Intelligent anti-blocking system, method and device for gas distribution plate of fluidized bed roaster

Abstract

The invention relates to the technical field of fluidized bed roamers, in particular to an intelligent anti-blocking system, method and device for a gas distribution plate of a fluidized bed roaster. Installing two groups of nozzle arrays on the side wall of the fluidized bed roaster, and adjusting the spraying direction of nozzles to be aligned with the small hole area of the distribution plate; high-precision temperature and pressure sensors are installed at the edge and corner blockage high-incidence area of the distribution plate, real-time and continuous monitoring of temperature-pressure data is achieved, and key supporting data are provided for system diagnosis and control. An integrated programmable logic controller system is introduced, when a sensor captures signals indicating that small holes are possibly blocked, such as abnormal temperature drop or obvious pressure rise, a PLC immediately judges the existence and position of blockage and triggers a preset blockage clearing program, a nozzle is driven to spray high-pressure pulse airflow, and blockages are efficiently cleared. The system has the characteristics of intelligence, automation, high efficiency and the like, can prevent the problem of blockage of the gas distribution plate of the fluidized bed roaster, and ensures high efficiency and stability of equipment operation.

Description

Technical Field

[0001] The invention relates to the technical field of fluidized bed roasting furnaces, and in particular to an intelligent anti-blocking system, method and device for a gas distribution plate of a fluidized bed roasting furnace. Background Art

[0002] Fluidized bed roasting furnace is a kind of equipment widely used in industrial production. It allows air to enter the furnace from the bottom of the furnace through the gas distribution plate. The charge particles are stirred by the air and tumble up and down to form a boiling state. In the boiling state, the ore particles are separated and fully contacted with the air, which improves the reaction rate and heat transfer effect of the roasting process. Among them, the gas distribution plate is the key functional unit in the fluidized bed roasting furnace. Its design usually adopts a porous flat plate structure, which can support solid materials and cause a certain resistance to the airflow passing through the distribution plate, so as to achieve uniform gas distribution. This distribution plate has been widely used in industry for its wide process adaptability and economic benefits.

[0003] Prior art 1, Chinese patent, application number 202210189303.7 discloses a boiling chamber air distribution structure, including a flower plate, a plurality of holes are evenly arranged on the flower plate, each hole of the feeding part of the flower plate is upwardly installed with a first hood, and the hole of the discharging part of the flower plate is upwardly installed with a second hood; the first hood includes a first cylinder, and the first cylinder is evenly provided with a plurality of upper air distribution holes along the circumference; each upper air distribution hole is inclined to form an upward air outlet direction with a high outside and a low inside; the second hood includes a second cylinder, and the second cylinder is evenly provided with a plurality of horizontal air distribution holes along the circumference; the first and second cylinders are respectively provided with a first and a second cap body at the top and bottom, and a boiling roasting furnace using the air distribution structure and a method of using the same are also disclosed. Although the roasting efficiency is improved by extending the air time of the ore and shortening the deposition time before entering the furnace, thereby significantly reducing energy consumption, the screen is prevented from being blocked by using invalid vibration, providing a basis for setting a screen at the furnace gas outlet to coarsely dry dust particles, thereby reducing the energy consumption of the dust removal process. However, there will be a problem of sieve hole blockage, which is easy to become a dust or material accumulation point, causing small hole blockage.

[0004] Prior art 2, Chinese patent, application number 202310306978.X discloses a continuous reforming mixed feed anti-blocking coiled tube heat exchanger, including a shell, which is connected to the mixed feed box through the lower tube box flange at the lower end of the shell, and the mixed feed box is divided by a tube sheet and a gas distribution plate, and is penetrated by the crude oil center tube, and gas nozzles are distributed on the gas distribution plate, and a liquid nozzle is arranged on the wall of the crude oil center tube above the gas distribution plate, and the liquid sprayed by the liquid nozzle and the gas sprayed by the gas nozzle can be cross-mixed evenly, so that the mixed material enters the heat exchange tube together. Although the gas nozzle allows the sprayed gas to be fully mixed with the liquid at a certain speed and then quickly enter the heat exchange tube, the mixed material stays in the lower tube box for a short time, and the liquid nozzle accelerates the liquid spray speed through the slot-type tangential swirl, so that the liquid is fully refined, and its droplets are fully mixed with the rapidly sprayed gas and then enter the heat exchange tube, avoiding the mixed material staying on the gas distribution plate for a long time and causing material crystallization and blockage. However, in actual industrial operations, the gas distribution plate is easily affected by factors such as material particle characteristics, fluid dynamics behavior, and improper operation and maintenance, which destroys the uniform distribution of gas in the furnace, resulting in a decrease in the processing capacity of the roasting furnace, an unnecessary increase in energy consumption, and degradation of product quality.

[0005] Prior art three, Chinese patent, application number 202110133546.4 discloses a method for stabilizing the temperature of a fluidized bed roasting furnace, including a fluidized bed roasting furnace body, a vibrating motor arranged in a silo, a feeding belt scale arranged below the silo and above the feeding port, an air inlet valve arranged at the front section of a fan of the fluidized bed roasting furnace, and a vent valve arranged at the rear end of the fan of the fluidized bed roasting furnace; the temperature control method includes: S1, start the control program and set a preset value; S2, obtain the real-time value of each parameter; S3, eliminate the abnormal situation of material cutoff; S4, adjust the feed amount based on temperature feedback; S5, adjust the feed amount based on the change of air volume. Although the feed amount is adjusted according to the temperature feedback, the feed amount is also adjusted according to the change of air volume that may occur during the production process of the fluidized bed roasting furnace, and the possible material cutoff caused by blockage is also considered, which is conducive to improving the stability of the temperature control of the fluidized bed roasting furnace. However, when the small holes of the distribution plate are clogged, manual cleaning or high-pressure air blowing and chemical cleaning from the bottom of the distribution plate are used. However, these methods have the disadvantages of complex operation, high cost, easy damage to the equipment structure and limited effect on stubborn blockages.

[0006] At present, the existing technologies 1, 2 and 3 have the problem that the gas distribution plate is easily affected by factors such as material particle characteristics, fluid dynamics behavior, and improper operation and maintenance, and the sieve holes are frequently blocked. Especially at the edges and corners of the distribution plate, due to the weak airflow, it is easy to become dust or material accumulation points, causing the small holes to be blocked, destroying the uniform distribution of gas in the furnace, resulting in a decrease in the processing capacity of the roasting furnace, an unwarranted increase in energy consumption, and degradation of product quality. After the small holes of the distribution plate are blocked, manual cleaning or high-pressure air blowing and chemical cleaning from the bottom of the distribution plate are used, but these methods have the problems of complex operation, high cost, easy damage to the equipment structure, and limited effect on stubborn blockage. At present, there is a lack of an efficient and accurate online monitoring technology to evaluate the state of the small holes of the distribution plate in real time, and the response mechanism to the blockage condition is lagging. Therefore, this study proposes an intelligent system integrating real-time monitoring and instant response, which can monitor the state of the small holes of the distribution plate with high precision and continuously, and automatically trigger an efficient clearing strategy when the distribution plate is blocked, so as to maintain the uniform distribution of the airflow and ensure the long-term stable operation of the boiling roasting furnace. Summary of the invention

[0007] The main purpose of the present invention is to provide an intelligent anti-clogging system, method and device for the gas distribution plate of a fluidized bed roasting furnace, so as to solve the problem that the gas distribution plate in the prior art is easily affected by factors such as material particle characteristics, fluid dynamics behavior, and improper operation and maintenance, and the sieve holes are frequently clogged, especially at the edges and corners of the distribution plate, where the airflow is weak and dust or material accumulation points are easily formed, causing the small holes to be clogged, thereby destroying the uniform distribution of gas in the furnace, resulting in a decrease in the processing capacity of the roasting furnace, an unwarranted increase in energy consumption, and degradation of product quality. After the small holes of the distribution plate are clogged, manual cleaning or high-pressure air blowing and chemical cleaning from the bottom of the distribution plate are used. However, these methods have the problems of complex operation, high cost, easy damage to the equipment structure, and limited effect on stubborn blockages.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] An intelligent anti-blocking system for a gas distribution plate of a fluidized bed roasting furnace, comprising: an intelligent detection sensor component, a PLC automatic control component and a side wall high-pressure air nozzle component;

