CN101318158A - Control method for grinding process optimization of cement factory - Google Patents
Control method for grinding process optimization of cement factory Download PDFInfo
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- CN101318158A CN101318158A CNA2008100177190A CN200810017719A CN101318158A CN 101318158 A CN101318158 A CN 101318158A CN A2008100177190 A CNA2008100177190 A CN A2008100177190A CN 200810017719 A CN200810017719 A CN 200810017719A CN 101318158 A CN101318158 A CN 101318158A
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The invention discloses an optimal control method for a grinding process in a cement plant. By collecting grinding process signals and taking the advanced control as the core, the method realizes automatic control of material level and material level distribution, automatic control of circulating load and ventilation and also realizes optimization of material level of every bin in the mill, optimization of material velocity, optimization of circulating load and ventilation and also realizes output control of feed quantity, rotational speed of a powder-choosing machine and the rotational speed of a fan. The method optimizes the whole grinding process and realizes maximum time-production operation of the grinding process and minimum grinding unit consumption. At the same time, the failure of the grinding process is diagnosed, the safety of the grinding process is estimated, the grinding process is evaluated and analyzed, and the reasonable suggestion is given to the operation of the grinding process, thus assuring a continual, stable, safe and economical operation of the grinding process. The method can be widely used in the grinding process in the cement plant or in similar grinding processes in other fields.
Description
Technical field
The present invention relates to the automatic control technology field, be specifically related to control method for grinding process optimization of cement factory.
Background technology
Cement production process need be controlled the chemical composition (content of calcium, iron, sulphur etc.) of product, the fineness (or specific area) of control product, improves the output of grinding production process simultaneously under the requirement of satisfying quality.
At present the Microcomputerized dosing system that adopts of China cement plant has realized the control to each road material blanking ratio, makes that chemical analysis reaches qualified requirement in the production process.But exist when carrying out fineness control, mainly rely on operator's experience control feeding capacity, be difficult to be issued to the defective of maximum production in up-to-standard condition.
Summary of the invention
The purpose of this invention is to provide a kind of at the Grinding Process in Cement Plants process, with continuously, stable, safety, economical operation is target, and is rational in infrastructure, operation, easy to maintenance, reliable a kind of control method for grinding process optimization of cement factory.
In order to overcome the defective of prior art, technical scheme of the present invention is to solve like this:
A kind of control method for grinding process optimization of cement factory, its special character comprises the steps:
1), the advanced control module of grinding process is obtained grinding process historical data and real time data;
2), the advanced control module of grinding process is carried out material level and each storehouse material level by the grinding process historical data obtained and real time data and is distributed and be optimized, circulating load is optimized, material flow is optimized, ventilation is optimized, and draw best material level and each storehouse material level and distribute and set, optimum cycle load setting, best material flow are set and the optimal ventilation amount is set;
3), the advanced control module of grinding process provides grinding process fault diagnosis and security assessment information;
4), the advanced control module of grinding process provides grinding process postitallation evaluation and suggestion for operation information;
5), be set at target, employing Multivariable Decoupling Control, the rotation speed of fan of controlled output-feeding capacity, powder concentrator rotating speed and ventilation or distributing air damper aperture with material level and each storehouse material level distribution setting, circulating load setting, material flow setting and ventilation.
Described a kind of control method for grinding process optimization of cement factory, its special character is that the advanced control module of grinding process has the objective optimization function, grinding process optimization is divided into static optimization and dynamic optimization dual mode, its grinding process static optimization mode makes up the grinding process optimization model by obtaining the grinding process operational factor, and constantly model is upgraded according to service data, carry out grinding process optimization according to grinding process optimization model and running status; Grinding process dynamic optimization mode by applying disturbance, is determined to optimize direction according to the result when grinding process moves, and according to optimization objective function optimal operational condition is searched for, and the selection of grinding process optimization target can be determined according to actual needs.
Described a kind of control method for grinding process optimization of cement factory, its special character is that described material level and each storehouse material level distribution are optimized, circulating load is optimized, material flow is optimized, to ventilation be optimized can select one of them, two or connect more than, the setting that distributes of resulting best material level and each storehouse material level, optimum cycle load setting, best material flow is set and the optimal ventilation amount is set, should be mutually one of them, two or connect individual more than.
