Pressure SIS control system for synthesizing trans-dichloroethylene

Abstract

The invention relates to the technical field of chemical process control, and discloses a pressure SIS control system for trans-dichloroethylene synthesis, which comprises a synthesis monitoring module, a multi-source data acquisition module, a parameter adjustment module, an early warning module, a human-computer interaction interface module and a self-adaptive optimization module, the multi-source data acquisition module acquires data, the data analysis module calculates a synthesis pressure supplement coefficient, a synthesis temperature supplement coefficient and a pressure early warning value of the jth workshop section, the parameter adjustment module adjusts the pressure and temperature of the synthesis reaction according to the calculation result, and the early warning module performs real-time grading early warning according to the numerical range of the pressure early warning value. The man-machine interaction interface module displays the system operation state, key parameters and early warning information and receives an instruction of an operator to realize man-machine interaction, and the self-adaptive optimization module optimizes the system performance according to historical data and real-time monitoring data.

Description

Technical Field

[0001] The present invention relates to the technical field of chemical process control, in particular to a pressure SIS control system for trans-dichloroethylene synthesis. Background Art

[0002] In the synthesis of trans-dichloroethylene, precise control of pressure and temperature is crucial for ensuring stable reaction progress, improving reaction selectivity, and ensuring production safety. However, traditional control systems often have numerous shortcomings when dealing with fluctuations in raw material properties, changing environmental conditions, and the dynamic nature of the process.

[0003] On the one hand, even slight variations in the purity and composition of raw materials, as well as ambient pressure, can lead to pressure deviations during synthesis reactions, thus affecting reaction stability and safety. Traditional pressure control methods typically employ fixed thresholds for monitoring, which are difficult to adapt to complex process fluctuations, prone to insufficient control precision, and even potentially pose safety risks.

[0004] On the other hand, fluctuations in reaction temperature can also significantly impact the synthesis of trans-dichloroethylene. Excessively high or low temperatures not only reduce reaction selectivity and increase byproduct formation, but can also exacerbate safety risks. Traditional temperature control methods often lack sufficient flexibility and precision to account for variations in raw material temperature and ambient temperature, making it difficult to ensure that the reaction proceeds at optimal temperatures.

[0005] In addition, traditional early warning systems mostly use a single fixed threshold for pressure monitoring. When the process fluctuates greatly, false alarms or missed alarms are prone to occur, and it is impossible to issue early warnings and handle pressure anomalies in a timely and accurate manner. This, to a certain extent, limits the stability and safety of the trans-dichloroethylene synthesis process.

[0006] Therefore, developing a pressure SIS control system for trans-dichloroethylene synthesis that can adapt to raw material fluctuations and environmental changes, accurately control pressure and temperature, effectively warn and scientifically deal with pressure anomalies is of great practical significance for improving production efficiency and reducing safety risks. Summary of the Invention (1) Technical problems solved

[0007] In response to the shortcomings of the existing technology, the present invention provides a pressure SIS control system for the synthesis of trans-dichloroethylene, which has the advantages of dynamic pressure and temperature compensation, graded early warning and precise disposal, high adaptability and high safety. It solves the problems that the traditional fixed threshold control method is difficult to adapt to process fluctuations, lacks control accuracy, is prone to false alarms or missed alarms, and increases safety risks. (2) Technical solution

[0008] To achieve the above-mentioned object, the present invention provides the following technical solution: a pressure SIS control system for trans-dichloroethylene synthesis, comprising a synthesis monitoring module, a multi-source data acquisition module, a parameter adjustment module, an early warning module, a human-computer interaction interface module and an adaptive optimization module; The synthesis monitoring module monitors the key parameters of each section of the synthesis equipment in real time; The multi-source data acquisition module collects characteristic data of different raw materials and simultaneously obtains temperature and pressure data and environmental impact data of each synthesis process section monitored by the synthesis monitoring module; The data analysis module dynamically calculates the synthetic pressure supplement coefficient , synthetic temperature supplement coefficient And the pressure warning value of the jth section , generate early warning logic; The parameter adjustment module calculates the synthetic pressure supplement coefficient based on the data analysis module. , synthetic temperature supplement coefficient , adjusting the pressure and temperature control set points for the synthesis reaction; The early warning module monitors the pressure early warning value in real time According to the numerical range of the data, real-time graded warnings are issued and corresponding measures are taken; The human-computer interaction interface module is used to display the system operation status, key parameters and warning information, and receive instructions from operators to achieve human-computer interaction; The adaptive optimization module automatically adjusts the control strategy based on historical data and real-time monitoring data to optimize system performance.

[0009] Preferably, the synthesis monitoring module includes a raw material pretreatment monitoring unit, a catalytic reaction monitoring unit, a separation monitoring unit and a distillation monitoring unit. The raw material pretreatment monitoring unit is used to monitor the raw material pretreatment process, including the temperature, pressure, flow rate and impurity content parameters during the gas cabinet buffering, water-soluble impurity removal of the water washing tank, and sulfide and phosphide removal operations of the adsorption tank; the catalytic reaction monitoring unit is used to monitor the key parameters of the catalytic reaction process, including the temperature, pressure, reaction rate, raw material feed rate, catalyst activity state and component concentration of the product in the reactor, and to evaluate the reaction progress and safety in real time; the separation monitoring unit is used to monitor various parameters in the product separation process, such as the liquid level of the gas-liquid separator, the condensing temperature and pressure of the condenser, the recovery flow rate of uncondensed gas, and the concentration of trichloroethane, solvent and by-products in the liquid phase crude product; the distillation monitoring unit is used to monitor the temperature, pressure, flow rate, component concentration parameters at the top and bottom of the tower during the distillation process, and monitor the treatment process of the light / heavy component residues in the intermittent tower.

