Dangerous chemical safety production risk monitoring and early warning system and method

Abstract

The invention relates to the technical field of chemical production, in particular to a dangerous chemical safety production risk monitoring and early warning system and method, and the method comprises the steps: obtaining a production plan and a logistics plan from a database; flow paths and participated production links of different chemicals are obtained through production process information; constructing a chemical risk monitoring list, updating the chemical risk monitoring list in real time according to the form change of the chemicals in each process link in the production process flow, and representing the states of the corresponding chemicals in different process links by using arrays; according to the process links in which the chemicals participate, constructing a state representation matrix of the corresponding chemicals; based on the final product information, obtaining a state representation matrix of a plurality of chemicals participating in the production process flow, and constructing a finished product state representation matrix; and analyzing the state representation matrix of the chemicals and the state representation matrix of the finished products to obtain risk prediction values of different process links.

Description

Technical Field

[0001] The present invention relates to the technical field of chemical production, and particularly to a safety production risk monitoring and early warning system and method for hazardous chemicals. Background Art

[0002] Hazardous chemicals refer to those substances with characteristics such as toxicity, corrosiveness, explosiveness, flammability or combustibility support, which can cause damage to human health, facility safety and even the environment, including but not limited to highly toxic chemicals and other potentially dangerous chemical substances. During the operation of chemical enterprises, it is often necessary to handle and use a variety of such high-risk items. In view of this, it becomes particularly important to build a mechanism dedicated to identifying and managing the safety hazards brought by these substances.

[0003] The currently adopted method is mainly to classify various chemicals into corresponding safety levels according to their own hazards, and set different safety management areas accordingly; at the same time, the specific conditions of the location (such as temperature, air pressure, etc.) will also be considered to comprehensively evaluate the possible safety hazards and set corresponding alarm thresholds.

[0004] However, in actual chemical production activities, the production of each chemical product involves multiple steps and different types of chemicals. The specific threat level faced by each process link and the probability of accidents it may cause often rely on personal judgment, and there is no generally applicable standard or model for reference. This approach not only easily leads to insufficient attention to high-risk links, but also may cause excessive unnecessary attention to low-risk parts, thus affecting the overall efficiency and cost control. Summary of the Invention Brief Description of the Drawings

[0005] Figure 1 It is a flowchart of a safety production risk monitoring and early warning method for hazardous chemicals of the present invention. Detailed Embodiments

[0006] The following description is used to disclose the present invention so that those skilled in the art can implement the present invention. The preferred embodiments in the following description are only examples, and those skilled in the art can think of other obvious variations. The basic principles defined in the following description can be applied to other embodiments, variations, improvements, equivalent embodiments and other technical solutions without departing from the spirit and scope of the present invention.

[0007] It can be understood that the term "one" should be understood as "at least one" or "one or more". That is, in one embodiment, the number of an element can be one, while in other embodiments, the number of the element can be multiple. The term "one" cannot be understood as a limitation on the number.

[0008] Reference Figure 1 , the technical solution provided by the present invention is: a method for monitoring and warning of safety production risks of hazardous chemicals, including the following steps:

[0009] Step 1: Obtain the production plan and logistics plan from the database, extract the chemical information, final product information, and production process flow information required for production from the production plan, and obtain the chemical procurement plan information from the logistics plan.

[0010] Among them, the chemical information required for production includes the name of the chemical raw material, the form during chemical storage, the chemical form before the chemical participates in the reaction, and the chemical form when the chemical participates in the reaction. The chemical form includes solid, liquid, and gas; the final product information includes the name of the final product, the chemical form of the final product, and the chemical form during the storage of the final product; the production process flow information includes the process flow, the process parameters of each process link, the name of the process link, the number of process links, the code of the process link, and the names of all chemicals participating in each process link; the chemical procurement plan information includes the name of the purchased chemical, the data of the purchased chemical, the arrival time of the purchased chemical, and the chemical form during the storage of the purchased chemical.