[0010] Among them, the intelligent detection sensor component installs high-precision temperature and pressure sensors at the edges and corners of the distribution plate and other areas prone to clogging, to achieve real-time and continuous monitoring of temperature and pressure data in the areas prone to clogging, record the data, and transmit the collected data to the PLC automatic control component for analysis;

[0011] The PLC automatic control component is responsible for receiving signals from the sensor and quickly processing data to identify and determine the blockage of the small holes in the distribution plate. Once the blockage is confirmed, the PLC will automatically activate the nozzle and perform high-pressure pulse airflow cleaning operations to solve the blockage problem in a timely manner; and it is connected to the display screen to accurately transmit various data and status information to the display unit in real time;

[0012] The side wall high-pressure air nozzle assembly has nozzles evenly distributed on the side wall of the roasting furnace, and the spray direction is aimed at the small hole area of ​​the gas distribution plate; the efficient high-pressure pulse air source provides high-pressure pulse airflow, and responds quickly after receiving the command of the PLC automatic control component, providing strong wind support for the nozzle.

[0013] As a further improvement of the present invention, the PLC automatic control component comprises:

[0014] The data receiving module, the PLC automatic control component receives the temperature and pressure data collected by the intelligent detection sensor component in real time, pre-processes the received data for the next step of analysis and judgment; and visualizes the pre-processed data on the display screen;

[0015] The analysis and judgment module sets thresholds for temperature and pressure respectively according to historical data. When the temperature after pre-processing is lower than the threshold, a start signal is sent to the instruction sending module; if the temperature is higher than the threshold, the detection continues; when the pressure value after pre-processing is higher than the threshold, a start signal is sent to the instruction sending module; if the pressure value is lower than the threshold, the detection continues;

[0016] The command sending module, when receiving the start signal sent by the analysis and judgment module, warns on the display screen that the gas distribution plate may be blocked, and sends a start command to the side wall high-pressure air nozzle assembly; when receiving the stop signal sent by the blockage re-check module, the warning is cancelled, and a stop command is sent to the side wall high-pressure air nozzle assembly;

[0017] The blockage re-inspection module continues to collect temperature and pressure data in real time after sending instructions to the side wall high-pressure air nozzle assembly. When the collected temperature is higher than the preset threshold and the pressure value is lower than the preset threshold, a stop signal is sent to the instruction sending module.

[0018] As a further improvement of the present invention, the side wall high pressure air nozzle assembly comprises:

[0019] The instruction receiving module is responsible for receiving instructions from the PLC automatic control component and controlling the start or stop of the high-efficiency high-pressure pulse air source module according to the instruction information;

[0020] The side wall nozzle array module has nozzles evenly distributed on the side wall of the roasting furnace, and the spray direction is aimed at the small hole area of ​​the gas distribution plate. It has the ability to spray high-pressure pulse airflow to clean the blockages in the small holes.

[0021] The high-efficiency high-pressure pulse air source module, as the power core of the cleaning mechanism, can provide high-pressure pulse airflow up to 0.7MPa; under the command of the PLC automatic control component, the high-pressure pulse air source can respond quickly and provide strong wind support for the nozzle to ensure that the blockage is completely cleared.

[0022] To achieve the above object, the present invention also provides the following technical solutions:

[0023] An intelligent anti-blocking method for a gas distribution plate of a fluidized bed roasting furnace, comprising:

[0024] The temperature and pressure sensors installed in the potential blockage area of ​​the gas distribution plate perform continuous process monitoring of the temperature-pressure parameters in the roasting furnace and transmit the collected data to the PLC automatic control component in real time; at the same time, the PLC transmits the temperature-pressure data and system status information to the display screen to achieve intuitive and real-time monitoring of the system. Under normal operating conditions, the data recorded by the sensor is maintained within the preset safety threshold range;

[0025] When the small holes of the gas distribution plate are clogged due to dust or material accumulation, the airflow path is restricted, the gas resistance increases, and the local heat transfer efficiency decreases, which manifests as a significant increase in pressure and an abnormal decrease in temperature. The PLC automatic control component processes the signals from the temperature and pressure sensors through a preset algorithm. Once it detects that the temperature and pressure data exceed the safety threshold range, the system immediately determines the existence and location of the blockage.

[0026] After determining the location of the blockage, the PLC automatic control component will automatically trigger the corresponding nozzle to spray 0.7MPa high-pressure pulse airflow for 15 seconds, using its powerful impact force to effectively disintegrate and clear the blockage in the small hole; after the cleaning is completed, if the system monitors that the temperature-pressure data has returned to the standard operating range, indicating that the blockage has been cleared, the PLC automatic control component stops the nozzle spraying operation and the system returns to the real-time monitoring state; if the monitoring data still shows abnormalities, the system automatically restarts the cleaning process until the blockage is completely cleared and the sensor signal returns to stability.

[0027] As a further improvement of the present invention, the process of calculating the degree of pore blockage includes:

[0028] During the operation of the fluidized bed roasting furnace, the charge particles are in a boiling state under the action of gas injection, and the gas is in full contact with the solid charge. This is a typical gas-solid two-phase flow, and the particle behavior can be deeply analyzed and accurately predicted by computational fluid dynamics methods. The motion trajectory, velocity distribution and interaction of particles in a complex flow field are simulated to provide a basis for the design of key injection parameters of the gas distribution plate clearing system;

[0029] The flow of the gas phase is solved by the continuity equation, momentum equation and energy equation, and the turbulent pulsation is simulated by the Realizable ke turbulence model. The movement of particles is solved by Newton's second law, and the collision of particles is solved by the discrete element method.

[0030] As a further improvement of the present invention, the process of determining the blocking position includes:

[0031] The temperature and pressure data of the gas distribution plate are collected in real time through temperature sensors and pressure sensors. The safety threshold is preset according to historical data. The real-time collected temperature and pressure data are compared with the safety threshold. If the safety threshold is exceeded, an alarm is issued and the data is transmitted to the PLC automatic control component.

[0032] The PLC automatic control component will pre-process the temperature and pressure data to obtain a data set; build a model for determining the blockage position, train the blockage position model based on historical data, input real-time data into the model for simulating the blockage position, and determine the blockage position by comparing the maximum and minimum index values ​​under normal operating conditions with the index values ​​under simulated blockage conditions;

[0033] According to the judgment result, the data collected by the pressure sensor at the corresponding position is retrieved and analyzed to obtain the blockage position; the obtained blockage position is transmitted to the PLC automatic control component; the PLC automatic control component performs corresponding operations according to the blockage position.

[0034] As a further improvement of the present invention, the process of determining the blocking position model includes:

[0035] The collected temperature and pressure data are processed in a unified time frequency and outlier manner, and the data are processed uniformly into average values ​​within a period of time, and the data are stored according to the time series structure. For some data with abnormalities, the data are directly eliminated;

[0036] The blockage location model is trained based on historical data, and the pressure frequency index and standard deviation values ​​are collected under simulated blockage conditions. A blockage simulation test is performed using valves such as check valves. The blockage location is determined by comparing the maximum and minimum index values ​​under normal operating conditions with the index values ​​under simulated blockage conditions.

[0037] The blockage position determination model is debugged to ensure the temperature control accuracy and stability, and optimized as needed; real-time data is input into the blockage position determination model for determination, and the blockage position data is output.

