CN105021030A - Integrated automation control system for aluminum oxide clinker kiln - Google Patents

Abstract

The invention relates to an integrated automation control system for an aluminum oxide clinker kiln. The integrated automation control system for the aluminum oxide clinker kiln is structurally characterized in that (1) the integrated automation control system for the aluminum oxide clinker kiln is composed of a process control system and a process management system; (2) the rotary kiln process management system is composed of a basic automation system, a multimedia monitoring system and an optimal control system; and (3) the rotary kiln process management system is composed of an operation management part and a system management part. By means of the integrated automation control system for the aluminum oxide clinker kiln, the methods of intelligent modeling and intelligent control are comprehensively used, so that human intelligence behaviors are introduced into rotary kiln process control to the maximum degree, and the aims of guaranteeing clinker quality, improving the kiln running rate and reducing the energy consumption are guaranteed.

Description

A kind of alumina rotary kiln integrated automation control system

Technical field:

The invention belongs to aluminum oxide production process technical field of automatic control, particularly relate to a kind of alumina rotary kiln integrated automation control system.

Background technology:

Process for making alumina mainly comprises Bayer process, sintering process and Baeyer, sintering combination method according to the feature of process ore.Sintering process production procedure in sintering process or combination method is specially process low-grade Al materials and Bayer process red mud and design, and sinter leaching is the critical process of sintering process, combination method alumina producing.In prior art, the Pa Daluofu factory of Kazakhstan is on the sinter leaching Process ba-sis of advanced design, adopt the method setting up strict heat balance mechanism model, half industrial experiment kiln has carried out a large amount of experimental analyses, achieve the automatic control of sinter leaching rotary kiln, but this technique and control method and be not suitable for raw ingredients, coal elemental composition fluctuates large working condition.

More domestic large alumina producers did some significant practices in the automatic control technology application aspect of chamotte kiln, but current most of chamotte kiln is still in artificial or semiautomatic control state, cause thus producing the problems such as unstable, operation rate is low and production capacity is low, clinker quality is unstable, dust collection effect is undesirable.Because traditional temperature thermocouple is difficult to install application because of the rotation of kiln body, the measuring method of current burning zone temperature mainly contains two kinds: a kind of is that burning zone temperature measured by the infrared of equipped with non-contact before rotary kiln end or fiber ratio color temperature measurer, the actual temperature that material between clinkering zone and salband can only be detected, and in kiln, smog and dust interference cause measure error larger; Another kind method is, adopts computer digital image treatment technology, carries out computing to the clinkering zone flame image data of cameras capture, extracts flame temperature grade and change information, carries out unity loop control in this, as feedback signal to burning zone temperature.This method accuracy of detection is lower, when kiln flame clear picture, substantially can reflect kiln temperature situation of change; But when kiln temperature is lower, in kiln, dust and smog increase the interference that image detects, and detect accuracy low.This method affects comparatively large by kiln coal powder injection condition, kiln circle characteristic etc. simultaneously, is unsuitable for promoting.

In addition, in control method, the method that main employing fuzzy control and PID control to combine realizes the unity loop control of burning zone temperature, but because burning zone temperature detects by noise jamming serious, process has that Great inertia, large time delay, coupling are serious, service condition and working conditions change frequent, the limitation of PID control and conventional fuzzy control, the adaptive capacity of this control system is poor, only just can put into operation under the more stable condition of kiln condition.Therefore, this patent is for the control problem of large-sized rotary kiln process, the data message that rotary kiln Optimal Control System can provide according to means such as chamotte kiln monitored automatically instrument, on-line analysis instrument, assays is proposed, the various normal and abnormal kiln condition of automatic identification chamotte kiln, provide the expert's Operating Guideline under various kiln condition, make chamotte kiln operating personnel rise to expert teacher from empirical within a short period of time, thus make the management of chamotte kiln technical operation reach higher level; Realize the online real-time optimal control of chamotte kiln, stablize chamotte kiln kiln condition, the running rate improving chamotte kiln and output clinker quality.

Summary of the invention:

The object of the invention is the overall control target from rotary kiln process, by integrated use intelligent modeling and intelligent control method, to greatest extent the intelligent behavior of people is incorporated in rotary kiln process control, consider the complexity of productive target, the security of operating condition and on distributed computer control system (DCS) can implementation issue, provide a kind of alumina rotary kiln integrated automation control system.