[0011] Step 2: Obtain the circulation paths of different chemicals and the production links they participate in through the production process information, and obtain the purchased chemical information and transportation time point information from the raw material procurement plan. Specifically:

[0012] Extract the production process flow, the code of each process link, and the names of the chemicals participating in each process link from the production process flow information;

[0013] Obtain the names of all chemicals participating in the production process, and form the corresponding circulation paths in the order of the process links participated by each chemical;

[0014] Perform one-hot encoding on the name of each chemical to obtain a path code, and distinguish the circulation paths of different chemicals through the path code;

[0015] Obtain the purchased chemical information and transportation time point information from the raw material procurement plan, and arrange the storage area and monitor the process of transferring the raw materials to the storage area according to the purchased chemical information and transportation time point information;

[0016] Step 3: Construct a chemical risk monitoring list, and update the chemical risk monitoring list in real time according to the changes in the forms of chemicals in each process link of the production process flow, and use the array S i_j =(s i , n j , θ j , λ i)Indicates the status of the corresponding chemical in different process steps; among them, s i , n j , θ j , λ i respectively represent the morphological characterization parameters, the encoding of the process step where the chemical i is located, the flow direction characterization parameter, and the correlation coefficient of the chemical i in the process step j. Specifically, it includes the following sub-steps:

[0017] Step 3.1: Extract the production process flow, the encoding of each process step, and the names of the chemicals participating in each process step from the production process flow information; obtain the names of all chemicals participating in the production process, and form the corresponding circulation paths according to the sequence of the process steps participated by each chemical; perform one-hot encoding on the names of each chemical to obtain the path encoding, and distinguish the circulation paths of different chemicals through the path encoding.

[0018] Step 3.2: Obtain the name of the chemical and the corresponding circulation path of the chemical;

[0019] Pass the circulation path of the chemical through the process time series Y i =(n j , n j+1 ...、n j+k ) is represented, where n j+k represents the (j + k)-th process step participated by the chemical i, j represents the chemical i starts participating from the j-th step of the entire process flow, j≥1; k = 0, 1,..., m, m represents the total number of process steps that the chemical i needs to participate in, and construct the chemical state time series S i =(S i_j , S i_j+1 , …, S i_j+k ); establish a chemical monitoring list, and each row of the chemical monitoring list includes the name of a chemical, the corresponding process time series, and the chemical state time series.

[0020] Step 3.3: Obtain the chemical state time series from the chemical monitoring list; extract the chemical form of the chemical in a process step from the chemical state time series; obtain the form of the chemical participating in each process step from the production process information, and the form of participating in each process step includes: directly participating in the chemical reaction of the process step where it is located, not participating in the chemical reaction of the process step where it is located, and assisting the chemical reaction of the process step where it is located;

[0021] If the form of the chemical changes when participating in the process step where it is located, then change the chemical state time series; specifically, if the form of the chemical changes from liquid to gas and then from gas to liquid, then modify s i , so that s i= 1; If the form of the chemical only changes once, do not modify s i ;

[0022] If the flow direction of the chemical changes when participating in the process step it is in, replace the chemical state time sequence; Specifically, if there are two different flow directions when the chemical participates in the process environment it is in, modify θ i , so that θ i = 1.

[0023] For example, in the production process flow, some chemicals participate in the process step in the form of a catalyst or a cooling medium. For example, the Freon in the evaporation box uses the change in its form to complete the endothermic and exothermic processes. Due to the change in form, the state equation of this type of chemical will represent s i assigned a value of 1.

[0024] Since it does not participate in the reaction and is usually not considered as the first step of the process step.

[0025] When calculating the state representation matrix of the product, it is considered as the second process step. Since the form of the chemical entering the second process step is usually considered not to change, that is, the first column of the chemical state representation matrix is all 0, and the obtained product is independent of the s i value.

[0026] IV. According to the process steps participated by the chemical, construct the state representation matrix of the corresponding chemical; Based on the final product information, obtain the state representation matrices of multiple chemicals participating in the production process flow and construct the finished product state representation matrix. Specifically, it includes the following sub-steps:

[0027] Step 4.1. Assume that chemical i participates in k process steps in total, and use k to replace n j+k ;

[0028] Then, the state representation matrix of chemical i is:

[0029]

[0030] Assume that the state of chemical i does not change in the k process steps, then s i = 0;

[0031] Step 4.2. Assume that chemical i participates in the corresponding process steps in the order of the process time sequence, then θ k = 0;

[0032] Then the state representation matrix of chemical i is converted to:

[0033] where i = 1, 2,..., M, and M represents the total number of chemicals;

[0034] Step 4.3: Obtain the process flow for generating the finished product information based on the final product information.

[0035] Based on the process flow of the finished product information, obtain the chemicals involved in each process step and the morphological characterization parameter information of each chemical in the corresponding process step.

[0036] Construct the state representation matrix for each chemical. i = 1, 2, …, M;

[0037] Based on the process flow, obtain the state representation matrix of the final product:

[0038] where, represents the matching matrix of the m-th process step, represents the transpose matrix of K i+1 of.

