TWI768545B - Method of controlling coal management system - Google Patents
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本發明係關於煤耗控制,特別是一種控制煤耗系統之方法。 The present invention relates to coal consumption control, especially a method for controlling coal consumption system.
水泥生產會產生煤耗,然而煤耗過多不但增加製造成本,也會造成環境汙染。水泥之生產線包含許多產線設備,每條生產線都有近萬個監控點。雖然這些監控點可以提供窯況之監控資料,然而監控點數量太多,操作人員難以依照所有監控點的監控資料全面迅速判斷窯況,導致產線設備調整間隔時間過久,不夠即時也不夠正確,無法有效降低煤耗。 Cement production will generate coal consumption, however, excessive coal consumption will not only increase manufacturing costs, but also cause environmental pollution. The cement production line includes many production line equipment, and each production line has nearly 10,000 monitoring points. Although these monitoring points can provide monitoring data of kiln conditions, the number of monitoring points is too large, and it is difficult for operators to comprehensively and quickly judge the kiln conditions according to the monitoring data of all monitoring points, resulting in the adjustment interval of production line equipment being too long, not being timely or correct. , which cannot effectively reduce coal consumption.
本發明實施例提供一種控制煤耗系統之方法。煤耗系統包含中控系統及複數個監控點,該些監控點設置於複數個產線設備上。控制煤耗系統之方法包含該些監控點獲得監控資料,中控系統依據監控資料選定候選特徵集及建立煤耗模型,中控系統依據煤耗模型產生該些監控點中之可控監控點之建議操作值,及產線設備依據建議操作值進行運作以達成目標工況。 Embodiments of the present invention provide a method for controlling a coal consumption system. The coal consumption system includes a central control system and a plurality of monitoring points, and these monitoring points are set on a plurality of production line equipment. The method for controlling the coal consumption system includes obtaining monitoring data from the monitoring points, the central control system selecting a candidate feature set and establishing a coal consumption model according to the monitoring data, and the central control system generating the recommended operating values of the controllable monitoring points among the monitoring points according to the coal consumption model , and the production line equipment operates according to the recommended operating values to achieve the target operating conditions.
1:煤耗系統 1: Coal consumption system
101至10N:監控點 101 to 10N: Monitoring points
12:中控系統 12: Central control system
200:方法 200: Method
S202至S208,S302至S312,S402及S404,S502及S504:步驟 S202 to S208, S302 to S312, S402 and S404, S502 and S504: Steps
第1圖係為本發明實施例中之一種煤耗系統之方塊圖。 FIG. 1 is a block diagram of a coal consumption system according to an embodiment of the present invention.
第2圖係為第1圖中之煤耗系統的操作方法之流程圖。 FIG. 2 is a flow chart of the operation method of the coal consumption system of FIG. 1 .
第3圖係為第2圖中之操作方法的步驟S204之流程圖。 FIG. 3 is a flowchart of step S204 of the operation method in FIG. 2 .
第4圖係為第3圖中之一種建模步驟S306之流程圖。 FIG. 4 is a flowchart of a modeling step S306 in FIG. 3 .
第5圖係為第3圖中之另一種建模步驟S306之流程圖。 FIG. 5 is a flowchart of another modeling step S306 in FIG. 3 .