The technical solution adopted for the present invention to solve the technical problems is:

Alumina rotary kiln integrated automation control system is made up of Process Control System and course management system, to ensure clinker quality, improve kiln running rate, to reduce energy consumption.Realize this control system to comprise the following steps:

Step one: the general structure determining the alumina rotary kiln integrated automation control system be made up of Process Control System and course management system.

Step 2: adopt intelligent coordinated variable-structure control technology, Intelligent predictive control technology, Adaptive Fuzzy Control technology, intelligent correction control technology, proposes the rotary kiln Process Control System be made up of basic automation systems, multimedia monitor system and Optimal Control System.Basic automation systems comprise feeds coal process control subsystem, aeration step RACS, smoke evacuation process control subsystem, feeding procedure RACS.Multimedia monitor system comprises kiln combustion condition monitoring subsystem, feed opening grog condition monitoring subsystem and cooler outlet grog condition monitoring subsystem.Optimal Control System comprises sintering process Optimal Control System.

Step 3: to ensure clinker quality, to improve kiln running rate, reduction energy consumption for target, integrated application administrative decision, Optimal Setting, intelligent coordinated technology, propose to manage by operational management and system the rotary kiln course management system formed.Operational management comprises system monitoring, fault diagnosis, equipment control, production safety management, report generation and printing, system communication and Operating Guideline function.System management comprises security of system, user management and system navigate function.

Accompanying drawing explanation

Fig. 1 aluminium oxide burns till rotary kiln production process complex automatic system and forms block diagram

Fig. 2 alumina clinker burns till rotary kiln production process Process Control System structure chart

Fig. 3 alumina clinker burns till rotary kiln Technical innova-tion structure chart

Fig. 4 alumina clinker burns till rotary kiln production process complex automatic system functional tree

The chain controlling functions figure of logic that Fig. 5 air blast starts

The chain controlling functions figure of logic that Fig. 6 air blast stops

The chain controlling functions figure of logic that Fig. 7 feeder starts

The chain controlling functions figure of logic that Fig. 8 feeder stops

The chain controlling functions figure of logic that Fig. 9 induced-draft fan stops

The chain controlling functions figure of logic of Figure 10 cooler scram

The chain controlling functions figure of logic of Figure 11 kiln unit starting

Figure 12 alumina clinker burns till rotary kiln production process optimization controlling functions tree graph

Figure 13 alumina clinker burns till rotary kiln Technical innova-tion function tree graph

Detailed description of the invention:

Below in conjunction with accompanying drawing, the present invention is described in further detail.

1, system architecture

1.1 system global structure

Aluminium oxide as shown in Figure 1 burns till rotary kiln production process complex automatic system and forms block diagram:

This patent combined aluminum oxide burns till the feature of rotary kiln production process, the alumina clinker proposing course management system and Process Control System double-layer structure composition burns till rotary kiln production process complex automatic system, wherein Process Control System comprises basic automation systems, Optimal Control System and multimedia monitor system, and course management system manages two parts by operational management and system and forms.Process Control System and course management system realize the information integerated between two-layer and subsystems by Information Level net and Ethernet, control and the computer network such as automation net, mechanical floor net and real-time data base, thus realize the comprehensive automation that alumina clinker burns till rotary kiln production process.

1.2 Process Control System structures

Alumina clinker burns till the structure chart of rotary kiln industries process control system as shown in Figure 2.

Process Control System comprises basic automation systems, multimedia monitor system and Optimal Control System.Basic automation systems comprise feeds coal process control subsystem, aeration step RACS, smoke evacuation process control subsystem, feeding procedure RACS.Multimedia monitor system comprises kiln combustion condition monitoring subsystem, feed opening grog condition monitoring subsystem and cooler outlet grog condition monitoring subsystem.Optimal Control System comprises sintering process Optimal Control System.

1.3 course management system structures

Alumina clinker burns till rotary kiln Technical innova-tion system architecture as shown in Figure 3.