[0039] For example, if a chemical production process flow includes four process steps, including Chemical 1, Chemical 2, and Chemical 3; Chemical 2 directly participates in the chemical reaction in the second process step of the entire production process, and Chemical 3 directly participates in the chemical reaction in the third process step of the entire production process;

[0040] The forms of Chemical 1, Chemical 2, and Chemical 3 do not change during the entire production process, and there is no situation where the flow directions of the three chemicals change;

[0041] Then the state representation matrix of Chemical 1 is The state representation matrix of Chemical 2 is The state representation matrix of Chemical 3 is K 3 =(0 1 0 λ 3 );

[0042] Then the state representation matrix of the final product is:

[0043]

[0044] Each row of the state representation matrix of the final product corresponds to the three process steps.

[0045] where, where, the determination of the correlation coefficient is based on the importance of each chemical in the product in the production process flow, or the difficulty of being replaced by other materials, and the correlation coefficients are all less than 1.

[0046] As can be seen from the above formula, the state representation matrix of the final product contains polynomials of three chemical correlation coefficients, and the degree of each polynomial is 3, which is equal to the number of chemicals. Thus, the relationship between the degree of the polynomial and the number of chemicals participating in the reaction is established.

[0047] Among them, from the coefficient before λ 3 it can be seen that the third chemical has the least influence on the state of the first process step and the greatest influence on the state of the third process step.

[0048] V. By analyzing the state representation matrix of chemicals and the state representation matrix of the finished product, obtain the risk prediction values of different process steps. Specifically, it includes the following steps:

[0049] Extract the morphological characterization parameter data of the corresponding chemicals from each process step to form a morphological time series;

[0050] Extract the correlation coefficient data of the corresponding chemicals from each process step to form a correlation coefficient series;

[0051] Identify whether each element in the state representation matrix of the final product includes a polynomial of the correlation coefficient term; if so, obtain the coefficient of each correlation coefficient product term, the degree of the correlation coefficient product term, and the constant term in the polynomial to form an associated state vector set Among them, a l 、f l 、c l respectively represent the coefficient of the correlation coefficient product term, the degree of the correlation coefficient product term, and the constant term of the polynomial in the l-th element;

[0052] Set the target value C 0 = 1 and the return value B, loop through the morphological time series, count the number of target values contained in the morphological time series. If the target value is not contained, then B = 1; otherwise, B = 0, and output the number of target values;

[0053] Take a l 、f l 、c l in the associated state vector corresponding to each process step to form a monitoring feature data set; after normalizing the feature data set, input it into a pre-trained prediction model to output the risk prediction value;

[0054] The prediction model is:

[0055] Among them, α 0 is the intercept, α i is the regression coefficient, σ is the error term, μ 0 is the basic weight value, μ is the weight coefficient, and r is the number of variables.

[0056] Taking the above process flow as an example:

[0057] The morphological time series is a = (0, 0, 0, 0), and the correlation coefficient series is b = (λ 1 , λ 2 , λ 3 , λ 4 );

[0058]

[0059] Among them, the degree of the product term of the correlation coefficient is 3, that is, three chemical substances participate in the reaction, and there is a greater safety risk during the reaction. Therefore, the weight coefficient

[0060] will be input into the prediction model to predict the probability of risks occurring in each process link, so that the process link with the highest probability can be monitored with emphasis.

[0061] In some embodiments, the present method is also applicable to the risk monitoring of auxiliary equipment.

[0062] For example, the evaporation tank is usually a component of the cooling system. Taking the chemical substance in the evaporation tank as chemical substance 1 and the cooling medium as chemical substance 2, its product can be considered as liquid water. Referring to the above calculation process, the state representation matrix of the product can be obtained. Because, after the coolant passes through the high-temperature reaction kettle, it will be vaporized and can be considered as steam when input into the heat exchange process link. After heat exchange, it becomes liquid water (the final product). Through the monitoring model, the risk probability of the heat exchange link is predicted.

[0063] The present invention also provides a computer-readable storage medium, which stores a computer program, and the computer program is executed by a processor to implement the above-mentioned method for monitoring and warning the safety production risks of hazardous chemicals.