第1圖係為本發明實施例中之一種煤耗系統1之方塊圖。煤耗系統1可用於水泥廠以降低煤耗。煤耗可以標準煤耗表示。煤耗系統1包含監控點101至10N及中控系統12,N為大於1之正整數。中控系統12可於電腦或電腦網路中運行。監控點101至10N可設置於水泥廠中之複數個產線設備上用以測量該些產線設備之監控資料,及透過有線或無線連接耦接於中控系統12。中控系統12可設置於水泥廠或遠端電腦機房,每一產線設備上可設置至少一監控點。監控點101至10N可將監控資料傳送至中控系統12,中控系統12可將監控資料儲存於資料庫,依據監控資料產生該些產線設備之建議操作值,及將建議操作值回傳至水泥廠以使該些產線設備依據建議操作值進行運作,達成降煤減碳的效益同時維持穩定運作。
FIG. 1 is a block diagram of a
水泥廠中之複數個產線設備可包含生料秤、煤粉秤、預熱機、分解爐、迴轉窯、篦冷機、高溫風機、冷卻風機、窯頭罩、窯頭排風機及其他產線設備。煤粉秤將煤粉餵入迴轉窯及窯尾分解爐進行燃燒,所產生的熱氣流可將生料秤餵入預熱機的水泥生料進行預熱,接著進入分解爐,通過迴轉窯後再經由篦冷機冷卻以產生水泥熟料(cement clinker)。水泥熟料之產生可受到預熱機之出口之溫度及壓力、分解爐之入口之溫度及壓力、迴轉窯之轉速及溫度、高溫風機及冷卻風機之風量及溫度、煤量之影響。監控點101至10N可為速度計、加速度計、轉速計、風量計、電流感測器、電壓感測器、功率感測器、溫度感測器、壓力感測器、濃度感測器、影像感測器、音訊感測器或其他感測器。監控點101至10N可分為可控監控點、不可控監控點、環境監控點、品質監控點、結
構式資料監控點及非結構式資料監控點。可控監控點可監控轉速、風量、電流、電壓、功率等可控變數。不可控監控點可監控溫度、壓力等不可控變數。環境監控點可監控氮氧化物濃度或一氧化碳濃度等環境變數。例如,濃度感測器可監控氮氧化物(NOx)濃度及/或一氧化碳(CO)濃度以確保煤耗模型的建議不會使環境品質超標。品質監控點可監控水泥生料量或水泥熟料量等品質變數。結構式資料監控點可監控轉速、風量、溫度、壓力、濃度、震動等可以列表方式記錄之變數。非結構式監控點可監控影像或聲音等無法以列表方式記錄之變數。
Multiple production line equipment in a cement plant can include raw meal scales, pulverized coal scales, preheaters, precalciners, rotary kilns, grate coolers, high temperature fans, cooling fans, kiln head covers, kiln head exhaust fans and other production lines equipment. The pulverized coal scale feeds the pulverized coal into the rotary kiln and the kiln tail calciner for combustion, and the generated hot air can feed the raw material scale into the cement raw meal of the preheater for preheating, and then enter the calciner, after passing through the rotary kiln. It is then cooled via a grate cooler to produce cement clinker. The production of cement clinker can be affected by the temperature and pressure of the outlet of the preheater, the temperature and pressure of the inlet of the calciner, the speed and temperature of the rotary kiln, the air volume and temperature of the high temperature fan and the cooling fan, and the amount of coal. The
監控點101至10N可設置於產線設備之關鍵監控位置用以監控影響產生水泥熟料之變數。舉例而言,分解爐之入口係為關鍵監控位置,分解爐之入口之溫度及壓力可反映水泥生料之狀態,因此溫度感測器及壓力感測器可設置於分解爐之入口以感測分解爐之入口之溫度及壓力,中控系統12可依據分解爐之入口之溫度及壓力而產生水泥生料量及煤耗量之建議操作值。在一些實施例中,中控系統12可依據經驗值設置水泥生料量及煤耗量之建議操作值,進而使水泥廠降低0.28%(約7,000公噸)之煤耗量。中控系統12可將水泥生料量及煤耗量之建議操作值傳送至水泥廠之顯示裝置,操作人員可依據顯示螢幕上顯示之建議操作值設定生料秤及煤粉秤。在一些實施例中,中控系統12亦可將水泥生料量及煤耗量之建議操作值分別傳送至生料秤及煤粉秤,生料秤及煤粉秤可分別依據建議操作值自動調整水泥生料量及煤耗量。
The
此外,轉速計及溫度計可設置於迴轉窯,壓力感測器及溫度計可設置於窯頭罩,轉速計可設置於窯頭排風機,電流感測器及風量計可設置於高溫風機及冷卻風機,速度計可設置於篦冷機,及其他監控點可設置於該些產線設備之其他關鍵監控位置。在一些實施例中,中控系統12可依據監控點101至10N
測量到之監控資料建立煤耗模型,及依據煤耗模型產生監控點101至10N中之可控監控點之建議操作值,進一步使水泥廠降低1.02%(約24,000公噸)之煤耗量。例如,可控監控點可為迴轉窯之轉速計及冷卻風機之風量計。中控系統12可依據煤耗模型產生迴轉窯之轉速及冷卻風機之風量之建議操作值。中控系統12可將迴轉窯之轉速及冷卻風機之風量之建議操作值傳送至水泥廠之顯示裝置,操作人員可依據顯示螢幕上顯示之建議操作值設定迴轉窯及冷卻風機。在一些實施例中,中控系統12亦可將迴轉窯之轉速及冷卻風機之風量之建議操作值分別傳送至迴轉窯及冷卻風機,迴轉窯及冷卻風機可分別依據建議操作值自動調整水泥生料量及煤耗量。