[0038] To achieve the above object, the present invention also provides the following technical solutions:

[0039] An intelligent anti-blocking device for a gas distribution plate of a fluidized bed roasting furnace, comprising: an explosion-proof hole, an exhaust duct, a secondary air port, an ignition port, an overflow port, a discharge port, a gas distribution plate, a wind chamber, a wind chamber discharge port, solid particles, a wind port, a cooling pipe, a feed port and an upper roasting space;

[0040] Among them, an explosion-proof hole is opened at the top of the roasting furnace; an exhaust duct is opened on one side of the upper roasting space, and solid particles are below the upper roasting space. A secondary air inlet is opened on the outer wall of the solid particles on one side of the exhaust duct, and an ignition port is below the secondary air inlet. An overflow port is arranged below the ignition port, and a discharge port is arranged at the bottom of the outer wall of the solid particles, and the bottom of the solid particles is a gas distribution plate; a feed port is arranged on the side of the solid particles opposite to the exhaust duct, and a cooling pipe is arranged below the feed port; a funnel-shaped wind chamber is arranged below the solid particles, and the wind chamber exhaust port is directly below, and an air port is opened on one side of the feed port.

[0041] As a further improvement of the present invention, it comprises: a nozzle, a gas distribution plate, a wind chamber, a nozzle array, a temperature and pressure sensor and a fluidized bed roasting furnace shell;

[0042] Among them, on the shell of the fluidized bed roasting furnace above the gas distribution plate, a nozzle array is evenly distributed on its side wall, and temperature and pressure sensors are evenly installed on the gas distribution plate.

[0043] The present invention has a significant anti-clogging effect. It utilizes a nozzle array to spray a high-pressure pulse airflow to immediately clear the distribution plate, significantly improving the anti-clogging performance of the distribution plate, ensuring uniform distribution of gas in the fluidized bed, maintaining the heat transfer efficiency of the fluidized bed roasting furnace, and improving the efficiency, safety, and stability of the overall operation of the system; the distribution plate clearing function is automatically upgraded, and the PLC automatic control component receives real-time data from temperature and pressure sensors to automatically identify and process the blockage condition, significantly reducing the need for manual intervention, improving the intelligence level of distribution plate cleaning, and enhancing the operating efficiency and safety of the system; the equipment durability is greatly extended, and the systematic clearing and maintenance strategy effectively reduces the wear and damage of the gas distribution plate, extends the service life of key equipment components, and reduces the equipment update cycle and related capital investment; the operation and maintenance costs are significantly reduced, and the real-time monitoring and feedback of the temperature and pressure sensors ensure that the system can quickly respond to and handle blockage events, significantly reducing the downtime and maintenance operations caused thereby, significantly reducing the system operation and maintenance costs, and improving the overall economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 It is a functional module schematic diagram of an embodiment of the intelligent anti-blocking system for gas distribution plate of a fluidized bed roasting furnace of the present invention;

[0045] Figure 2A schematic diagram of the pulse cycle of a high-efficiency high-pressure pulse air source module of an embodiment of the intelligent anti-blocking system for a gas distribution plate of a fluidized bed roasting furnace of the present invention;

[0046] Figure 3 A schematic flow chart of the steps of an embodiment of the intelligent anti-blocking method for a gas distribution plate of a fluidized bed roasting furnace according to the present invention;

[0047] Figure 4 It is a schematic diagram of an embodiment of the intelligent anti-blocking method for the gas distribution plate of a fluidized bed roasting furnace of the present invention;

[0048] Figure 5 This is a basic principle diagram of solving the gas-solid two-phase coupling problem in one embodiment of the intelligent anti-blocking method for a gas distribution plate of a fluidized bed roasting furnace according to the present invention;

[0049] Figure 6 It is a structural diagram of an embodiment of the intelligent anti-blocking device for the gas distribution plate of a fluidized bed roasting furnace of the present invention;

[0050] Figure 7 This is a structural diagram of a nozzle executing the injection of high-pressure pulse airflow in one embodiment of the intelligent anti-blocking device for a gas distribution plate of a fluidized bed roasting furnace of the present invention;

[0051] Figure 8 It is a structural schematic diagram of an embodiment of an electronic device of the present invention;

[0052] Fig. 9 It is a schematic structural diagram of an embodiment of the storage medium of the present invention. DETAILED DESCRIPTION

[0053] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0054] The terms "first", "second" and "third" in the present invention are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Therefore, the features defined as "first", "second" and "third" can explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "multiple" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined. All directional indications (such as up, down, left, right, front, back...) in the embodiments of the present invention are only used to explain the relative position relationship, movement, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication also changes accordingly. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but optionally also includes steps or units that are not listed, or optionally also includes other steps or units inherent to these processes, methods, products or devices.

[0055] Reference to an "embodiment" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiment may be included in at least one embodiment of the present invention. The appearance of the phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0056] like Figure 1 As shown, this embodiment provides an embodiment of an intelligent anti-blocking system for a gas distribution plate of a fluidized bed roasting furnace. In this embodiment, the intelligent anti-blocking system for a gas distribution plate of a fluidized bed roasting furnace includes an intelligent detection sensor component, a PLC automatic control component and a side wall high-pressure air nozzle component;

[0057] Among them, the intelligent detection sensor component installs high-precision temperature and pressure sensors at the edges and corners of the distribution plate and other areas prone to clogging, to achieve real-time and continuous monitoring of temperature and pressure data in the areas prone to clogging, record the data, and transmit the collected data to the PLC automatic control component for analysis;

[0058] The PLC automatic control component is responsible for receiving signals from the sensor and quickly processing data to identify and determine the blockage of the small holes in the distribution plate. Once the blockage is confirmed, the PLC will automatically activate the nozzle and perform high-pressure pulse airflow cleaning operations to solve the blockage problem in a timely manner; and it is connected to the display screen to accurately transmit various data and status information to the display unit in real time;

[0059] The side wall high-pressure air nozzle assembly has nozzles evenly distributed on the side wall of the roasting furnace, and the spray direction is aimed at the small hole area of ​​the gas distribution plate; the efficient high-pressure pulse air source provides high-pressure pulse airflow, and responds quickly after receiving the command of the PLC automatic control component, providing strong wind support for the nozzle.

[0060] Preferably, the intelligent detection sensor component of this embodiment installs high-precision temperature and pressure sensors in areas prone to blockage, monitors the temperature and pressure data of these areas in real time and continuously, and records them; transmits the collected data to the PLC automatic control component for further analysis; the PLC receives the signal from the sensor, processes the data, identifies and determines the blockage of the small holes in the distribution plate; once the blockage is confirmed, the nozzle is automatically activated to perform the high-pressure pulse airflow cleaning operation; it is connected to the display screen to transmit data and status information in real time; the nozzles in the side wall high-pressure air nozzle assembly are evenly distributed on the side wall of the roasting furnace, aimed at the small hole area of ​​the gas distribution plate, and the high-efficiency high-pressure pulse air source provides high-pressure pulse airflow; it responds quickly after receiving the PLC command to provide strong wind support for the nozzle.

[0061] In summary, this embodiment improves the monitoring accuracy and timeliness of blockage risks, provides accurate data support for processing, realizes rapid response and automated processing of blockage problems, improves the operating efficiency and stability of the system, provides intuitive data display through the display screen, and facilitates operator monitoring and management, ensures the accuracy and effectiveness of cleaning operations, and powerful wind support can completely clear blockages, and the collaborative work with the PLC system improves the automation level of the overall system.

[0062] Furthermore, in the intelligent anti-blocking system of the gas distribution plate of the fluidized bed roasting furnace of this embodiment, the PLC automatic control component includes:

[0063] The data receiving module, the PLC automatic control component receives the temperature and pressure data collected by the intelligent detection sensor component in real time, pre-processes the received data for the next step of analysis and judgment; and visualizes the pre-processed data on the display screen;

[0064] The analysis and judgment module sets thresholds for temperature and pressure respectively according to historical data. When the temperature after pre-processing is lower than the threshold, a start signal is sent to the instruction sending module; if the temperature is higher than the threshold, the detection continues; when the pressure value after pre-processing is higher than the threshold, a start signal is sent to the instruction sending module; if the pressure value is lower than the threshold, the detection continues;

[0065] The command sending module, when receiving the start signal sent by the analysis and judgment module, warns on the display screen that the gas distribution plate may be blocked, and sends a start command to the side wall high-pressure air nozzle assembly; when receiving the stop signal sent by the blockage re-check module, the warning is cancelled, and a stop command is sent to the side wall high-pressure air nozzle assembly;

[0066] The blockage re-inspection module continues to collect temperature and pressure data in real time after sending instructions to the side wall high-pressure air nozzle assembly. When the collected temperature is higher than the preset threshold and the pressure value is lower than the preset threshold, a stop signal is sent to the instruction sending module.