Course management system manages two parts by operational management and system and forms.Operational management comprises system monitoring, fault diagnosis, equipment control, production safety management, report generation and printing, system communication and Operating Guideline.System management comprises security of system, user management and system navigate.

2, systemic-function

Alumina clinker burns till the function of rotary kiln production process complex automatic system as shown in Figure 4.

Alumina clinker burns till rotary kiln production process complex automatic system and comprises Process Control System and course management system.Process Control System realizes the chain control of logic, basic circuit controls and optimal control function.Course management system manages two parts by operational management and system and forms.Operational management comprises production operation, production monitoring, fault in production diagnosis, equipment control, production safety management, report printing.System management comprises system security management, system navigate and system communication.

Complex automatic system achieves burns till process control and the process management of rotary kiln production at central control room to alumina clinker.Basic automatization and Optimal Control System are realized by active station and engineer station, are placed on central control room.Meanwhile, multimedia monitor system is also placed in central control room.Be sent to Process Control System from the data of production process collection, by Process Control System, it processed, realize the basic automatization function such as equipment start-stop control, interlocking to production process.Data gathered from production process or by the data after Process Control System process, are sent to course management system, are monitored and manage by course management system to it.Operator at central control room by monitored picture and multimedia to the supervision picture of production outdoor scene, overall monitor SINTERING PRODUCTION situation, thus production process is operated accurately or implements necessary manual intervention.

2.1 Process Control System functions

The operation that alumina clinker burns till rotary kiln can be divided into three phases, i.e. startup stage, normal operating phase and stop phase.The start stop operation of the apparatus such as rotary kiln unit, feeder, air blast, induced-draft fan and cooler has been needed in startup and stop phase, and normal operating phase mainly realizes the control adjustment operation to each production process variable, comprise basic loop closed loop control operations and senior optimal control operation.Therefore the process control function that alumina clinker burns till rotary kiln complex automatic system comprises the chain control of logic, basic circuit controls and optimal control function, is described below respectively.

2.1.1 the chain controlling functions of logic

The chain control of logic can realize the unit start-stop operation of each apparatus and the start-stop operation that links completely.Switch, contacts status are read in the chain control of logic, check condition of work and the restriction relation of each equipment, send switching value output signal, control the opening and closing etc. of the starting of each equipment motor and stopping, valve.

Sequential control is carried out to motor and air door, it is not the simple arrangement of manual operation code, but after considering the factors such as the start and stop characteristic of object, the Changing Pattern of information and the processing method of fault, carry out analysis arrangement, thus arrange out the logical relation of automatic operation.

The control overflow that the start and stop demand fulfillment of each apparatus is certain, will complete corresponding setting up procedure in start-up course, each step has certain condition limit value.Such as air blast at least will meet the following conditions and could start in startup:

1) overload signal is invalid;

2) fluid coupling aperture <5%

3) run signal is effective;

4) cold-air flap aperture <5%.

Feeder at least will meet the following conditions and could start in startup:

1) automatic signal is effective;

2) overload signal is invalid;

3) run signal is invalid;

4) air blast starts.

The chain control of logic mainly comprises the unit start-stop operation of the apparatus such as rotary kiln unit, feeder, air blast, induced-draft fan and cooler and the start-stop operation that links completely, as shown below respectively.

1) the chain controlling functions of logic of Fig. 5 air blast startup;

2) the chain controlling functions figure of logic of Fig. 6 air blast stopping;

3) the chain controlling functions figure of logic of Fig. 7 feeder startup;

4) the chain controlling functions figure of logic of Fig. 8 feeder stopping;

5) the chain controlling functions figure of logic of Fig. 9 induced-draft fan stopping;

6) the chain controlling functions figure of the logic of Figure 10 cooler scram;

7) the chain controlling functions figure of the logic of Figure 11 kiln unit starting.

2.1.2 basic circuit controls function

Basis circuit controls can realize the accurate control operation of each production process technology parameter.

Affecting alumina clinker, to burn till the factor of rotary kiln combustion process a lot, primary air pressure, wind flow are the important operation conditions of kiln operation, (kiln liner, kliner coating situation under certain working condition, ature of coal situation, coal injection pipe position etc.) ensure that primary air pressure, wind flow are relatively stable in suitable opereating specification, combustion process good in guarantee chamotte kiln.

