基于自动配料的水泥生料质量控制研究

发布时间：2018-02-03 02:03

本文关键词： 生料质量控制智能控制专家系统　出处：《济南大学》2015年硕士论文　论文类型：学位论文

【摘要】：生料质量控制是水泥生产的基础,质量合格、稳定的生料不仅可以使熟料质量稳定,而且可以降低熟料烧成过程的难度。石灰饱和系数、硅酸率和铝氧率是反映生料质量的通用指标,三率值的合格与否是生料质量好坏的直观反映。国内水泥生料配料过程总体上仍处于人工或半自动控制状态,传统的控制方式时间滞后性很大,且配比调整依靠的是操作员工作经验,没有严格计算过程,受人为主观因素影响较大,从而不能保证水泥生料质量稳定。前期国内水泥企业已开始应用元素在线分析仪,可以实时检测入磨皮带或出磨空气斜槽内生料的化学成分,为配比的自动计算提供了基础。所以,从国内外生料质量控制的研究现状出发,采用先进控制算法,实现生料质量控制的科学化、自动化,对水泥企业控制产品质量甚至稳定窑系统烧成具有重要意义。本文通过对国内多家水泥企业生料质量控制环节的深入了解,针对传统离线式和安装了元素在线分析仪的在线式生料质量控制分别提出了相应的质量控制设计方案。本文主要工作内容如下:(1)离线式生料质量控制不能得到生料成分实时反馈结果,使用数据为化验室每小时的报样。为了解决离线调整的弊端,提出如下控制方案:针对人工控制时遇到的特殊工况,设计了专家控制器,进行分工况处理;充分总结现场操作人员操作经验,并结合化验室人员建议,形成专家控制器的规则库,从而达到自动控制模仿人工控制规则的目的;配比的计算使用增量式寻优方法,减小了由于原料成分代表性差、波动大带来的误差。(2)在线式生料质量控制由于安装了元素在线分析仪,可以得到生料成分实时反馈结果。元素在线分析仪由于原理不同分为磨后应用与磨前应用。两种应用均可以实时检测生料成分,大大减少了滞后时间。针对两种在线式应用,本文提出的控制方案类似:根据元素分析仪的反馈、响应周期的设定和三率值设定智能选择使用偏差控制器、趋势控制器和前馈控制器输出三率值的不同工况,并将此作为专家控制器的输入,由专家控制器输出相应的调节方案。(3)根据离线式生料质量控制的特点及设计方案开发了离线式生料质量控制软件。由于应用现场没有在线条件,故该软件完全离线,不在线实时获取生料全分析数据,也不在线实时修改DCS配料秤给定。生料全分析数据依靠人工输入,计算配比显示在软件界面上,再由操作员手动修改DCS配料秤给定。该软件使用VB编写。(4)根据在线式生料质量控制的特点及设计方案开发了在线式生料质量控制软件。软件通过OPC分别与DCS和分析仪进行数据通讯,结合SQL Server数据库对数据进行实时读写操作,完成成分读取与配比计算输出过程。该软件亦使用VB编写。
[Abstract]:Raw meal quality control is the basis of cement production. Qualified and stable raw meal can not only make clinker quality stable, but also reduce the difficulty of clinker sintering process and lime saturation coefficient. The ratio of silicic acid and aluminum oxide is a general index to reflect the quality of raw material, and the quality of raw meal is directly reflected by whether the three ratio values are qualified or not. The process of cement raw meal batching in China is still in the state of manual or semi-automatic control on the whole. The traditional control mode has a great lag in time, and the proportion adjustment depends on the operator's working experience, there is no strict calculation process, and it is greatly influenced by human subjective factors. Therefore, the quality of cement raw material can not be guaranteed. In the early stage, domestic cement enterprises have started to use element on-line analyzer, which can detect the chemical composition of raw material in the slant groove of grinding skin or air in real time. It provides the basis for the automatic calculation of the proportion. Therefore, starting from the current research situation of raw meal quality control at home and abroad, the advanced control algorithm is adopted to realize the scientific and automatic raw meal quality control. It is of great significance for cement enterprises to control the quality of products and even to stabilize the firing of kiln system. This paper makes a thorough understanding of the quality control links of raw materials in many domestic cement enterprises. The corresponding quality control design schemes for traditional off-line and on-line raw meal quality control systems with element on-line analyzer are proposed. The main work of this paper is as follows: 1). The quality control of off-line raw meal can not get the real-time feedback result of raw material composition. In order to solve the problem of off-line adjustment, the following control schemes are put forward: according to the special working conditions encountered in manual control, the expert controller is designed to deal with the sub-working conditions; The operation experience of field operators is summarized, and the rule base of expert controller is formed in combination with the advice of laboratory personnel, so as to achieve the purpose of automatic control and imitation of manual control rules. The incremental optimization method was used to reduce the error caused by the large fluctuation of raw material composition, and the on-line raw meal quality control was due to the installation of element on-line analyzer. The element on-line analyzer can be divided into post-grinding application and pre-grinding application because of different principles. Both applications can be used to detect raw meal composition in real time. The delay time is greatly reduced. For two on-line applications, the control scheme proposed in this paper is similar: according to the feedback of the element analyzer, the setting of response period and the setting of three-rate value, the intelligent selection using deviation controller. The trend controller and the feedforward controller output three rate values in different working conditions, and this is taken as the input of the expert controller. According to the characteristics of off-line raw meal quality control and the design scheme, the off-line raw meal quality control software is developed. Because there is no on-line condition in the application field. Therefore, the software is completely off-line, not on-line real-time acquisition of raw material total analysis data, nor online real-time modification of DCS batching scale given. Raw meal total analysis data rely on manual input, the calculation ratio is displayed on the software interface. Then the operator manually modifies the DCS batching scale given. The software is written with VB. According to the characteristics and design scheme of on-line raw material quality control, the software of on-line raw meal quality control is developed. The software communicates with DCS and analyzer separately through OPC. Combined with SQL Server database to read and write the data in real time, the process of component reading and proportion calculation and output is completed. The software is also written in VB.
【学位授予单位】：济南大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TQ172.6

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