In addition, the tachometer and thermometer can be installed in the rotary kiln, the pressure sensor and thermometer can be installed in the kiln head cover, the tachometer can be installed in the kiln head exhaust fan, and the current sensor and air volume meter can be installed in the high temperature fan and cooling fan , the speedometer can be set in the grate cooler, and other monitoring points can be set in other key monitoring positions of the production line equipment. In some embodiments, the
在一些實施例中,中控系統12可預設使用煤耗模型產生建議操作值,若建議操作值超出其上下限,或當該些產線設備依據建議操作值進行運作會造成工況危機時,中控系統12可切換至依據經驗值產生建議操作值或由人工決定建議操作值。工況危機可包含溫度超出溫度上下限或壓力超出壓力上下限。
In some embodiments, the
第2圖係為煤耗系統1的操作方法200之流程圖。操作方法200包含步驟S202至S208,用以建立煤耗模型及使用煤耗模型產生建議操作值,進而使水泥廠之產線設備達成目標工況。任何合理的技術變更或是步驟調整都屬於本發明所揭露的範疇。步驟S202至S208的詳細內容如下所述:步驟S202:監控點101至10N獲得監控資料;步驟S204:中控系統12依據監控資料選定候選特徵集及建立煤耗模型;步驟S206:中控系統12依據煤耗模型產生監控點101至10N之可控
監控點之建議操作值;步驟S208:產線設備依據建議操作值進行運作以達成目標工況。
FIG. 2 is a flow chart of a
在步驟S202中,監控點101至10N以相同之預定時間間隔獲得監控資料。預定時間間隔可為30秒。在步驟S204中,中控系統12會選定候選特徵集及建立煤耗模型。候選特徵集可包含複數個候選特徵,例如水泥生料量、水泥熟料量、煤耗量、分解爐之入口之溫度、迴轉窯之轉速及冷卻風機之風量。中控系統12使用對應該些候選特徵之監控資料建立煤耗模型,及依據煤耗模型所產生之預測誤差判定是否更新候選特徵集中之候選特徵。步驟S204之詳細步驟如第3圖之流程圖所示,在後續段落會說明。在步驟S206中,中控系統12會以固定時間或不以固定時間產生可控監控點之建議操作值。固定時間可為10分鐘。中控系統12可將每個可控監控點之監控資料在其上下限範圍內進行調整以提供每個可控監控點之建議操作值,用以降低煤耗。例如,若目前水泥生料量為0.5公噸且水泥生料量之上下限範圍在每小時正負2公噸,中控系統12可建議將水泥生料量之建議操作值增加至1公噸,用以降低煤耗。每個可控監控點之監控資料的上下限範圍可以從經驗值獲得或在達成穩定工況的情況下從煤耗模型或其他模型計算得出。其他模型可為壓力模型或溫度模型。穩定工況可包含維持溫度於溫度上下限之內及維持壓力於壓力上下限之內。例如,若溫度上下限為1400℃至1200℃,中控系統12可調整溫度模型中之水泥生料量以判定水泥生料量之上下限範圍要維持在每小時正負2公噸之間才可維持溫度於1400℃至1200℃之間。在一些實施例中,若可控監控點的數量大於1,則中控系統12可針對每個可控監控點之建議操作值設定優先順序,及依據優先順序產生產線設備之建議操作值。操作人員可依據優先順序使用建議操作值設定該些產線設備,或該些產線設備可依據優先順序使用建議操作值進行運作。在步驟S308中,目標工況可
為穩定工況、降低煤耗、提升產量、或任兩者。
In step S202, the
第3圖係為第2圖中之操作方法的步驟S204之流程圖。步驟S204包含步驟S302至S312,步驟S302至S306用以建立煤耗模型,步驟S308至S312用以選定候選特徵集。任何合理的技術變更或是步驟調整都屬於本發明所揭露的範疇。步驟S302至S312的詳細內容如下所述:步驟S302:中控系統12接收複數個候選特徵作為候選特徵集;步驟S304:中控系統12依據候選特徵集使用監控資料更新複數組建模資料集;步驟S306:中控系統12依據該些組建模資料集建立煤耗模型;步驟S308:中控系統12將每組建模資料集中之更新資料輸入煤耗模型以產生預測誤差;步驟S310:中控系統12判定預測誤差是否大於誤差臨界值;若是,繼續步驟S312;若否,進入步驟S206;步驟S312:中控系統12更新候選特徵集。
FIG. 3 is a flowchart of step S204 of the operation method in FIG. 2 . Step S204 includes steps S302 to S312, where steps S302 to S306 are used to establish a coal consumption model, and steps S308 to S312 are used to select candidate feature sets. Any reasonable technical changes or step adjustments belong to the scope disclosed by the present invention. The details of steps S302 to S312 are as follows: step S302: the
在步驟S302中,每個候選特徵對應監控點101至10N之一者。例如,水泥生料量可對應生料秤;水泥熟料量可對應熟料秤;煤耗量可對應煤粉秤;分解爐之入口之溫度可對應分解爐之入口之溫度計;迴轉窯之轉速可對應迴轉窯之轉速計;及冷卻風機之風量可對應冷卻風機之風量計。在步驟S304中,每組建模資料集對應該些候選特徵之一者,中控系統12可將監控點101至10N之監控資料依序更新至對應組組建模資料集。例如,中控系統12可依據時間順序將所有水泥生料量儲存於第1組建模資料集;將所有水泥熟料量儲存於第2組建模