[0064] Embodiments disclosed by the present invention. The processes described above with reference to the flowcharts can be implemented as computer software programs. Embodiments disclosed by the present invention include a computer program product, which includes a computer program carried on a computer-readable medium. The computer program contains program codes for executing the methods shown in the flowcharts. In such an embodiment, the computer program can be downloaded and installed from a network through a communication part, and / or installed from a removable medium. When the computer program is executed by a central processing unit (CPU), the above-mentioned functions defined in the methods of the present application are executed. It should be noted that the above-mentioned computer-readable medium in the present application can be a computer-readable signal medium, a computer-readable storage medium, or any combination of the two. A computer-readable storage medium can, for example but not limited to, be an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination of the above. More specific examples of a computer-readable storage medium can include but are not limited to: an electrical connection with one or more wire segments, a portable computer disk, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), an optical fiber, a portable compact disk read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the above. In the present application, a computer-readable storage medium can be any tangible medium that contains or stores a program, and this program can be used by or in combination with an instruction execution system, apparatus, or device. And in the present application, a computer-readable signal medium can include a data signal propagated in a baseband or as part of a carrier wave, in which computer-readable program codes are carried. Such a propagated data signal can take various forms, including but not limited to electromagnetic signals, optical signals, or any suitable combination of the above. A computer-readable signal medium can also be any computer-readable medium other than a computer-readable storage medium, and this computer-readable medium can send, propagate, or transmit a program for use by or in combination with an instruction execution system, apparatus, or device. The program codes contained on the computer-readable medium can be transmitted by any appropriate medium, including but not limited to: a wireless segment, a wire segment, an optical cable, RF, etc., or any suitable combination of the above.

[0065] The flowcharts and block diagrams in the accompanying drawings illustrate the possible architectures, functions, and operations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagram may represent a module, a segment of a program, or a part of code, which contains one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions noted in the blocks may occur in a different order than that noted in the accompanying drawings. For example, two consecutive blocks shown may actually be executed substantially in parallel, and they may sometimes be executed in the reverse order, depending on the functions involved. It should also be noted that each block in the block diagram and / or flowchart, and combinations of blocks in the block diagram and / or flowchart, can be implemented by a dedicated hardware-based system that performs the specified functions or operations, or can be implemented by a combination of dedicated hardware and computer instructions.

[0066] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are only examples and do not limit the present invention. The objectives of the present invention have been fully and effectively achieved. The functions and structural principles of the present invention have been demonstrated and illustrated in the embodiments. Without departing from the said principles, any changes or modifications can be made to the embodiments of the present invention.

Claims

1. A method for monitoring and early warning of production safety risks of hazardous chemicals, characterized in that: The method comprises: Obtain production plans and logistics plans from the database, extract information on chemicals, final products and production process flow required for production from the production plan, and obtain chemical procurement plan information from the logistics plan; Obtain the circulation paths and production links of different chemicals through production process information, and obtain the purchased chemical information and transportation time point information from the raw material procurement plan; Construct a chemical risk monitoring list, update the chemical risk monitoring list in real time according to the changes in the form of chemicals in each process link in the production process, and use array S i_j =(s i , n j ,θ j ,λ i ) represents the status of the corresponding chemicals in different process links; among them, s i 、n j ,θ j , i They represent the morphological characterization parameters of chemical i in process link j, the code of the process link, the flow characterization parameters and the correlation coefficient respectively; According to the process links in which the chemicals are involved, the state representation matrix of the corresponding chemicals is constructed; based on the final product information, the state representation matrix of multiple chemicals involved in the production process is obtained to construct the finished product state representation matrix; By analyzing the chemical status representation matrix and the finished product status representation matrix, the risk prediction values ​​of different process links can be obtained.

2. A method for monitoring and early warning of production safety risks of hazardous chemicals according to claim 1, characterized in that: The chemical information required for production includes the name of the chemical raw material, the form of the chemical when stored, the chemical form before the chemical participates in the reaction, and the chemical form of the chemical when participating in the reaction, and the chemical form includes solid, liquid and gaseous states; the final product information includes the name of the final product, the chemical form of the final product, and the chemical form of the final product when stored; the production process information includes the process flow, the process parameters of each process link, the name of the process link, the number of process links, the code of the process link, and the names of all chemicals involved in each process link; The chemical procurement plan information includes the name of the purchased chemical, the data of the purchased chemical, the arrival time of the purchased chemical, and the chemical form of the purchased chemical when it is stored.

3. A method for monitoring and early warning of production safety risks of hazardous chemicals according to claim 2, characterized in that: The method of obtaining the circulation paths and involved production links of different chemicals through production process information includes the following steps: Extract the production process flow, the code of each process link and the name of the chemicals involved in each process link from the production process flow information; Obtain the names of all chemicals involved in the production process, and construct the corresponding circulation path according to the sequence of process links in which each chemical participates; Perform unique-hot encoding on the name of each chemical to obtain the path code, and use the path code to distinguish the circulation paths of different chemicals.