Described a kind of control method for grinding process optimization of cement factory, its special character is that the advanced control module of grinding process has postitallation evaluation and suggestion for operation function, postitallation evaluation and suggestion for operation provide current operation postitallation evaluation, and the operation of grinding process provided suggestion, its suggestion is meant steel ball, forging interpolation, best powder concentrator rotating speed.
Described a kind of control method for grinding process optimization of cement factory, its special character is that the advanced control module of grinding process has fault diagnosis and security evaluation function, on the one hand can be to the grinding process diagnosing malfunction, comprise the real time fail diagnosis, its fault diagnosis comprises in fracture, putty, the grinding machine unusual; According to service data the security of whole grinding process operation is assessed, provided the safety evaluation result.
The present invention compared with prior art, along with the raising that in the production process of cement plant automatization level is required, the raising that raising that performance driving economy requires and security of operation require, in order to solve existing issue, basic outlet is to improve the automatization level of grinding system, implement automatic improving, with the safety and economic operation is target, operation characteristic at grinding system, the control strategy that advanced control algorithm combines with conventional control algolithm, guaranteed the grinding continuous economic stability operation of uniting, guaranteed that grinding machine can operate in the maximum production state all the time under the prerequisite that guarantees the fineness index; It is stable to have controlled steel ball and material's proportion in running, thereby just make that product fineness is stable, uniformity improves, dust pollution and noise pollution are made moderate progress, the cement plant production process is reduced power consumption, increasing economic efficiency has crucial meaning; Simultaneously, can effectively reduce the vibrations of mill body, prevent empty mill and full mill, alleviate operation, labour intensity, reduce maintenance cost, improve working environment, realized the automatic control of whole grinding process, and whole grinding process is optimized, has advantage rational in infrastructure, easy to operate, energy-saving and cost-reducing.One side can improve mill hourly output, improves the mill product quality; Can guarantee on the other hand grinding process continuously, stable, safety, economical operation; Application of the present invention can also alleviate operations staff's labour intensity, reduces the grinding process maintenance, is widely used in manufacture of cement industry or other industry resemble process grinding process.
The present invention has following characteristics:
● can adapt to all kinds grinding process.
● can provide the grinding process optimization control scheme that gears to actual circumstances.
● guarantee the operation of grinding process continous-stable.
● can follow the tracks of the operation of predeterminated target optimum point.
● guarantee the grinding process safety and economic operation.
● can the guiding operation operation.
The technical indicator that the present invention can reach is as follows:
● improve unit-hour output: 〉=6%
● reduce the grinding unit consumption: 〉=5%
● reduce the consumption of steel ball liner plate: 〉=8%
● automatic devoting rate: 〉=95%
● stop full mill, empty mill fully.
Description of drawings
Fig. 1 is a grinding process optimization control structure block diagram;
Fig. 2 is a grinding process dynamic optimization flow chart;
Fig. 3 is grinding process material level setting value dynamic optimization flow chart;
Fig. 4 is grinding process measuring point and control point schematic diagram;
Fig. 5 is grinding process optimization control block diagram.
The specific embodiment
Accompanying drawing is embodiments of the invention.
Below in conjunction with accompanying drawing summary of the invention is described further:
With reference to shown in Figure 1, for grinding process optimization control structure block diagram, a kind of control method for grinding process optimization of cement factory has been described, comprise the steps:
1), the advanced control module of grinding process is obtained grinding process historical data and real time data;
2), the advanced control module of grinding process is carried out material level and each storehouse material level by the grinding process historical data obtained and real time data and is distributed and be optimized, circulating load is optimized, material flow is optimized, ventilation is optimized, and draw best material level and each storehouse material level and distribute and set, optimum cycle load setting, best material flow are set and the optimal ventilation amount is set;
3), the advanced control module of grinding process provides grinding process fault diagnosis and security assessment information;
4), the advanced control module of grinding process provides grinding process postitallation evaluation and suggestion for operation information;
5), be set at target with material level and each storehouse material level distribution setting, circulating load setting, material flow setting and ventilation, adopt Multivariable Decoupling Control, the rotation speed of fan of controlled output---feeding capacity, powder concentrator rotating speed and ventilation or distributing air damper aperture.