資料集;將所有分解爐之入口之溫度值儲存於第3組建模資料集,將所有迴轉窯之轉速值儲存於第4組建模資料集,及將所有冷卻風機之風量值儲存於第5組建模資料集;及將所有煤耗量儲存於目標煤耗資料集。在步驟S306中,中控系統12依據該些組建模資料集及複數個對應煤耗值訓練煤耗模型。例如,中控系統12可隨機從第1組至第5組建模資料集取出對應相同時間點之水泥生料量、水泥熟料量、分解爐之入口之溫度值、迴轉窯之轉速值及冷卻風機之風量值輸入煤耗模型以計算預測煤耗值,及調整煤耗模型中之複數個權重以使預測煤耗值趨近於對應相同時間點之煤耗值,進而建立煤耗模型。在建立煤耗模型後,中控系統12可依據候選特徵之重要性調整對應可控監控點之建議操作值的優先順序。候選特徵之重要性係相關於候選特徵在煤耗模型中之權重。當候選特徵之權重越大,則候選特徵之優先順序越高。當候選特徵之權重越小,則候選特徵之優先順序越低。建立煤耗模型之演算法可包含基於領域知識建構規則的(rule-based)演算法、線性/非線性演算法、集成式(ensemble)演算法、裝袋式(bagging)演算法、提升式(boosting)演算法、適應式學習演算法、其他機器學習演算法或上述演算法之結合。建模步驟S306可由第4圖所示之階層式建模實現,或由第5圖所示之限制式建模實現,在後續段落會說明。
In step S302, each candidate feature corresponds to one of the monitoring points 101 to 10N. For example, the amount of cement raw meal can correspond to the raw meal scale; the amount of cement clinker can correspond to the clinker scale; the coal consumption can correspond to the pulverized coal scale; the temperature at the inlet of the calciner can correspond to the thermometer at the inlet of the calciner; The tachometer corresponding to the rotary kiln; and the air volume of the cooling fan can correspond to the air volume meter of the cooling fan. In step S304 , each group of modeling data sets corresponds to one of the candidate features, and the
在步驟S308中,中控系統12將每組建模資料集中之更新資料輸入煤耗模型以產生預測煤耗值,及計算預測煤耗值及更新煤耗值之間之差值作為預測誤差。較小之預測誤差表示煤耗模型準確,煤耗模型預測得出之預測煤耗值接近真正之更新煤耗值。較大之預測誤差表示煤耗模型不準確,煤耗模型預測得出之預測煤耗值偏離真正之更新煤耗值。在步驟S310中,若預測誤差大於誤差臨界值,則需要更新候選特徵集(步驟S312)以重新訓練煤耗模型;若預測誤差不大於誤差臨界值,則不需要更新候選特徵集且可於後續程序中使用訓練完成
之煤耗模型。在一些實施例中,中控系統12可將候選特徵從該候選特徵集中移除以更新候選特徵集。在另一些實施例中,中控系統12可將另一候選特徵更新至該候選特徵集,另一候選特徵對應另一監控點。例如,另一候選特徵可為窯頭罩之壓力,另一監控點可為窯頭罩之壓力計。另一監控點可以是先前已設置於產線設備上但未使用之監控點,或是新設置於產線設備上之監控點。例如,可新增震動感測器至迴轉窯以增加監控點。
In step S308, the
第4圖係為第3圖中之一種建模步驟S306之流程圖。建模步驟S306包含步驟S402及S404,用以進行階層式建模以產生煤耗模型。任何合理的技術變更或是步驟調整都屬於本發明所揭露的範疇。步驟S402及S404的詳細內容如下所述:步驟S402:依據不可控監控點之對應候選特徵之對應建模資料集訓練第一模型以減小目標煤耗值及預測煤耗值之間之殘差;步驟S404:依據可控監控點之對應候選特徵之對應建模資料集訓練第二模型以減小殘差及預測殘差值之間之差值。 FIG. 4 is a flowchart of a modeling step S306 in FIG. 3 . The modeling step S306 includes steps S402 and S404 for performing hierarchical modeling to generate a coal consumption model. Any reasonable technical changes or step adjustments belong to the scope disclosed by the present invention. The details of steps S402 and S404 are as follows: Step S402: train the first model according to the corresponding modeling data set of the corresponding candidate features of the uncontrollable monitoring points to reduce the residual between the target coal consumption value and the predicted coal consumption value; step S404: Train the second model according to the corresponding modeling data set of the corresponding candidate features of the controllable monitoring points to reduce the difference between the residual and the predicted residual.
