unit 43, and the combustion-supporting air valve position control unit 41, the flue damper control unit 42 and the air blower control unit 43 are respectively connected with the working condition detection module 3;

the combustion-supporting air valve position control unit 41 is used for controlling the combustion-supporting air valve position;

the flue baffle control unit 42 is used for controlling the flue baffles;

the blower control unit 43 is configured to control the blower.

In the embodiment, the control law is automatically adjusted according to the change of the working condition parameters of the heating furnace and various interferences in the system, and the full-automatic optimization of the combustion process of the heating furnace is realized by controlling the combustion-supporting air valve position, the flue baffle and the air blower in real time.

Further, the cooperative control module 4 further includes an induced draft fan control unit 44, the induced draft fan control unit 44 is connected to the working condition detection module 3, and the induced draft fan control unit 44 is configured to control the induced draft fan.

In this embodiment, through the control to the draught fan, degree of automation can further be improved, can also promote the degree of accuracy of control in addition.

Further, the cooperative control module 4 further includes a valve control unit 45, the valve control unit 45 is connected to the operating condition detection module 3, and the valve control unit 45 is configured to control the valve.

In this embodiment, the degree of automation can be further improved by controlling the valve, and the accuracy of control can be improved.

Further, the cooperative control module 4 further includes a deep learning unit 46, the deep learning unit 46 and the combustion-supporting air valve position control unit 41, the flue baffle control unit 42, the blower control unit 43, the induced draft fan control unit 44, the valve control unit 45 is connected, the deep learning unit 46 is used for right the combustion-supporting air valve position control unit 41, the flue baffle control unit 42, the blower control unit 43, the induced draft fan control unit 44 and the valve control unit 45 perform data collection and learning.

In the present embodiment, the deep learning unit 46 can perform learning based on data generated by other units, and can perform online reasoning and system identification, and online tuning and optimization of an optimal control route according to accumulation of knowledge and experience. The method has the functions of good system adaptability, fault tolerance, robustness, organization function, real-time property, man-machine cooperation and the like.

Further, the hypoxic combustion control module 5 includes a time control unit 51, a consumption control unit 52, an air supply control unit 53 and a furnace pressure control unit 54, the time control unit 51, the consumption control unit 52, the air supply control unit 53 and the furnace pressure control unit 54 are connected in sequence, and the time control unit 51 is configured to perform calculation based on parameters to obtain the shortest response time; the consumption control unit 52 is used for calculating based on parameters to obtain the minimum fuel consumption control, the air supply control unit 53 is used for optimizing according to the fuel gas amount of the heating furnace to obtain the hot air supply amount and the smoke discharge amount, and the hearth pressure control unit 54 is used for automatically correcting the hearth pressure setting according to working condition parameters.

In the embodiment, under the same working condition, the heat efficiency of the heating furnace and the combustion effect can be finally summarized as the excess air coefficient in the heating furnace, and the excess air coefficient depends on the actual air distribution amount in the combustion process, namely the air-fuel ratio. The different excess air ratios are directly related to the fuel consumption of the furnace. The system obtains the optimal hot air supply volume and the optimal smoke discharge volume through short-time optimization according to the current fuel gas volume of the heating furnace, and the optimal combustion state of the heating furnace is always kept along with the total fuel gas volume of the furnace. On the premise of ensuring complete combustion of fuel and low pollutant discharge, the oxygen content required for participating in combustion is made to be the lowest to be used as the optimal state for automatically optimizing the air-fuel ratio. The magnitude of the hearth pressure influences the draft balance of a heating furnace system, directly influences the distribution and the residence time of high-temperature flue gas in the hearth, further influences the conduction rate of heat in the hearth, the diffusion rate of heat and the radiation efficiency of heat, and the factors are the keys finally influencing the thermal efficiency of the heating furnace. The automatic optimization control technology of the heating furnace is adopted, and a plurality of process parameters such as flue gas temperature, hearth temperature, flue gas oxygen content, carbon monoxide and the like are combined, so that the set value of the hearth pressure is automatically corrected to keep the set value in a more reasonable range, and the energy consumption of the heating furnace is reduced.

Further, the time control unit 51 includes a first data acquirer 511, a time controller 512, and a first fuzzy logic processor 513, where the first data acquirer 511, the time controller 512, and the first fuzzy logic processor 513 are sequentially connected, the first data acquirer 511 is configured to acquire a working condition parameter, the time controller 512 is configured to obtain a shortest time performance functional based on the working condition parameter, and the first fuzzy logic processor 513 is configured to implement automatic shortest time control by using a fuzzy logic processing method.

In the present embodiment, the main factors affecting this objective function are: fuel flow rate u (t), air flow rate v (t), furnace pressure p (t), and furnace temperature T (t);

they are interrelated and interactive. Namely:

J＝f[u(t),v(t),p(t),T(t)]

the heat efficiency of combustion in the heating furnace is a function of the ratio of combustion air to total fuel, namely:

η(t)＝Φ[v(t)/u(t)]

this forms an optimized combination of four variables in coordination with each other, i.e. an automatic optimization control of multiple variables. The first fuzzy logic processor 513 uses the theory of the automatic optimization control objective function and the artificial intelligence, adopts a fuzzy logic processing method, and applies a C + + software programming technology to realize the automatic optimization control with good performance and high practicability without establishing an accurate mathematical model.

Further, the consumption control unit 52 includes a second data acquirer 521, a consumption controller 522, and a second fuzzy logic processor 523, where the second data acquirer 521, the consumption controller 522, and the second fuzzy logic processor 523 are sequentially connected, the first data acquirer 511 is configured to acquire a working condition parameter, the consumption controller 522 is configured to obtain a minimum energy consumption performance functional based on the working condition parameter, and the first fuzzy logic processor 513 is configured to implement automatic minimum energy consumption control by using a fuzzy logic processing method.

In the present embodiment, the main factors affecting this objective function are: fuel flow rate u (t), air flow rate v (t), furnace pressure p (t), and furnace temperature T (t);

they are interrelated and interactive. Namely:

J＝f[u(t),v(t),p(t),T(t)]

with minimum fuel consumption control, the performance functional can be written as the following expression:

in the formula: uj (t) are the components of the m-dimensional control vector u (t); cj is a positive scaling factor. The two formulas are comprehensively simplified to obtain:

and then carrying out Hamilton transformation to obtain a minimum value.

The second fuzzy logic processor 523 implements the automatic optimization control of the automatic optimization control objective function and the artificial intelligence theory by using a fuzzy logic processing method and using a C + + software programming technique without establishing an accurate mathematical model.

In addition, the time control unit 51 and the consumption control unit 52 can be combined to make a judgment, so that a balanced control mode can be obtained.

In a second aspect, the present invention also provides a low oxygen combustion system for a heating furnace, comprising: the device comprises a heating furnace low-oxygen combustion device, a display 6 and a memory bank 7, wherein the display 6 and the memory bank 7 are respectively connected with the heating furnace low-oxygen combustion device.

In the present embodiment, the display 6 can visually display control information, thereby improving convenience of operation; the memory bank 7 can cache the generated control data, so that historical data can be inquired, and the reason can be conveniently found when a problem occurs.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.