The advanced control module of grinding process has the objective optimization function, grinding process optimization is divided into static optimization and dynamic optimization dual mode, its grinding process static optimization mode makes up the grinding process optimization model by obtaining the grinding process operational factor, and constantly model is upgraded according to service data, carry out grinding process optimization according to grinding process optimization model and running status; Grinding process dynamic optimization mode by applying disturbance, is determined to optimize direction according to the result when grinding process moves, and according to optimization objective function optimal operational condition is searched for, and the selection of grinding process optimization target can be determined according to actual needs.
Described material level and each storehouse material level distribute and are optimized, circulating load is optimized, material flow is optimized, to ventilation be optimized can select one of them, two or more, resulting best material level and each storehouse material level distribute and set, optimum cycle load setting, best material flow are set and the setting of optimal ventilation amount, should be mutually one of them, two or more.
The advanced control module of grinding process has postitallation evaluation and suggestion for operation function, and postitallation evaluation and suggestion for operation provide current operation postitallation evaluation, and the operation of grinding process is provided suggestion, and its suggestion is meant steel ball, forging interpolation, best powder concentrator rotating speed.
The advanced control module of grinding process has fault diagnosis and security evaluation function, can comprise the real time fail diagnosis to the grinding process diagnosing malfunction on the one hand, and its fault diagnosis comprises in fracture, putty, the grinding machine unusual; According to service data the security of whole grinding process operation is assessed, and provided the safety evaluation result.
Figure 2 shows that grinding process dynamic optimization flow chart, when dynamic optimization begins, record optimization target values at this moment, can select unit-hour output maximum or grinding unit consumption minimum, at first carry out material level and material level distribution optimization, after finishing, material level optimization enters circulating load optimization, after finishing, circulating load optimization enters material flow optimization, after finishing, material flow optimization enters ventilation optimization, after material flow optimization finishes, obtain the running status of this moment: material level and material level distribute, circulating load, material flow and ventilation, optimization target values before relatively optimization target values under this state and epicycle are optimized, if deviation is greater than setting deviation, enter next round optimization, if deviation finishes record running status at this moment less than setting deviation optimization, be that material level and material level distribute, circulating load, material flow and ventilation are optimal operational condition, and each runtime value is a grinding process control optimum setting value.
Material level is the height of material in grinding mill barrel both, and the interior material of grinding machine what characterize; It is each storehouse material level that material level distributes.There is direct relation in material in the grinding machine with grinding efficiency, in grinding machine material more after a little while, it is less to grind to form qualified fineness finished product, both mill hourly output was less; Limiting case, when being full of by material in the grinding machine, material can not get grinding, and forms full mill, and mill hourly output is almost nil, thereby exists tackling the best material level of maximum unit-hour output.The cement plant grinding machine mostly is compound mill greatly, and the material after preceding storehouse material screens through partition panel enters next storehouse and grinds, thereby each warehousing forms best material level and distributes at best material level.
For closed circuit mill (also claiming to close the stream mill), underproof grinding machine discharging comes back to the grinding machine feeding mouth after screening through powder concentrator, enters grinding machine once more and grinds, and this part feed back is a circulating load.Circulating load can prolong the grinding of material (generally not to be had and expect that the time that stops is longer in grinding machine often, the fineness of grinding is more little), simultaneously because the existence of powder concentrator, can effectively reduce overground (after the fineness of improved grinding reached the requirement index, continue to grind both overground), when overground the existence, the energy consumption of grinding process certainly will be higher, so there is the optimum cycle load.
Material flow, the i.e. flowing velocity of material in grinding machine.Material, can stay for some time in grinding machine to flowing out from the grinding machine outlet from entering grinding machine, and the time that ordinary material stops in grinding machine is longer, and the fineness of grinding is more little, and the time of staying is shorter, and the fineness of grinding is big more.The time that material flow and material stop in grinding machine is inversely proportional to.All can directly influence its product fineness and output to open circuit mill or closed circuit mill, thereby exist best material speed, best material speed promptly to ensure the quality of products and can reach the output maximum.