依照階層式建模產生之煤耗模型包含第一模型及第二模型,第一模型只包含不可控監控點之對應候選特徵,第二模型只包含可控監控點之對應候選特徵。在步驟S402中,由於第一模型只包含不可控監控點之對應候選特徵,訓練完成之第一模型產生之殘差已去除不可控監控點的影響。在步驟S404中,由於第一模型只包含可控監控點之對應候選特徵,訓練完成之第二模型可用以預測可控監控點的變化效果。在一些實施例中,中控系統12可在達成穩定工況的情況下將每個可控監控點之監控資料在其上下限範圍內調整以提供每個可控
監控點之建議操作值,進而降低預測煤耗值。
The coal consumption model generated according to the hierarchical modeling includes a first model and a second model, the first model only includes the corresponding candidate features of the uncontrollable monitoring points, and the second model only includes the corresponding candidate features of the controllable monitoring points. In step S402, since the first model only includes the corresponding candidate features of the uncontrollable monitoring points, the residuals generated by the trained first model have removed the influence of the uncontrollable monitoring points. In step S404, since the first model only includes the corresponding candidate features of the controllable monitoring points, the trained second model can be used to predict the change effect of the controllable monitoring points. In some embodiments, the
第5圖係為第3圖中之另一種建模步驟S306之流程圖。另一種建模步驟S306包含步驟S502及S504,用以進行限制式建模以產生煤耗模型。任何合理的技術變更或是步驟調整都屬於本發明所揭露的範疇。步驟S502及S504的詳細內容如下所述:步驟S502:依據監控點101至10N之對應候選特徵之該些組對應建模資料集訓練煤耗模型;步驟S504:依據目標產量使用煤耗模型計算監控點101至10N中之監控點101n之監控資料的上限及下限。
FIG. 5 is a flowchart of another modeling step S306 in FIG. 3 . Another modeling step S306 includes steps S502 and S504 for performing restricted modeling to generate a coal consumption model. Any reasonable technical changes or step adjustments belong to the scope disclosed by the present invention. The details of steps S502 and S504 are as follows: Step S502 : training the coal consumption model according to the sets of corresponding modeling data sets of the corresponding candidate features of the monitoring points 101 to 10N ; Step S504 : calculating the
在步驟S504中,目標產量為水泥熟料的預定目標產量。中控系統12可在訓練完成之煤耗模型中將水泥熟料之候選特徵的資料固定於預定目標產量,及在達成穩定工況的情況下分別調整每個可控監控點之監控資料以獲得每個可控監控點之監控資料的上下限。
In step S504, the target output is a predetermined target output of cement clinker. The
第1圖至第5圖之實施例依據產線設備之監控資料選取候選特徵集及建立煤耗模型,及使用煤耗模型提供產線設備之建議操作值以降低煤耗,減低水泥廠之運作費用,減少碳排放量,無須人工判斷產線設備之操作值即可快速正確地控制產線設備以產生水泥熟料。 The embodiments in Figures 1 to 5 select candidate feature sets and establish a coal consumption model based on the monitoring data of the production line equipment, and use the coal consumption model to provide the recommended operating values of the production line equipment to reduce coal consumption, reduce the operating cost of the cement plant, and reduce Carbon emissions, the production line equipment can be quickly and correctly controlled to produce cement clinker without manually judging the operating value of the production line equipment.
以上所述僅為本發明之較佳實施例,凡依本發明申請專利範圍所做之均等變化與修飾,皆應屬本發明之涵蓋範圍。 The above descriptions are only preferred embodiments of the present invention, and all equivalent changes and modifications made according to the scope of the patent application of the present invention shall fall within the scope of the present invention.
200:方法 200: Method
S202至S208:步驟 S202 to S208: Steps
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