For reaching the object of sinter leaching high yield, stable yields, become in limit of power in klining, its raw slurry discharge quantity required amount is slip pressure stability greatly.Discharge quantity is greatly the prerequisite of grog high yield, slip pressure stability is the basis ensureing that spray gun normally works, generally, slip pressure should control between 1.82MPa ~ 2.3MPa, slip pressure is little, and to produce slurry atomization bad, flow even the phenomenon of slurry, will drying capacity and the warm-up ability of kiln tail be had a strong impact on, and even affect grog burn till quality.Aborning, when there is stifled rifle or other situation causes pressure oscillation and discharge quantity to change, except fixing a breakdown in time, can regulating the rotating speed of feed pump, stablizing to regulating the charging of slip Stress control.

Burn till in rotary kiln complex automatic system at alumina clinker, devise the circuit controls to air blast flux, blast pressure, raw slurry flow.

2.1.3 optimal control function

Aluminum oxide production process has typical multivariable, close coupling, the complex industrial production process feature such as non-linear, adopt classical control system to be difficult to put into operation, the Advanced Control Techniques such as fuzzy control, Multimode Control, Based Intelligent Control, PREDICTIVE CONTROL must be adopted.

Alumina clinker burns till rotary kiln production process optimization controlling functions as shown in figure 12.On the basis that rotary kiln production process characteristic sum production target requires, application of advanced technology, produce structure changes adjust the methods such as coal control by positive sintering temperature and the automatic setting model of sintering range, rotary kiln production status intelligent forecast model, rotary kiln production multivariable multiobjective decision-making cooperation control, rotary kiln, achieve Accurate Prediction and the optimal control of key parameter.

1) positive sintering temperature and the automatic setting model of sintering range

In Rotary Kiln Process for Alumina Production production process, the change of raw ingredients is an impact that can not be ignored.Raw ingredients determines the sintering temperature of raw material.Sintering composition changes, and sintering temperature also can change thereupon.If the sintering temperature that sintering temperature and raw material require is inconsistent, clinker quality does not just reach quality standard.Visible, the temperature of raw ingredients and sintering belt is the principal element affecting clinker quality.The sintering temperature of raw material is weighed by positive sintering temperature and sintering range two indexs usually.Positive sintering temperature and sintering range experimentally measure definition.General beginning sintering temperature and the surface melting temperature experimentally marking grog.Surface melting temperature and the difference starting sintering temperature, be called sintering range.

Raw ingredients, on the impact of sintering temperature and sintering range, is described below:

Alumina silica ratio: to having the greatest impact of sintering temperature and sintering range.Sintering temperature improves with alumina silica ratio and improves; Sintering range reduces with alumina silica ratio and narrows.

Iron aluminum ratio: sintering temperature improves with iron aluminum ratio and declines; Not obvious on the impact of sintering range.

Alkali compares: sintering temperature improves than increasing with alkali; Sintering range broadens than increasing with alkali, and when alkali ratio is 0.9, sintering range is very narrow.

Calcium compares: the impact of calcium comparison sintering temperature is not obvious.

Therefore, in actual production process, be aware of raw ingredients, just can determine the positive sintering temperature that clinkersintering needs to reach and sintering range.In Rotary Kiln Process for Alumina Production complex automatic system, automatic control program according to current raw ingredients, can determine positive sintering temperature and sintering range setting value automatically.

2) rotary kiln production status intelligent forecast model

Rotary Kiln Process for Alumina Production production process has the characteristic of typical Great inertia, large time delay, and this point brings difficulty to operation control.As everyone knows, have the object of pure delay time, its control action has to pass through the identical time and could embody, and the control therefore within this time is nugatory.In the control operation of large-lag object, experienced operating personnel give us very large inspiration.Deposit in case there being purely retarded factor, a skilled operative employee, after study with summing up experience, correctly can identify the present situation of controlled device, or the situation of change of object in longer a period of time, thus the operation that effect estimated by corresponding band can be provided, avoid accommodative excess.People, in control procedure, although to controlled device and incomplete understanding, and does not know the mathematical models of object, by control practice repeatedly, and can some essential characteristics of understanding object gradually.By accumulation, sum up the response situation of object under certain input action, people can estimate the inertia of object and delayed roughly situation, sets up the forecast model about object in the brain.By means of this model, the control effects of people can be accomplished very good.There is no such forecast model, just not good control effects.This model is different from conventional Mathematical Modeling, and it is a kind of empirical model or knowledge model, is the description of the combination of qualitative and quantitative analysis about object.