Ventilation in the grinding machine, can reduce temperature of charge in the grinding machine on the one hand, prevent the appearance of " bag ball " phenomenon, fine powder in the grinding machine can be taken out of on the other hand prevent overground, thereby the ventilation in the grinding machine promptly influences stable, the safe operation of grinding process, again grinding process output there is certain influence, has optimum value equally.
Figure 3 shows that grinding process material level setting value dynamic optimization flow chart, when material level setting value dynamic optimization begins, record optimization target values at this moment, can select unit-hour output maximum or grinding unit consumption minimum, revise material level and material level distribution setting value, carry out material level control according to new material level and material level distribution setting value, judge whether grinding system reaches stable, grinding system reach stable after, obtain this moment the optimization target values under material level and the material level distribution, optimization target values before relatively optimization target values under this state and epicycle are optimized, if deviation enters next round optimization greater than setting deviation, if deviation finishes less than setting deviation optimization, record material level and material level distribution value at this moment is best material level and material level distribution setting value.
Circulating load optimization, material flow optimization and ventilation optimization employing and material level and the same method of material level distribution optimization are carried out.
Figure 4 shows that grinding process measuring point and control point schematic diagram, it among the figure closed-circuit grinding process, comprise pan feeding, grinding machine (for compound mill), discharging elevator, powder concentrator, also comprise ventilation blower fan in main motor and the grinding machine in addition, if for the open circuit mill then save powder concentrator.Measuring point is furnished with: feeding capacity, each storehouse material level, current of electric, power of motor, outlet blast, elevator electric current, powder concentrator rotating speed, Hui Fenliang.The control point comprises: feeding control point, air quantity control point and powder concentrator rotating speed control point.
Each storehouse material level can reflect that material level distributes; Current of electric is used for analyzing steel ball in the grinding machine, forging useful load when sky grinds, assistant analysis grinding machine material level when operation; The elevator electric current is used for characterizing material flow; Return powder reaction cycle load; Outlet blast reflection ventilation.
Figure 5 shows that grinding process optimization control block diagram, from left to right, at first select optimization aim: platform produces maximum (characterizing with feeding capacity) or unit power consumption of coal pulverizing minimum (characterizing divided by power of motor with feeding capacity), be optimized according to the quantity of state of optimization aim, obtain 1 storehouse material level setting, 2 storehouse material levels settings, 3 storehouse material levels settings, circulating load setting (levying), material flow setting (using elevator electric current sign), ventilation setting (with grinding machine outlet blast sign) with returning the powder scale to grinding process; Obtain each amount deviation by comparing with 1 storehouse level gauging value, 2 storehouse level gauging values, 3 storehouse level gauging values, circulating load measured value, material flow measured value, ventilation measured value; Each amount deviation and setting value are imported in the Multivariable Decoupling Control device, through controlled output---feeding capacity, powder concentrator rotating speed and rotation speed of fan controlled quentity controlled variable after the Multivariable Decoupling Control.
In sum, because the control mode of grinding process has computer centralized control, PLC control mode and DCS control mode, select the implementation of control algolithm at concrete control mode, adopt the mode that realizes on computers at the computer centralized control, can dynamically share having software transformation or new software and existing software data now; At the PLC control mode, basic controlling realizes that the advanced person is controlled on the host computer and realizes on the PLC controller; At the DCS control mode, control algolithm realizes that by DCS control platform advanced control section also can be realized by communication mode on the independent optimization station.
The Grinding Process in Cement Plants process exists open circuit mill, closed circuit mill, grinding machine be divided into tail unload formula, in unload the formula grinding machine, technology has dry method or wet method, can realize on existing theory of algorithm basis for other technological processes.Unload formula for example, can control two storehouse inventories, according to the mill feed material amount, control pan feeding discharge for wet production by material level Optimal Control principle.
For metallic ore, the nonmetallic ore grinding process of other and Grinding Process in Cement Plants similar process, with the production procedure of grinding machine as nucleus equipment, the present invention is effective equally.
At last, note also that what more than enumerate only is a specific embodiment of the present invention.Obviously, the invention is not restricted to above embodiment, many distortion can also be arranged.Protection scope of the present invention is all thought in all distortion that those of ordinary skill in the art can directly derive or associate from content disclosed by the invention.