[0067] Preferably, the data receiving module of the present embodiment receives the temperature and pressure data collected by the intelligent detection sensor component in real time, and pre-processes the received data, such as denoising, format conversion, etc., to facilitate data analysis; the pre-processed data is visualized on the display screen to facilitate operator monitoring; the analysis and judgment module sets the temperature and pressure thresholds according to historical data; the pre-processed data is analyzed in real time to determine whether the temperature and pressure exceed the thresholds; a signal to start or continue detection is sent to the instruction sending module according to the judgment result; the instruction sending module receives the start signal sent by the analysis and judgment module, and sends an early warning message to the display screen; sends a start instruction to the side wall high-pressure air nozzle assembly to deal with possible blockage; receives a stop signal sent by the blockage re-inspection module, cancels the early warning and sends a stop instruction to the side wall high-pressure air nozzle assembly; after sending the instruction to the side wall high-pressure air nozzle assembly, the blockage re-inspection module continues to collect temperature and pressure data in real time, determines whether the blockage is alleviated according to the collected data, and sends a stop signal to the instruction sending module to stop unnecessary operations.

[0068] To sum up, the data receiving module of this embodiment ensures the accuracy and completeness of the data, providing a reliable basis for data analysis; provides intuitive data display, and improves the monitoring efficiency and response speed of operators; the analysis and judgment module realizes real-time monitoring and early warning of temperature and pressure, and timely discovers potential problems; reduces false alarms and missed alarms, and improves the accuracy and reliability of the system; the instruction sending module responds to abnormal situations in a timely manner, reducing the impact of faults on the system; through early warning and instruction sending, the response speed and automation level of the system are improved; the blockage re-inspection module ensures that the operation of the side wall high-pressure air nozzle assembly is targeted, avoiding unnecessary energy consumption and wear, and through the re-inspection mechanism, improves the stability and reliability of the system and reduces the occurrence of misoperation.

[0069] Furthermore, in the intelligent anti-blocking system of the gas distribution plate of the fluidized bed roasting furnace of this embodiment, the side wall high-pressure air nozzle assembly includes:

[0070] The instruction receiving module is responsible for receiving instructions from the PLC automatic control component and controlling the start or stop of the high-efficiency high-voltage pulse air source module according to the instruction information;

[0071] The side wall nozzle array module has nozzles evenly distributed on the side wall of the roasting furnace, and the spray direction is aimed at the small hole area of ​​the gas distribution plate. It has the ability to spray high-pressure pulse airflow to clean the blockages in the small holes.

[0072] The high-efficiency high-pressure pulse air source module, as the power core of the cleaning mechanism, can provide high-pressure pulse airflow up to 0.7MPa; under the command of the PLC automatic control component, the high-pressure pulse air source can respond quickly and provide strong wind support for the nozzle to ensure that the blockage is completely cleared (the pulse cycle is as follows: Figure 2 shown).

[0073] Preferably, the instruction receiving module of this embodiment is responsible for receiving instructions from the PLC automatic control component, and controlling the start or stop of the high-efficiency high-pressure pulse air source according to the instruction information; the nozzles of the side wall blowing array module are evenly distributed on the side wall of the roasting furnace, and the injection direction is aligned with the small hole area of ​​the gas distribution plate, and it has the ability to spray high-pressure pulse airflow to clean blockages in the small holes; the high-efficiency high-pressure pulse air source module serves as the power core of the cleaning mechanism, and can provide a high-pressure pulse airflow of up to 0.7MPa, and can quickly respond to the instructions of the PLC automatic control component to provide strong wind support for the nozzle.

[0074] To sum up, the instruction receiving module of this embodiment realizes the precise control of the cleaning mechanism. Through the instructions of the PLC system, the cleaning process can be flexibly started or stopped to ensure that the cleaning operation is synchronized with the operating state of the roasting furnace, thereby improving the automation level and operating efficiency of the overall system; the side wall nozzle array module effectively solves the problem of blockage of the small holes in the gas distribution plate; the high-pressure pulse airflow can penetrate and remove the blockage, ensuring the uniform distribution of gas in the roasting furnace, thereby improving the stability and efficiency of the roasting process; the high-efficiency high-pressure pulse air source module provides powerful power support for the cleaning process; the high-pressure pulse airflow not only ensures the thorough removal of the blockage, but also improves the cleaning efficiency; at the same time, the rapid response capability enables the entire cleaning mechanism to flexibly respond to different cleaning needs, enhancing the adaptability and reliability of the system.

[0075] like Figure 3 As shown, this embodiment also provides an embodiment of a method for intelligently preventing blocking of a gas distribution plate of a fluidized bed roasting furnace. In this embodiment, the method for intelligently preventing blocking of a gas distribution plate of a fluidized bed roasting furnace is applied to the intelligent anti-blocking system for a gas distribution plate of a fluidized bed roasting furnace in the above embodiment. The method for intelligently preventing blocking of a gas distribution plate of a fluidized bed roasting furnace specifically includes the following steps:

[0076] Step S1: The temperature and pressure sensors installed in the potential blockage area of ​​the gas distribution plate perform continuous process monitoring of the temperature-pressure parameters in the roasting furnace, and transmit the collected data to the PLC automatic control component in real time; at the same time, the PLC transmits the temperature-pressure data and system status information to the display screen to realize intuitive and real-time monitoring of the system; under normal operating conditions, the data recorded by the sensor are maintained within the preset safety threshold range;

[0077] Among them, the PLC automatic control component introduces a dynamically adjusted response time formula:

[0078]

[0079] Where, T response Indicates the PLC response time after dynamic adjustment (unit: seconds), T base Indicates the basic response time, that is, the default response time when there is no temperature and pressure change (unit: second), K temp It represents the temperature change rate coefficient, which is used to adjust the effect of temperature change on response time. ΔT represents the temperature change (unit: Celsius). Δt represents the time interval (unit: seconds), that is, the time difference between two temperature measurements. K pressure It represents the pressure change rate coefficient, which is used to adjust the effect of pressure change on response time. ΔP represents the pressure change (unit: Pascal). Through this formula, the PLC can dynamically adjust its response time according to the real-time monitored temperature and pressure change rate, thereby improving processing efficiency while ensuring system safety.

[0080] Step S2: When the small holes of the gas distribution plate are blocked due to dust or material accumulation, the airflow path is restricted, the gas resistance increases, and the local heat transfer efficiency decreases, which is manifested as a significant increase in pressure and an abnormal decrease in temperature; the PLC automatic control component processes the signals from the temperature and pressure sensors through a preset algorithm. Once it is detected that the temperature and pressure data exceed the safety threshold range, the system immediately determines the existence and location of the blockage;

[0081] Step S3: After determining the location of the blockage, the PLC automatic control component will automatically trigger the corresponding nozzle to spray 0.7MPa high-pressure pulse airflow for 15 seconds, using its powerful impact force to effectively disintegrate and clear the blockage in the small hole; after the cleaning is completed, if the system monitors that the temperature-pressure data has returned to the standard operating range, indicating that the blockage has been cleared, the PLC automatic control component stops the nozzle spraying operation and the system returns to the real-time monitoring state; if the monitoring data still shows abnormalities, the system automatically restarts the cleaning process until the blockage is completely cleared and the sensor signal returns to stability.