4. A method for monitoring and early warning of production safety risks of hazardous chemicals according to claim 3, characterized in that: The step of constructing a chemical risk monitoring list includes the following steps: Obtain the name of the chemical and the circulation path of the corresponding chemical; The chemical flow path passes through the process sequence Y i =(n j 、n j+1 …、n j+k ) indicates that, where n j+k represents the j+kth process link in which chemical i participates, j represents that chemical i participates from the jth link of the entire process flow, j≥1; k=0, 1, …, m, m represents the total number of process links that chemical i needs to participate in, and constructs the chemical state time series sequence S corresponding to the process time series sequence i =(S i_j , S i_j+1 , ..., S i_j+k ); A chemical monitoring list is established, wherein each row of the chemical monitoring list includes a name of a chemical, a corresponding process time sequence and a chemical state time sequence.

5. A method for monitoring and early warning of production safety risks of hazardous chemicals according to claim 4, characterized in that: The real-time updating of the chemical risk monitoring list according to the changes in the form of chemicals in each process link in the production process includes the following steps: Obtain the chemical status time series from the chemical monitoring list; Extract the chemical form of the chemical in a process link from the chemical state time series; From the production process information, the form in which the chemical participates in each process link is obtained, wherein the form in which the chemical participates in each process link includes: directly participating in the chemical reaction in the process link, not participating in the chemical reaction in the process link, and assisting the chemical reaction in the process link; If the chemical changes state when it is in the process, modify the chemical state sequence; specifically, if the chemical changes from liquid to gas and then from gas to liquid, modify s i , so that i =1; If the chemical undergoes only one change in form, do not modify s i ; If the flow direction of the chemical changes when it participates in the process link, the chemical state time sequence is replaced; specifically, if the chemical has two different flow directions when it participates in the process environment, modify θ i , so that θ i =1.

6. A method for monitoring and early warning of production safety risks of hazardous chemicals according to claim 5, characterized in that: The process of constructing a state representation matrix of the corresponding chemicals according to the process links in which the chemicals are involved includes the following steps: Assume that chemical i is involved in k process steps, and replace n with k. j+k ; Then, the state representation matrix of chemical i is: Assume that the state of chemical i in k process links does not change, then s i =0; Assume that chemical i participates in the corresponding process link in the order of process timing sequence, then θ k =0; Then the state representation matrix of chemical i is converted to: Wherein i=1, 2, ..., M, and M represents the total number of chemicals.

7. A method for monitoring and early warning of production safety risks of hazardous chemicals according to claim 6, characterized in that: The method of obtaining a state representation matrix of multiple chemicals involved in the production process based on the final product information and constructing a finished product state representation matrix includes the following steps: According to the final product information, obtaining the process flow for generating the finished product information; According to the process flow of the finished product information, obtain the chemicals involved in each process link and the morphological characterization parameter information of each chemical in the corresponding process link; Construct a state representation matrix for each chemical; According to the process flow, the state representation matrix of the final product is obtained: in, represents the matching matrix of the mth process link, K i+1 The transposed matrix of .

8. A method for monitoring and early warning of production safety risks of hazardous chemicals according to claim 7, characterized in that: The method of obtaining risk prediction values ​​of different process links by analyzing the chemical state representation matrix and the finished product state representation matrix includes the following steps: Extract the morphological characterization parameter data of the corresponding chemicals from each process link to form a morphological time series; Extract the correlation coefficient data of the corresponding chemicals from each process link to form a correlation coefficient sequence; Identify whether each element in the state representation matrix of the final product includes a polynomial of the associated coefficient term; if so, obtain the coefficient of each associated coefficient product term, the degree of the associated coefficient product term and the constant term in the polynomial to form an associated state vector set in, a l 、f l 、c l They represent the coefficient of the product term of the correlation coefficient in the lth element, the degree of the product term of the correlation coefficient, and the constant term of the polynomial respectively; Set the target value C0=1 and the return value B, loop through the morphological time series, count the number of target values ​​in the morphological time series, if there is no target value, then B=1; otherwise, B=0, and output the number of target values; The a in the associated state vector corresponding to each process step l 、f l 、c l , forming a monitoring feature data set; inputting the feature data set into the prediction model after normalization, and outputting the risk prediction value; The prediction model is: Among them, α0 is the intercept, α i is the regression coefficient, σ is the error term, μ0 is the basic weight value, μ is the weight coefficient, and r is the number of variables.

9. A hazardous chemical production safety risk monitoring and early warning system, characterized in that: The system is used to execute a method for monitoring and early warning of production safety risks of hazardous chemicals as described in claims 1-8 above.

10. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a computer program, and the computer program is executed by a processor to implement a method for monitoring and early warning of production safety risks of hazardous chemicals as described in any one of claims 1 to 8.

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