Embodiment
Certain cement plant cement grinding mill grinding type is closed circuit mill, and the grinding machine specification is: 3.2m * 13m, and two storehouses mill, design rating is 60t/h, and maximum ball load is 133 tons, and bistrique is furnished with the rolling, scattering system.Its grinding production process technology flow process is: the material that proportioning is good is transported to roll squeezer front end 40t small feed bin through elevator, material is through the roll squeezer extruding and be promoted to beater, through the material after breaing up two flow directions are arranged, thicker material is transmitted equipment and delivers to the 40t small feed bin, suitable material enters the bistrique storehouse, delivers to grinding machine through the quantitative feeding scale of rotor and grinds; Go out to wear into product cement and carry out meal separation and dedusting flow process through powder concentrator, the finished product that fineness is qualified is sent to cement bunker, and the underproof cement grinding mill that is sent to grinds again.
Because this cement grinding mill has been realized feed proportioning system by ABB DCS system, and behind the small feed bin of joining material, the roll squeezer end is furnished with material and breaks up equipment, the quantitative feeding scale of rotor is used to control mill feed material total amount, i.e. unit-hour output.So utilize ABB DCS system configuration language the cement grinding mill grinding process optimization is controlled configuration, gather grinding machine 1 storehouse material level signal, grinding machine 2 storehouse material level signals, grinding machine current signal, powder concentrator current signal, mill tail elevator current signal, grinding machine gateway pressure difference signal, powder concentrator tach signal, front and back bearing shell oil temperature signal and feed back amount signal, control feeding capacity (by the quantitative feeding scale of rotor), powder concentrator rotating speed and air-introduced machine baffle opening.
At first the advanced control module of grinding process is obtained grinding process historical data and real time data, data comprise: grinding machine 1 storehouse material level signal (scope 0-100%), grinding machine 2 storehouse material level signals (scope 0-100%), grinding machine current signal (0-130A), powder concentrator current signal (0-280A), mill tail elevator current signal (0-100A), grinding machine gateway pressure difference signal (0-6000Pa), powder concentrator tach signal (0-1440 rev/min), front and back bearing shell oil temperature signal (0-60 ℃), feed back amount signal (0-300t/h), feeding capacity signal (0-100t/h), air-introduced machine baffle opening signal (0-100%).
The advanced control module of grinding process carries out material level and each storehouse material level distribution is optimized, and obtains the best material level 80% in best material level 78%, 2 storehouse, 1 storehouse; Circulating load is optimized, obtains optimum cycle load 183t/h; Material flow is optimized, obtains the dynamo-electric stream of corresponding best speed-raising 86A; Ventilation is optimized obtains best gateway pressure reduction 5200Pa, corresponding maximum mill hourly output 77t/h, the cement of this moment goes out grinding rate 2.8 ± 0.2.
According to the grinding machine 1 storehouse material level signal that collects, grinding machine 2 storehouse material level signals, grinding machine current signal, powder concentrator current signal, mill tail elevator current signal, grinding machine gateway pressure difference signal, powder concentrator tach signal, front and back bearing shell oil temperature signal, feed back amount signal, feeding capacity signal, air-introduced machine baffle opening signal, the advanced control module of grinding process provides grinding process fault diagnosis and security assessment information, comprise whether existing unusually in the grinding machine, have liner plate to come off usually, warning messages such as partition panel stops up, " bag ball ", full mill, fracture, bearing shell overtemperature.
According to the grinding machine 1 storehouse material level signal that collects, grinding machine 2 storehouse material level signals, grinding machine current signal, powder concentrator current signal, mill tail elevator current signal, grinding machine gateway pressure difference signal, powder concentrator tach signal, front and back bearing shell oil temperature signal, feed back amount signal, feeding capacity signal, air-introduced machine baffle opening signal, the advanced control module of grinding process provides grinding process postitallation evaluation and suggestion for operation information, comprise that 1 storehouse steel ball is on the high side or on the low side, 2 storehouse steel balls are on the high side or on the low side; Each order of classes or grades at school operation result contrast, and provide corresponding suggestion.The steel ball addition adds 16 tons of maximum gauge steel balls according to suggestion; Produce deviation and surpass 1 ton when each order of classes or grades at school, or produce deviation above 1 ton with mean time, suggestion optimization is put into operation, to guarantee the grinding system optimized operation.