[0082] Preferably, in step S1 of this embodiment, temperature and pressure sensors are installed in the potential blockage area, so that the temperature and pressure parameters in the roasting furnace can be monitored in real time; data is transmitted to the PLC automatic control component in real time, ensuring the timeliness and accuracy of the data; the PLC transmits the data to the display screen, realizing intuitive and real-time monitoring of the system; in step S2, the PLC automatic control component processes the sensor signal through a preset algorithm, and can accurately determine the existence and location of the blockage; when abnormal data is detected, corresponding processing is immediately performed, thereby improving the response speed of the system; in step S3, the PLC automatic control component automatically triggers the nozzle to spray high-pressure pulse airflow to effectively clear the blockage; after the cleaning is completed, the system determines whether to stop spraying according to the monitoring data to ensure that the blockage is completely cleared (for specific schematic diagrams, refer to the attached Figure 4 ).

[0083] In summary, this embodiment prevents the occurrence of blockage problems in advance and detects abnormal situations in time through real-time monitoring; improves the safety and stability of the system to ensure the normal operation of the roasting furnace; promptly detects and solves blockage problems to prevent the problem from further deteriorating; reduces production interruptions and equipment damage caused by blockages, and improves production efficiency; realizes automated processing of blockage problems, reduces manual intervention, and improves work efficiency, and ensures that blockage problems are resolved through continuous monitoring and automatic restart of the cleaning process.

[0084] Furthermore, the process of transmitting the collected data to the PLC automatic control component in real time in step S1 specifically includes the following steps:

[0085] S11: In the potential blockage area of ​​the gas distribution plate, the temperature and pressure sensors are designed as a distributed network. Each sensor node is responsible for monitoring the environmental parameters in a specific area and transmitting the data to the central control unit through an independent channel;

[0086] S12: Each sensor channel is equipped with a high-speed data acquisition module, which collects data at a sampling rate of thousands of times per second; multiple sensor channels work simultaneously, each collecting data and performing preliminary processing, and the central control unit uses parallel processing technology to simultaneously receive and process data from multiple channels;

[0087] S13: Each sensor channel is equipped with an automatic calibration function to calibrate the working status of the sensor in real time during the data collection process; the automatic calibration function detects and corrects the drift and error of the sensor; each sensor channel compresses the collected raw data in real time before the data is transmitted to the central control unit;

[0088] Among them, the real-time data compression formula is:

[0089] C(t)=AdaptiveQuantize(EnhancedWaveletTransform(D(t),W,H),Q(t))

[0090] Wherein, C(t) represents the compressed data sequence, which represents the compressed data at time t; D(t) represents the original data sequence, which represents the original sensor data at time t; EnhancedWaveletTransform represents the enhanced wavelet transform function, which is used to convert the original data from the time domain to the frequency domain and extract different frequency components; AdaptiveQuantize represents the adaptive quantization function, which is used to dynamically adjust the quantization step size according to the current data characteristics and reduce the data precision; W represents the wavelet basis matrix, which represents the wavelet basis function set used by the wavelet transform; H represents the high-pass filter matrix, which is used to extract high-frequency components in the wavelet transform; Q(t) represents the adaptive quantization step size matrix, which represents the dynamic quantization step size at time t.

[0091] The original data D(t) is subjected to enhanced wavelet transform and decomposed into components of different frequencies.

[0092]

[0093] In the formula, α j,k represents the wavelet coefficient, which represents the frequency component at scale j and position k, φ j,k represents the wavelet basis function, represents the wavelet function at scale j and position k, W T represents the wavelet basis matrix, which contains multiple wavelet basis functions, H represents the high-pass filter matrix, which is used to extract high-frequency components, J represents the maximum scale, represents the number of decomposition layers, and K represents the number of positions at each scale.

[0094] Adaptive Quantize: Adaptive quantization is performed on the coefficients after enhanced wavelet transform, and the quantization step size is dynamically adjusted according to the current data characteristics;

[0095]

[0096] Where Q(t) represents the adaptive quantization step size matrix, which represents the dynamic quantization step size at time t, Q(t) j,k represents the quantization step at scale j and position k, round represents the rounding function, and the wavelet coefficient is divided by the adaptive quantization step and then rounded; through the above steps, the original data D(t) is converted into compressed data C(t), realizing more complex and efficient real-time data compression.

[0097] Preferably, in step S11 of this embodiment, the distributed sensor network is used. Each sensor node is responsible for monitoring the environmental parameters of a specific area through the distributed sensor network, ensuring comprehensive coverage and accurate monitoring of potential congestion areas; each sensor node works independently and does not interfere with each other, reducing data conflicts and delays, and improving the stability and reliability of data acquisition. Step S12 high-speed data acquisition and parallel processing, the high-speed data acquisition module performs data acquisition at a sampling rate of thousands of times per second, ensuring the meticulousness and real-time nature of the data, and being able to capture tiny environmental changes; multiple sensor channels work simultaneously, each collecting data and performing preliminary processing, and the central control unit simultaneously receives and processes data from multiple channels through parallel processing technology, greatly improving the efficiency of data acquisition and processing. Step S13 automatic calibration and data compression, each sensor channel is equipped with an automatic calibration function, which can calibrate the working state of the sensor in real time during the data acquisition process, detect and correct the drift and error of the sensor, and ensure the accuracy and reliability of the collected data; before the data is transmitted to the central control unit, each sensor channel compresses the collected raw data in real time, and adopts an efficient compression algorithm, which can significantly reduce the bandwidth requirements for data transmission without losing data accuracy, and improve the efficiency of data transmission.

[0098] In summary, the multi-channel parallel data acquisition technology of this embodiment realizes comprehensive monitoring of potential congestion areas through a distributed sensor network; high-speed data acquisition and parallel processing technology ensure the real-time nature of data and the efficiency of processing; automatic calibration function and data compression technology ensure the accuracy of data and the efficiency of transmission; it provides high-quality, real-time data support for PLC automatic control components, ensuring the stable operation of the system and the reliability of intelligent anti-congestion processing.

[0099] Furthermore, the process of calculating the pore blockage degree in step S2 specifically includes the following steps:

[0100] During the operation of the fluidized bed roasting furnace, the charge particles are in a boiling state under the action of gas injection, and the gas is in full contact with the solid charge. This is a typical gas-solid two-phase flow, and the particle behavior can be deeply analyzed and accurately predicted by computational fluid dynamics methods. The motion trajectory, velocity distribution and interaction of particles in a complex flow field are simulated to provide a basis for the design of key injection parameters of the gas distribution plate clearing system;

[0101] Step S21: Solve the flow of the gas phase through the continuity equation, momentum equation and energy equation, and simulate the turbulent pulsation through the Realizable ke turbulence model, the expression of which is as follows:

[0102]

[0103]

[0104] Step S22: The motion of the particles is solved by Newton's second law, and the expression is as follows:

[0105]

[0106] where F P is the drag force on the particle, which is expressed as follows:

[0107]

[0108] Step S23: Solve the collision of particles by discrete element method, and the expression is as follows:

[0109]

[0110] In the formula, α g represents the gas volume fraction, ρ g represents the gas density, represents the gas velocity vector, P represents the pressure, τ represents the stress tensor, represents the gravitational acceleration vector, represents the reaction force of the particle on the gas, C p,g represents the specific heat capacity of the gas, T g represents the gas temperature, λ represents the thermal conductivity, Φ p represents the energy transfer from particles to gas, k represents the turbulent kinetic energy, and u j Indicates the gas dynamic viscosity, μ t represents the turbulent viscosity, σ k Prandtl number, G, representing turbulent kinetic energy k represents the turbulent kinetic energy generation term, ε represents the turbulent kinetic energy dissipation rate, Y m represents the contribution of pulsation expansion in compressible turbulence, σ ε The Prandtl number represents the turbulent kinetic energy dissipation rate, C1 and C2 represent empirical constants, S represents the modulus of the strain rate tensor, ν represents the kinematic viscosity, and m p represents the particle mass, represents the particle velocity vector, represents the drag force, represents gravity, represents the virtual mass force, represents the pressure gradient force, represents the collision force, τ r is the drag time constant, ρ p represents the particle density, d p represents the particle diameter, C D Re is the drag coefficient, p represents the particle Reynolds number, K represents the collision stiffness coefficient, χ represents the restitution coefficient, represents the collision normal unit vector, m1 and m2 represent the masses of the two colliding particles, and η represents the collision overlap coefficient. represents the relative velocity vector of the two particles, Represents the position vector of the two colliding particles.