In Rotary Kiln Process for Alumina Production complex automatic system, the analysis that we deeply and carefully have learned kiln operation personnel judges experience, after study after a while and experience accumulation, establishes Alumina Rotary Kiln operating mode intelligent forecast model.Practice shows, under certain conditions, although people does not also know the Mathematical Modeling of controlled device, intelligent forecast model can qualitative and part quantitative recognition controlled device, for Rotary Kiln Process for Alumina Production control system provides important feedback and information of forecasting.

3) rotary kiln production multivariable multiobjective decision-making cooperation control

Rotary Kiln Process for Alumina Production production process is a multiobject complex process of multivariable, the control objectives of this system can be summarized as following some:

A) burning zone temperature should according to the difference of raw ingredients, is stabilized in the temperature range that ensures completely required by chemical reaction;

B) stablize kiln end temperature, maintain rational thermal regulation, ensure drying capacity and presintering degree;

C) monitor kiln tail negative pressure within the specific limits, ensure chamotte kiln security of operation, stable conditions, can form stable heat flow field;

D) kiln tail excess air coefficient is controlled in rational scope, to ensure that sufficient combustion reduces heat loss again as far as possible.

E) in kiln operation controls, how to coordinate numerous control objectives and have great importance.Such as, rational multi-objective coordinated control can solve the loop cycle phenomenon of traditional rotary kiln production process.

Loop cycle is a kind of situation of instability, and such as, in kiln, reducing appears in material load, causes burning zone temperature raise and force operating personnel to reduce firing rate.Then, burning zone temperature starts to decline, and forces again operating personnel to increase firing rate.In severe cases, although firing rate reaches ceiling, temperature may continue to reduce.Kiln is once being absorbed in abnormal situation in this wise, and loop cycle will repeat.Explaining from rotary kiln production mechanism, when burning zone temperature declines, in order to keep due temperature in clinkering zone, having to adjust firing rate.But clinkering zone only accounts for long 7 to 10 meters of kiln, and dry zone after clinkering zone, preheating zone Sum decomposition band may reach 70 to 80 meters.When due to burning zone temperature too high and when reducing firing rate, just decrease the heat supply to preheating zone Sum decomposition band.When this batch materials reached clinkering zone after 40 to 50 minutes, because preheating needs more firing rate to keep burning zone temperature not.At this moment, more fuel quantity to about 70 to 80 meters long dry zone, material supply in the Sum decomposition band of preheating zone is than more heat usually.When this batch materials arrived clinkering zone after 40 to 50 minutes, because preheating excessively makes burning zone temperature raise again.Thus loop cycle is successive.

In traditional kiln operation, why occur that loop cycle phenomenon is exactly because just consider burning zone temperature control objectives in operation, and do not take into account other control objectives such as kiln end temperature.Because of this operation for rotary kiln must accomplish that multivariable is taken into account, multi-objective coordinated.In Rotary Kiln Process for Alumina Production complex automatic system, multiobjective decision-making cooperation control comprehensively analyzes each control objectives, according to the various operating modes of burning zone temperature, kiln end temperature, the combination of flue gas O2 content, cooperation control is carried out to coal-supplying amount, primary air flow, secondary air flow, achieves and guarantee clinker quality, keep kiln thermal regulation to stablize, improve the multiple-objection optimization of combustion position.

4) rotary kiln is produced structure changes and is adjusted coal control

In kiln operation controls, on the one hand due to rotary kiln, to see that fire operation has the grasp of its particularity as coal opportunity, coal amplitude very important, and requiring should be very sharp to temperature changing trend, and the response of plus-minus coal wants fast; On the other hand, rotary kiln process is again a typical great inertia link, and choosing of coal-supplying amount adjustment cycle can not be too fast.Rotary kiln is produced structure changes and is adjusted coal to control to consider between rapidity and stability, achieves rational coal supply and controls.