According to optimizing the result: best material level: the best material level 80% in best material level 78%, 2 storehouse, 1 storehouse; Optimum cycle load 183t/h; The dynamo-electric stream of best speed-raising 86A; Best gateway pressure reduction 5200Pa, corresponding maximum mill hourly output 77t/h, the control output feeding capacity that adopts the decoupling zero control algolithm to obtain this moment is 77 ± 3t/h; The powder concentrator rotating speed is 874 ± 100 rev/mins; Air-introduced machine baffle opening 66 ± 2%.
After system's operation, cement output is brought up to 77t/h from original 71t/h, volume increase 8.5%, reduce grinding unit consumption 7.8%, the fineness qualification rate brings up to 100% by original 80%, the fluctuation of fineness from originally ± 1.5 be reduced to ± 0.2 the continuous economic stability operation of grinding machine, grinding machine can operate in the maximum production state all the time under the prerequisite that guarantees the fineness index; It is stable to have controlled steel ball and material's proportion in running, thereby make that product fineness is stable, uniformity improves, and ensures the quality of products, improves output, has improved dust pollution and noise pollution to some extent, reduce cement plant production process power consumption, increasing economic efficiency has crucial meaning; Simultaneously, prevent empty mill and full mill, alleviate operation, labour intensity, reduce maintenance cost, improve working environment, have remarkable economic efficiency and good social benefit.
Claims (5)
1, a kind of control method for grinding process optimization of cement factory, its feature comprises the steps:
1), the advanced control module of grinding process is obtained grinding process historical data and real time data;
2), the advanced control module of grinding process is carried out material level and each storehouse material level by the grinding process historical data obtained and real time data and is distributed and be optimized, circulating load is optimized, material flow is optimized, ventilation is optimized, and draw best material level and each storehouse material level and distribute and set, optimum cycle load setting, best material flow are set and the optimal ventilation amount is set;
3), the advanced control module of grinding process provides grinding process fault diagnosis and security assessment information;
4), the advanced control module of grinding process provides grinding process postitallation evaluation and suggestion for operation information;
5), be set at target, employing Multivariable Decoupling Control, the rotation speed of fan of controlled output-feeding capacity, powder concentrator rotating speed and ventilation or distributing air damper aperture with material level and each storehouse material level distribution setting, circulating load setting, material flow setting and ventilation.
2, a kind of control method for grinding process optimization of cement factory according to claim 1, the advanced control module that it is characterized in that grinding process has the objective optimization function, grinding process optimization is divided into static optimization and dynamic optimization dual mode, its grinding process static optimization mode makes up the grinding process optimization model by obtaining the grinding process operational factor, and constantly model is upgraded according to service data, carry out grinding process optimization according to grinding process optimization model and running status; Grinding process dynamic optimization mode by applying disturbance, is determined to optimize direction according to the result when grinding process moves, and according to optimization objective function optimal operational condition is searched for, and the selection of grinding process optimization target can be determined according to actual needs.
3, a kind of control method for grinding process optimization of cement factory according to claim 1, it is characterized in that described material level and each storehouse material level distribution are optimized, circulating load is optimized, material flow is optimized, to ventilation be optimized can select one of them, two or more, resulting best material level and each storehouse material level distribute and set the optimum cycle load setting, best material flow is set and the setting of optimal ventilation amount, should be mutually one of them, two or more.
4, a kind of control method for grinding process optimization of cement factory according to claim 1, the advanced control module that it is characterized in that grinding process has postitallation evaluation and suggestion for operation function, postitallation evaluation and suggestion for operation provide current operation postitallation evaluation, and the operation of grinding process provided suggestion, its suggestion is meant steel ball, forging interpolation, best powder concentrator rotating speed.
5, a kind of control method for grinding process optimization of cement factory according to claim 1, the advanced control module that it is characterized in that grinding process has fault diagnosis and security evaluation function, on the one hand can be to the grinding process diagnosing malfunction, comprise the real time fail diagnosis, its fault diagnosis comprises in fracture, putty, the grinding machine unusual; According to service data the security of whole grinding process operation is assessed, and provided the safety evaluation result.
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