[0111] Preferably, this embodiment couples the solution of fluid and particles, analyzes the gas flow characteristics and particle characteristics, and accurately predicts the location and degree of blockage of the small holes in the distribution plate. Optimize the design of key parameters of the spray cleaning system, including the precise setting of the spray speed, the diameter of the air outlet hole, and the spray time, to ensure that the cleaning mechanism can efficiently and accurately remove the small hole blockage and maintain the stability and continuity of the boiling roasting furnace (see the attached schematic for the specific principle diagram). Figure 5 ).

[0112] In summary, this embodiment uses computational fluid dynamics methods to deeply analyze and accurately predict particle behavior, simulate the motion trajectory, velocity distribution and interaction of particles in a complex flow field; provide a basis for the design of key injection parameters of the gas distribution plate clearing system, and ensure the effectiveness and pertinence of subsequent clearing work; improve the understanding of the flow state of particles inside the boiling roasting furnace, which is helpful to prevent and deal with the problem of small hole blockage; provide a scientific basis for optimizing the clearing system, reduce blind operation and waste of resources; solve the flow of gas phase through the continuity equation, momentum equation and energy equation, simulate turbulent pulsation, and obtain the gas phase flow characteristics; reveal the flow law of gas phase in the boiling roasting furnace, which is useful for analyzing particles It provides a basis for the interaction with gas; helps to optimize gas distribution and improve gas utilization efficiency; solves the movement of particles through Newton's second law to obtain the movement state of particles in the flow field; takes into account the influence of multiple forces such as drag, gravity, Magnus force, pressure gradient force and collision force; deeply understands the movement law of particles in the boiling roasting furnace, and provides a basis for predicting the location of particle blockage; helps to optimize the particle processing process and improve production efficiency; solves the collision of particles through the discrete element method to obtain the interaction force between particles; reveals the collision law of particles in the flow field, which provides a basis for analyzing the cause of particle blockage; helps to optimize particle distribution and flow state and reduce the risk of blockage.

[0113] Furthermore, the process of determining the blocking position in step S2 specifically includes the following steps:

[0114] Step S24: The temperature and pressure data of the gas distribution plate are collected in real time through the temperature sensor and the pressure sensor, and the safety threshold is preset according to the historical data. The temperature and pressure data collected in real time are compared with the safety threshold. If the safety threshold is exceeded, an alarm is issued and the data is transmitted to the PLC automatic control component;

[0115] Step S25: The PLC automatic control component pre-processes the temperature and pressure data to obtain a data set; constructs a blockage position determination model, trains the blockage position model based on historical data, inputs real-time data into the blockage position determination model for simulation, and determines the blockage position by comparing the maximum and minimum index values ​​under normal operating conditions with the index values ​​under simulated blockage conditions;

[0116] Step S26: according to the judgment result, retrieve the data collected by the pressure sensor at the corresponding position, analyze it and obtain the blockage position; transmit the obtained blockage position to the PLC automatic control component; the PLC automatic control component performs corresponding operations according to the blockage position.

[0117] Preferably, in step S24 of this embodiment, the temperature and pressure data of the gas distribution plate are collected in real time through temperature sensors and pressure sensors to ensure the accuracy and timeliness of the data; a safety threshold is preset according to historical data, and the real-time data is compared with the threshold to detect abnormal situations in time; when the data exceeds the safety threshold, an alarm is issued and the data is transmitted to the PLC automatic control component, thereby realizing a rapid response to potential problems; in step S25, the PLC automatic control component pre-processes the temperature and pressure data to obtain a data set, constructs a model for determining the blockage position, and trains the model through historical data to improve the accuracy and reliability of the model; the real-time data is input into the blockage position determination model for simulation, and the blockage position can be accurately determined by comparing the indicator values ​​under normal operation and simulated blockage conditions; in step S26, according to the judgment result, the pressure sensor data of the corresponding position is retrieved for analysis to further confirm the blockage position; the blockage position is transmitted to the PLC automatic control component, and the system performs corresponding operations according to the blockage position, thereby realizing a rapid response and processing to the blockage problem and reducing the production interruption time.

[0118] In summary, this embodiment improves the monitoring capability of the working status of the gas distribution plate, which helps to prevent and deal with blockage problems; through real-time data feedback, it provides a decision-making basis for the PLC automatic control component, which helps to achieve intelligent management; it realizes intelligent judgment of blockage problems and improves judgment efficiency and accuracy; through model training and optimization, it continuously improves the intelligence level of the system and provides strong support for production; it improves production efficiency and product quality and reduces losses caused by blockage problems; through intelligent management, it realizes comprehensive monitoring and optimization of the production process and enhances the competitiveness of the enterprise.

[0119] Furthermore, the process of determining the blocking location model in step S25 specifically includes the following steps:

[0120] Step S251: performing time frequency and outlier processing on the collected temperature and pressure data, uniformly processing the data into an average value within a period of time, and storing the data according to the time series structure. For some data with abnormalities, the data is directly removed;

[0121] Step S252: training a blockage position model based on historical data, collecting pressure frequency index and standard deviation value under simulated blockage conditions, and performing blockage simulation tests using valves such as check valves; and determining the blockage position by comparing the maximum and minimum index values ​​under normal operating conditions with the index values ​​under simulated blockage conditions;

[0122] Step S253: debug the blockage position determination model to ensure the temperature control accuracy and stability, and optimize as needed; input the real-time data into the blockage position determination model for determination, and output the blockage position data.

[0123] Preferably, step S251 of this embodiment unifies the temperature and pressure data at different time points to the same time frequency to ensure the comparability and consistency of the data; identifies and eliminates abnormal data points to prevent abnormal data from interfering with the analysis; uniformly processes the data into an average value over a period of time to reduce data fluctuations and improve data stability and reliability; stores data according to a time series structure to facilitate time series analysis and model training; uses valves such as check valves to perform blockage simulation tests to collect pressure frequency index and standard deviation values ​​under simulated blockage conditions; step S252 trains the blockage position model based on historical data so that the model can learn the data feature differences between normal operation and identification of blockage conditions; determines the blockage position by comparing the maximum and minimum index values ​​under normal operation conditions with the index values ​​under simulated blockage conditions; step S253 debugs the blockage position determination model to ensure the temperature control accuracy and stability of the model; optimizes the model according to actual needs to improve the prediction accuracy and robustness of the model; inputs real-time data into the blockage position determination model for judgment, and outputs the blockage position data.

[0124] In summary, this embodiment improves the efficiency and accuracy of data processing, improves the accuracy and reliability of the blockage location model through simulation testing and data training; provides an effective diagnostic tool for blockage problems in actual production, and helps to promptly discover and deal with blockage problems; improves the practicability and accuracy of the model through debugging and optimization, and provides strong support for actual production; realizes real-time monitoring and judgment of blockage problems, and helps to reduce production interruption time and maintenance costs.

[0125] like Figure 6As shown, this embodiment also provides an embodiment of an intelligent anti-blocking device for a gas distribution plate of a fluidized bed roasting furnace. In this embodiment, the intelligent anti-blocking device for a gas distribution plate of a fluidized bed roasting furnace is applied to the intelligent anti-blocking system for a gas distribution plate of a fluidized bed roasting furnace in the above embodiment. The intelligent anti-blocking device for a gas distribution plate of a fluidized bed roasting furnace comprises: an explosion-proof hole 1, an exhaust duct 2, a secondary air port 3, an ignition port 4, an overflow port 5, a discharge port 6, a gas distribution plate 7, a wind chamber 8, a wind chamber discharge port 9, solid particles 10, a wind port 11, a cooling pipe 12, a feed port 13 and an upper roasting space 14;

[0126] Among them, the explosion-proof hole 1 is opened at the top of the roasting furnace; an exhaust duct 2 is opened on one side of the upper roasting space 14, and solid particles 10 are arranged below the upper roasting space 14. A secondary air port 3 is opened on the outer wall of the solid particles 10 on one side of the exhaust duct 2, and an ignition port 4 is arranged below the secondary air port 3. An overflow port 5 is arranged below the ignition port 4. A discharge port 6 is opened at the bottom of the outer wall of the solid particles 10, and a gas distribution plate 7 is arranged at the bottom of the solid particles 10; a feed port 13 is arranged on the side of the solid particles 10 opposite to the exhaust duct 2, and a cooling pipe 12 is arranged below the feed port 13; a funnel-shaped wind chamber 8 is arranged below the solid particles 10, and an air chamber exhaust port 9 is arranged directly below, and a wind port 11 is opened on one side of the feed port 13;

[0127] Preferably, in this embodiment, the fuel is ignited through the ignition port to generate heat; the air enters the furnace through the wind chamber and the air port, passes through the gas distribution plate, and fully contacts with the solid particles in the upper roasting space to achieve heat transfer; the furnace gas is discharged through the exhaust duct, and the air intake of the secondary air port is adjusted as needed; the pressure in the furnace is controlled by the explosion-proof hole; after the processing is completed, the solid particles are discharged through the discharge port.