2.2 course management system functions

Alumina clinker burns till the function of rotary kiln Technical innova-tion system as shown in figure 13, and process management function comprises operational management and system management function.

2.2.1 operational management function

1) production operation function

A. by operational procedure requirement, the selection of the scene contact before driving and equipment operating mode (dynamic, the soft manual and Automatic Control of skilled hand) is realized.

B. hard manual control mode: this control mode retains the controlling functions of on-the-spot various console, cabinet, independent of computer control system, in equipment debugging, overhaul of the equipments and computer control system debugging or when safeguarding, this control mode is guaranteed to meet on-the-spot actual needs, to maintain the needs of basic production, operator on low-voltage distribution cabinet or field operation box, directly can carry out start-stop operation to field apparatus by action button or bat-handle switch; By manual operator, hard Non-follow control is carried out to Field adjustment Fa Deng executing agency.In priority level, on-site manual control mode rank is the highest.In this mode, any automated manner is invalid.

C. soft manual control mode: allow operating personnel in control room, according to site specific, directly the start-stop of various equipment is operated and the aperture of various valve is adjusted from Dynamic System station.

D. Automatic Control control mode: when operating personnel select full-automatic mode, automatic control system by according to prefabricated application program automatically to various equipment carry out sequence start and stop, interlocked control and according to actual production ruuning situation, according to certain control strategy, various controlled parameter to be carried out in real time, closed-loop control.

E., detailed operation guidance information is provided, comprises soft manual operation and instruct and throw full automatic working guidance.

2) production monitoring function

A. the alumina clinker main technologic parameters of burning till rotary kiln is as burning zone temperature, temperature of kiln head, kiln end temperature, kiln tail oxygen content, kiln tail CO content, head pressure, tail negative pressure, slip pressure etc. carry out on-line checkingi by instrument and meter for automation, carry out the process such as linearisation and digital filtering by computer control system.

B. all technological parameters are presented in dynamic process flow chart picture in real time.In this kind of picture, except the chamotte kiln technological process of production is shown visually, can in real time, on its corresponding position, show actual value, the alarm condition and mode of operation etc. of various technological parameter exactly.

C. adopt the standard visual format of software, the correlation according to variable arranges overview panel displaying contents, off-limit alarm value, completes the functions such as automatic/hand switches, given parameters is arranged.Tendency chart form is adopted to record and show to important parameter.

D. according to the operating habit of operating personnel, the simulation of relevant parameter packet design is monitored picture, with the form simulation field instrument of bar graph, shows the setting value of various parameter, detected value, alarming value, operating value and valve opening.

E. comprehensive analysis and judgement are carried out to sinter leaching production status, judge that conclusion real-time online shows.

F. special kiln condition is reported to the police, send alarm sound prompting, and the process providing current special operation condition is instructed.

G. be respectively equipped with industrial tv monitoring system at kiln combustion band and feed opening place, provide good environment for operating personnel grasp the production status understanding kiln truly.

H. kiln combustion situation multimedia monitoring.When tradition adopts manually-operated mode to control rotary kiln production, operating personnel carry out judgement operation mainly through " seeing fire " before kiln." seeing fire " is exactly directly observe clinkering zone flame and material situation through glass screen before rotary kiln, then analyzes production status, determination operation action.When operating personnel move into master-control room from operating room before kiln, consider from the integrality of information and the continuity of operation, this part important information must be supplied to operating personnel, and kiln combustion situation multimedia monitoring just achieves this purpose.Kiln combustion situation is presented on master-control room industrial television by it, see that fiery personnel can away from clearly observing flame situation of change and clinkersintering situation in the control room before kiln, computer multi-media system playback history image can also be passed through, the operating condition of rotary kiln under the various operating mode of analysis contrast.