[0128] In summary, the explosion-proof hole of this embodiment can automatically open and release the internal pressure when the pressure in the furnace increases abnormally, thereby preventing the equipment from being damaged due to overpressure; ensuring the safe operation of the roasting furnace and preventing safety accidents caused by excessive pressure; the waste gas or excess heat generated in the furnace is discharged through the exhaust duct to maintain the temperature and atmosphere in the furnace; ensuring the stability of the environment in the furnace and improving the heating efficiency and product quality; during the heating process, the air intake of the secondary air port is adjusted as needed to promote the chemical reaction in the furnace or adjust the atmosphere, improve the flexibility and controllability of the heating process, and optimize the heating effect; ignite the fuel through the ignition port to generate heat and provide a heating source for the solid particles; when there is too much material in the furnace, the material can be discharged through the overflow port to Maintain material balance in the furnace; prevent excessive material accumulation resulting in uneven heating or equipment damage; after processing, the solid particles are discharged from the furnace through the discharge port, realizing continuous or intermittent processing of solid particles and improving production efficiency; the feed port is used to feed the solid particles to be processed into the furnace, realizing continuous or intermittent feeding of solid particles and ensuring the continuity of the production process; the cooling pipe is used to cool the heated solid particles or other components in the furnace to prevent overheating or damage; protect equipment safety and extend service life; the funnel-shaped wind chamber and wind chamber exhaust port provide space for gas flow in the furnace, and are connected to the gas distribution plate through the wind port to control the gas flow and pressure, ensure the stability and controllability of the gas flow in the furnace, and improve heating efficiency.

[0129] Furthermore, if Figure 7 As shown, in the intelligent anti-blocking device for the gas distribution plate of the fluidized bed roasting furnace of this embodiment, the nozzle performs the operation of spraying high-pressure pulse airflow, including: a gas distribution plate 7, a wind chamber 8, a nozzle array 15, a temperature and pressure sensor 16 and a fluidized bed roasting furnace shell 17;

[0130] Among them, on the fluidized bed roasting furnace shell 17 above the gas distribution plate 7, a nozzle array 15 is evenly distributed on its side wall, and temperature and pressure sensors 16 are evenly installed on the gas distribution plate 7.

[0131] Preferably, the temperature and pressure sensor 16 installed on the gas distribution plate 7 in this embodiment continuously monitors the temperature-pressure parameters in the roasting furnace. When it is detected that the 7 small holes of the gas distribution plate are blocked due to dust or material accumulation, it manifests as a significant increase in pressure and an abnormal drop in temperature. Once it is detected that the temperature and pressure data exceed the safety threshold range, the existence and position of the blockage are immediately judged and the blockage position is determined. The corresponding nozzle is automatically triggered to clear the blockage in the small hole with its high-pressure pulse airflow. After the cleaning is completed, the temperature-pressure data is monitored to return to the standard operating range, indicating that the blockage has been cleared, then the nozzle spraying operation is stopped and the system returns to the real-time monitoring state. If the monitoring data still shows abnormalities, the system automatically restarts the cleaning process until the blockage is completely cleared and the sensor signal returns to stability.

[0132] To sum up, the gas distribution plate 7 of this embodiment, as the core component of gas distribution, is responsible for evenly distributing the airflow into the roasting furnace, ensuring that the material can be evenly heated and roasted, improving the roasting efficiency and product quality, and avoiding local overheating or insufficient roasting; the nozzle array 15 is automatically triggered according to the sensor signal to spray high-pressure pulse airflow to accurately remove blockages, realizing an intelligent and automated cleaning process, reducing manual intervention and downtime, and improving production efficiency and safety; the temperature and pressure sensor 16 monitors the temperature and pressure changes of the gas distribution plate 7 and its surrounding environment in real time, and detects blockages in time; it provides accurate monitoring data, provides a reliable basis for timely detection and accurate cleaning of blockages, and effectively prevents production failures and safety hazards caused by blockages.

[0133] like Figure 8 As shown, this embodiment provides an embodiment of an electronic device. In this embodiment, the electronic device 18 includes a processor 181 and a memory 182 coupled to the processor 181.

[0134] The memory 182 stores program instructions for implementing the intelligent anti-blocking method for the gas distribution plate of the fluidized bed roasting furnace of any of the above-mentioned embodiments.

[0135] The processor 181 is used to execute the program instructions stored in the memory 182 to carry out the layout of the intelligent anti-blocking system of the gas distribution plate of the boiling roasting furnace.

[0136] The processor 181 may also be referred to as a CPU (Central Processing Unit). The processor 181 may be an integrated circuit chip having signal processing capabilities. The processor 181 may also be a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components. The general-purpose processor may be a microprocessor or the processor may also be any conventional processor, etc.

[0137] Further, Fig. 9This is a schematic diagram of the structure of a storage medium of an embodiment of the present application. The storage medium 19 of the embodiment of the present application stores program instructions 191 that can implement all the above methods, wherein the program instructions 191 can be stored in the above storage medium in the form of a software product, including several instructions for enabling a computer device (which can be a personal computer, server, or network device, etc.) or a processor to execute all or part of the steps of the methods described in each embodiment of the present application. The aforementioned storage medium includes: various media that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, or terminal devices such as a computer, a server, a mobile phone, and a tablet.

[0138] In the several embodiments provided by the present invention, it should be understood that the disclosed systems, devices and methods can be implemented in other ways. For example, the device embodiments described above are only schematic, for example, the division of units is only a logical function division, and there may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interfaces, devices or units, which can be electrical, mechanical or other forms.

[0139] In addition, each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above integrated unit may be implemented in the form of hardware or in the form of software functional units. The above is only an implementation mode of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly used in other related technical fields, is also included in the patent protection scope of the present invention.

[0140] The specific implementation methods of the invention are described in detail above, but they are only examples, and the invention is not limited to the specific implementation methods described above. For those skilled in the art, any equivalent modification or substitution of the invention is also within the scope of the invention, therefore, the equalization, modification, improvement, etc. made without departing from the spirit and principle of the invention should be included in the scope of the invention.

Claims

1. An intelligent anti-blocking system for a gas distribution plate of a fluidized bed roasting furnace, the intelligent anti-blocking system for a gas distribution plate of a fluidized bed roasting furnace comprising: Intelligent detection sensor components are used to install temperature and pressure sensors at the edges and corners of the distribution plate that are prone to blockage, to achieve real-time and continuous monitoring of temperature and pressure data in the areas prone to blockage, record data, and transmit the collected data to the PLC automatic control component for analysis; The PLC automatic control component is used to receive signals from the sensor and perform data processing to identify and determine the blockage of the small holes in the distribution plate. Once the blockage is confirmed, the PLC will automatically activate the nozzle and perform high-pressure pulse airflow cleaning operations to solve the blockage problem in a timely manner; And connected to the display screen, transmitting various data and status information to the display unit in real time and accurately; Side wall high pressure air nozzle assembly, used for nozzles evenly distributed on the side wall of the roasting furnace, with the spray direction aimed at the small hole area of ​​the gas distribution plate; The efficient high-pressure pulse air source provides high-pressure pulse airflow, responds quickly after receiving instructions from the PLC automatic control component, and provides strong wind support for the nozzle.