I. feed opening grog situation multimedia monitoring.The final products that alumina clinker burns till rotary kiln production are alumina clinkers, and the final grog unit weight of General Requirements is 1.2 ~ 1.45 kilograms/liter.So-called unit weight sieves in cooler outlet sampling, gets the grog that granularity is 3 ~ 10 millimeters, weigh the weight of one liter.Unit weight represents the quality of grog grindability and sintering degree.Burn till rotary kiln production as alumina clinker the most directly to feed back, the unit weight of on-the-spot grog detects main hand sample and measures, and measuring method is backward and the sampling period is long, controls to have little significance for real-time operation.But experienced operating personnel, by observing clinker particles, can judge sinter leaching quality.High-quality grog major part should be 5 ~ 30 millimeters, and in grey black, epigranular, carries underburnt material secretly without frit.Under traditional working condition, operating personnel in person arrive end opening and observe grog situation, obtain the operational feedback of a period of time.Burn till in complex automatic system at alumina clinker, feed opening grog situation is directly presented on master-control room industrial television by feed opening grog situation multimedia monitoring.See that fiery personnel clearly observing clinker quality situation away from the control room before kiln, can also pass through computer multi-media system playback history image, the operating condition of rotary kiln under the various operating mode of analysis contrast.

3) artificial information's set-up function

A. the setting and adjustment of various control set-point is realized, and the online input of loop control parameters and working condition parameter, selection and amendment.Although automatic control program cuts much ice in complex automatic system, people still plays the key effect do not replaced in monitoring system.Some important parameters in automatic control system change along with the change of production process parameters, and such as different raw slurry compositions requires different sintering temperatures, different atures of coal, determines different coal amplitude etc.Also do not have suitable detection means to these production process parameters at present, thus some important parameters of pattern-recognition and control algolithm need artificial setting, operating personnel or directly setup control parameter or input working condition parameter.The control set-point of setting and adjustment is needed to comprise burning zone temperature bound setting value and kiln end temperature upper limit set value.Circuit controls relevant parameter comprises coal amplitude, uses coal total amount bound and induced-draft fan throttle opening bound.Working condition parameter is raw slurry composition mainly, comprises raw material alumina silica ratio, iron aluminum ratio, alkali ratio and calcium ratio.

B. the online input of equipment status parameter, selection and amendment is realized.Automatic control system needs to determine that some equipment state is to carry out suitable adjustment operation, and such as duplex tube helix feeder state needs operating personnel to do corresponding setting.

4) fault in production diagnostic function

A. fault in production is detected in real time, Timeliness coverage fault in production.Alumina clinker burns till rotary kiln fault in production and comprises situations such as running coal, fracture, kiln caudal knot scar is serious, kiln ventilation is smooth, kiln cylinder body burning red, lower coal inequality is frequent, coal injection pipe operating condition is improper.

B., detailed tutorial message is provided, comprises phenomenon of the failure description, failure reason analysis and troubleshooting suggestion.Such as run coal and refer to that coal dust firing is incomplete, and confusingly together with waste gas, discharge sinter leaching rotary kiln with carbon monoxide form with coal.The phenomenon of running coal has the shinny thread flame that flashes in flame; Kiln ash band black; Coal grain is accidentally had to burn in grog.Once wind is not enough to produce the reason of running coal, and coal confusingly mixes bad with air; Burning zone temperature is low, and coal confusingly can not burn very well; Or because the Secondary Air having thick ring formation etc. to cause in exhaust blower fault, flue blockage and chamotte kiln is not enough.Instructing the process of running coal is have a power failure to gather dust; Once, suitably should adjust when Secondary Air is not enough, eliminate the reason of improper ventilation; Adjustment coal consumption etc.

5) production equipment management function

A. equipment fault is reported to the police, the maintenance of equipment is managed, ensure the safe operation of equipment.

B. there is the automatic processing capacity of feeder disorderly closedown.Feeder puts into operation period automatically, and if desired stop a feeder, handling failure, then see that fiery personnel are without the need to manual by system switchback, and the rotating speed of the feeder that these needs will stop by automatic control program is automatically added on another feeder still continuing to run; After the feeder that pending fault is shut down restarts operation, the current rotating speed of the feeder of former normal operation will be divided equally on two feeders by automatic control program automatically.

6) production safety management function

A. realize the interlock protection of equipment room, confirm before key operation performs.

B. for the start and stop of key equipment, defining operation condition carries out restriction protection.

C. in automatic control and soft Non-follow control process, to the maloperation that operating personnel may occur, application software package has the function taking corresponding remedial measure.

7) production report printing function

A. production report statistical function is realized.For important thermal parameter, electric parameter and the report printing of continuous data record.Statistical report form by hour, order of classes or grades at school, day, cumulative calculation in units of the moon, and to export with report form.Monitored parameter record form Stochastic sum timing two kinds of forms can print production process monitoring parameter.Technological parameter trend curve (real-time tendency and historical trend) display and printing.

B. fault report capability is realized, with random or timing form print fault form.

C. realize alarm/event record and report capability, comprise operator's operation note, technological parameter or equipment state and control mode change, the display of the information such as generation, confirmation of reporting to the police and printing.

D. data statistic analysis function.Historical data gathers and stores with automatic archiving; With chart and the automatic log history data of statistical report form, for event analysis in the future provides foundation.

E., ruuning situation statistical report form statistical function is provided.Comprise each class burning zone temperature distribution statistics (i.e. the cumulative time of different range residing for each class burning zone temperature, reflecting that quality condition is burnt till in per tour), each class raw slurry flux cumulating statistics (reflecting that output condition is burnt till in per tour), automatic operational percentage statistics (reflecting the situation that puts into operation of automatic control system) of automatic control system.

2.2.2 system management function

1) system security management function

A. register by the different stage of operator, system engineer, administrative staff, realize user's control authority differentiated control function.

B. can increase and delete user, the authority of user to be set and user cipher is modified.

C. system automatic production record event and user operation, report to the police to system exception simultaneously.

D. in the compilation process of each circuit controls program, safety, reliability are put in the first place, system communication fault, hardware out-of-limit to parameter gather fault and take appropriate measures.

E., under there is the situations such as operator station power down, work station power down or network communication fault, control program should have the function preventing loop settings value exception, even back to zero phenomenon from occurring, and except reporting to the police in time, takes appropriate measures.

F. extremely should be able to take appropriate measures to the collection signal that the faults such as system hardware collection fault, instrumentation, transducing unit occur, ensure that control loop normally works, production process safety.

2) system navigate function

A. the function of internal system navigation is realized.

B. the function of the switching between each monitored picture and the switching between subsystems is realized.

3. system communication function

A. have with workshop more than management level net MES system carry out the function of data communication.

B. there is the mutual communication of control system, contact and the function with other specialized control equipment communication between each kiln.

C. the communication interface with raw slurry compounding and controlling system is retained.

D. the communication interface with next procedure control system is retained.

Claims (2)

1. an alumina rotary kiln integrated automation control system, is characterized in that this system is by Process Control System and course management system.System realizes comprising the following steps:

Step one: the general structure determining the alumina rotary kiln integrated automation control system be made up of Process Control System and course management system.

Step 2: adopt intelligent coordinated variable-structure control technology, Intelligent predictive control technology, Adaptive Fuzzy Control technology, intelligent correction control technology, proposes the rotary kiln Process Control System be made up of basic automation systems, multimedia monitor system and Optimal Control System.Basic automation systems comprise feeds coal process control subsystem, aeration step RACS, smoke evacuation process control subsystem, feeding procedure RACS.Multimedia monitor system comprises kiln combustion condition monitoring subsystem, feed opening grog condition monitoring subsystem and cooler outlet grog condition monitoring subsystem.Optimal Control System comprises sintering process Optimal Control System.

Step 3: to ensure clinker quality, to improve kiln running rate, reduction energy consumption for target, integrated application administrative decision, Optimal Setting, intelligent coordinated technology, propose to manage by operational management and system the rotary kiln course management system formed.Operational management comprises system monitoring, fault diagnosis, equipment control, production safety management, report generation and printing, system communication and Operating Guideline function.System management comprises security of system, user management and system navigate function.

2. a kind of cement rotary kiln intelligent optimizing control system according to claim 1, is characterized in that step one proposes the architecture of the control integration be made up of Process Control System and course management system; Step 2 proposes rotary kiln Process Control System structure and the method for basic automation systems, multimedia monitor system and Optimal Control System composition; Step 3 proposes and manages by operational management and system the course management system formed.By integrated use intelligent modeling and intelligent control method, to greatest extent the intelligent behavior of people is incorporated in rotary kiln process control, to ensure clinker quality, improve kiln running rate, to reduce energy consumption.