2. The intelligent anti-blocking system for gas distribution plate of fluidized bed roasting furnace according to claim 1 is characterized in that: PLC automatic control components, including: The data receiving module is used for the PLC automatic control component to receive the temperature and pressure data collected by the intelligent detection sensor component in real time, pre-process the received data for the next step of analysis and judgment; and visualize the pre-processed data on the display screen; The analysis and judgment module is used to set thresholds for temperature and pressure respectively according to historical data. When the temperature is lower than the threshold after pre-processing, a start signal is sent to the instruction sending module; if the temperature is higher than the threshold, the detection continues; when the pressure value is higher than the threshold after pre-processing, a start signal is sent to the instruction sending module; if the pressure value is lower than the threshold, the detection continues; The command sending module is used to, upon receiving the start signal sent by the analysis and judgment module, warn on the display screen that the gas distribution plate may be blocked, and send a start command to the side wall high-pressure air nozzle assembly; upon receiving the stop signal sent by the blockage recheck module, cancel the warning and send a stop command to the side wall high-pressure air nozzle assembly; The blockage re-check module is used to continue to collect temperature and pressure data in real time after sending instructions to the side wall high-pressure air nozzle assembly. When the collected temperature is higher than the preset threshold and the pressure value is lower than the preset threshold, a stop signal is sent to the instruction sending module.

3. The intelligent anti-blocking system for gas distribution plate of fluidized bed roasting furnace according to claim 1 is characterized in that: Side wall high pressure air nozzle assembly, including: The instruction receiving module is used to receive instructions from the PLC automatic control component and control the start or stop of the high-efficiency high-pressure pulse wind source module according to the instruction information; The side wall nozzle array module is used to evenly distribute the nozzles on the side wall of the roasting furnace, aiming the spray direction at the small hole area of ​​the gas distribution plate, and has the ability to spray high-pressure pulse airflow to clean the blockage of the small holes; The high-efficiency high-pressure pulse air source module is used to respond to the high-pressure pulse air source under the instruction of the PLC automatic control component to provide wind support for the nozzle.

4. A method for intelligently preventing the gas distribution plate of a fluidized bed roasting furnace from being blocked, which is applied to the intelligent system for preventing the gas distribution plate of a fluidized bed roasting furnace as claimed in any one of claims 1 to 3, characterized in that: The intelligent anti-blocking method for the gas distribution plate of the fluidized bed roasting furnace comprises: The temperature and pressure sensors installed in the potential blockage area of ​​the gas distribution plate perform continuous process monitoring of the temperature-pressure parameters in the roasting furnace and transmit the collected data to the PLC automatic control component in real time; at the same time, the PLC transmits the temperature-pressure data and system status information to the display screen to achieve intuitive and real-time monitoring of the system; under normal operating conditions, the data recorded by the sensor is maintained within the preset safety threshold range; When the small holes of the gas distribution plate are clogged due to dust or material accumulation, the PLC automatic control component processes the signals from the temperature and pressure sensors through a preset algorithm, detects that the temperature and pressure data exceed the safety threshold range, and determines the existence and location of the blockage; After determining the location of the blockage, the PLC automatic control component will automatically trigger the corresponding nozzle to spray high-pressure pulse airflow to clear the blockage in the small hole; after cleaning, if the monitored temperature-pressure data returns to the standard operating range, indicating that the blockage has been cleared, the PLC automatic control component stops the nozzle spraying operation and the system returns to real-time monitoring status; if the monitoring data still shows abnormalities, the system automatically restarts the cleaning process until the blockage is completely cleared and the sensor signal returns to stability.

5. The intelligent anti-blocking method for the gas distribution plate of a fluidized bed roasting furnace according to claim 4 is characterized in that: The process of calculating the degree of pore blockage includes: Simulate the motion trajectory, velocity distribution and interaction of particles in complex flow fields to provide a basis for the design of key injection parameters of the gas distribution plate clearing system; The flow of the gas phase is solved by the continuity equation, momentum equation and energy equation, and the turbulent pulsation is simulated by the Realizable ke turbulence model; the movement of particles is solved by Newton's second law, and the collision of particles is solved by the discrete element method.

6. The intelligent anti-blocking method for the gas distribution plate of a fluidized bed roasting furnace according to claim 4 is characterized in that: The process of determining the blocking location includes: The temperature and pressure data of the gas distribution plate are collected in real time through temperature sensors and pressure sensors. The safety threshold is preset according to historical data. The real-time collected temperature and pressure data are compared with the safety threshold. If the safety threshold is exceeded, an alarm is issued and the data is transmitted to the PLC automatic control component. The PLC automatic control component will pre-process the temperature and pressure data to obtain a data set; build a model for determining the blockage position, train the blockage position model based on historical data, input real data into the model for simulating the blockage position, and determine the blockage position by comparing the maximum and minimum index values ​​under normal operating conditions with the index values ​​under simulated blockage conditions; According to the judgment result, the data collected by the pressure sensor at the corresponding position is retrieved and analyzed to obtain the blockage position; the obtained blockage position is transmitted to the PLC automatic control component; the PLC automatic control component performs corresponding operations according to the blockage position.

7. The intelligent anti-blocking method for the gas distribution plate of a fluidized bed roasting furnace according to claim 6 is characterized in that: The process of determining the blocking location model includes: The collected temperature and pressure data are processed in a unified time frequency and outlier manner, and the data are processed uniformly into average values ​​within a period of time, and the data are stored according to the time series structure. For some data with abnormalities, the data are directly eliminated; The blockage location model is trained based on historical data, the pressure frequency index and standard deviation values ​​are collected under simulated blockage conditions, and a blockage simulation test is performed using a valve; and the blockage location is determined by comparing the maximum and minimum index values ​​under normal operating conditions with the index values ​​under simulated blockage conditions; The blockage position determination model is debugged to ensure the temperature control accuracy and stability, and optimized as needed; real-time data is input into the blockage position determination model for determination, and the blockage position data is output.

8. An intelligent anti-blocking device for a gas distribution plate of a fluidized bed roasting furnace, which is applied to the intelligent anti-blocking system for a gas distribution plate of a fluidized bed roasting furnace as claimed in any one of claims 1 to 3, characterized in that: The intelligent anti-blocking device for the gas distribution plate of the fluidized bed roasting furnace comprises: an explosion-proof hole, an exhaust duct, a secondary air port, an ignition port, an overflow port, a discharge port, a gas distribution plate, a wind chamber, a wind chamber discharge port, solid particles, a wind port, a cooling pipe, a feed port and an upper roasting space; Among them, an explosion-proof hole is opened at the top of the roasting furnace; an exhaust duct is opened on one side of the upper roasting space, and solid particles are below the upper roasting space. A secondary air inlet is opened on the outer wall of the solid particles on one side of the exhaust duct, and an ignition port is below the secondary air inlet. An overflow port is arranged below the ignition port, and a discharge port is arranged at the bottom of the outer wall of the solid particles. The bottom of the solid particles is a gas distribution plate; a feed port is arranged on the side opposite to the exhaust duct of the solid particles, and a cooling pipe is arranged below the feed port.

9. The intelligent anti-blocking device for the gas distribution plate of a fluidized bed roasting furnace according to claim 8, characterized in that: A funnel-shaped wind chamber is arranged below the solid particles, an exhaust port of the wind chamber is located directly below the funnel, and a vent is opened on one side of the feed port.

10. The intelligent anti-blocking device for the gas distribution plate of a fluidized bed roasting furnace according to claim 8, characterized in that: include: Nozzles, gas distribution plates, wind chambers, nozzle arrays, temperature and pressure sensors, and fluidized bed roasting furnace shells; Among them, on the shell of the fluidized bed roasting furnace above the gas distribution plate, a nozzle array is evenly distributed on its side wall, and temperature and pressure sensors are evenly installed on the gas distribution plate.

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