[0010] Preferably, the multi-source data acquisition module includes a raw material characteristic data acquisition unit, a work section data acquisition unit and an environmental data acquisition unit, and the data analysis module includes a pressure supplement unit, a temperature supplement unit and a safety margin assessment unit.

[0011] Preferably, the raw material characteristic data acquisition unit acquires raw material characteristic data, including raw material purity, temperature, pressure, flow rate, component concentration and impurity content, through an online analyzer and a sensor.

[0012] Preferably, the section data acquisition unit acquires the data of each synthesis section through the sensors of the synthesis monitoring module and the online monitoring equipment, including temperature, pressure, flow, component concentration, liquid level and pH value.

[0013] Preferably, the environmental data acquisition unit collects environmental data, including workshop temperature, humidity, atmospheric pressure, and combustible gas concentration in the air, through temperature and humidity sensors, atmospheric pressure gauges, and gas detectors.

[0014] Preferably, the pressure supplement unit calculates the synthetic pressure supplement coefficient based on the raw material characteristic data and the environmental data. , and its calculation formula is: ; In the formula, represents the composite pressure supplement coefficient, Indicates the target pressure, Indicates the actual pressure, represents the pressure of the i-th raw material, represents the weight of the i-th raw material, Indicates environmental pressure, represents the weight of environmental pressure, Indicates the number of raw material types.

[0015] Preferably, the temperature supplementation unit calculates the synthetic temperature supplementation coefficient according to the raw material characteristic data and the environmental data. , and its calculation formula is: ; In the formula, represents the composite temperature supplement coefficient, Indicates the target temperature, Indicates the actual temperature, represents the temperature of the i-th raw material, represents the weight of the i-th raw material, Indicates the ambient temperature, represents the weight of the ambient temperature, Indicates the number of raw material types.

[0016] Preferably, the safety margin evaluation unit calculates the pressure warning value of the jth section according to the synthesis of each section data , wherein the value is the pressure warning value of one section, and the warning values of other sections are calculated by substituting the data of each section into the formula, and the formula is the same, and the formula is: ; In the formula, , wherein Pj represents the pressure warning value of the jth section, , wherein Sj represents the static safety threshold of the jth section, , wherein Cj represents the periodic fluctuation coefficient of the jth section, , wherein Fj represents the fluctuation frequency of the jth section, , wherein T represents the cumulative running time after the system is started, , wherein represents the phase angle of the jth section, , wherein represents the pressure change rate coefficient of the jth section, , wherein represents the pressure change rate of the jth section, , wherein represents the historical extreme value coefficient of the jth section, , wherein represents the maximum pressure fluctuation value within the last 24 hours of the jth section.

[0017] Preferably, the warning module performs real-time hierarchical warning by monitoring the value range of the pressure warning value , and takes corresponding measures.

[0018] Compared with the prior art, the present application provides a pressure SIS control system for trans-dichloroethylene synthesis, which has the following beneficial effects: 1. The present application calculates a synthesis pressure supplement coefficient , which is used as the basis for pressure parameter adjustment and is substituted into the pressure control algorithm of the parameter adjustment module for real-time pressure parameter dynamic correction, so that the system can adapt to the influence of different raw material characteristics and environmental pressure changes, and ensure that the synthesis reaction is stable within the preset pressure range, thereby solving the problem of insufficient pressure control precision caused by raw material fluctuation and environmental change, which easily leads to safety hazards.

[0019] 2. The present application calculates a synthesis temperature supplement coefficient , which is used as an important basis for temperature adjustment and is substituted into the temperature control model of the parameter adjustment module for real-time compensation correction of temperature, so that the system can accurately respond to the influence of raw material temperature difference and environmental temperature change on reaction temperature, and ensure that the synthesis reaction of trans-dichloroethylene is efficiently carried out under suitable temperature conditions, thereby solving the problems of reaction selectivity decline, increase of by-products and increase of safety risk caused by excessive temperature fluctuation.

[0020] 3、The jth section pressure early warning value is calculated , which is used as a standard for judging whether the section pressure is in a safe state, when the calculated jth section pressure early warning value is in the normal range, the system maintains a normal running state; when the calculated jth section pressure early warning value approaches the static safety threshold, the early warning module issues a primary early warning to remind the operator to pay close attention; when the calculated jth section pressure early warning value exceeds the static safety threshold, the early warning module issues a high-level early warning and triggers the corresponding emergency treatment measures, finally, the system solves the problem that the traditional fixed threshold early warning method is difficult to adapt to process fluctuations and is prone to false positives or false negatives, thereby improving the accuracy and timeliness of system pressure early warning.

[0021] 4、The system realizes scientific disposal of different degrees of pressure abnormal conditions through the cooperation of the hierarchical early warning mechanism, precise response measures corresponding to different levels and various modules, which can effectively avoid production interruption caused by over-treatment of slight abnormalities, and can respond in time when serious abnormalities occur, thereby minimizing safety risks and ensuring the stability and safety of the trans-dichloroethylene synthesis process. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 is the system flowchart of the present application; Figure 2 is the system running flowchart of example 1 of the present application; Figure 3 is the system running flowchart of example 3 of the present application. DETAILED DESCRIPTION

[0023] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0024] Please refer to Figure 1-3 , a pressure SIS control system for trans-dichloroethylene synthesis, comprising a synthesis monitoring module, a multi-source data acquisition module, a parameter adjustment module, an early warning module, a man-machine interface module and a self-adaptive optimization module; The synthesis monitoring module monitors the key parameters (including temperature, pressure, flow rate and component concentration) of each section of the synthesis equipment in real time. The multi-source data acquisition module acquires characteristic data of different raw materials, which facilitates adjustment of the control pressure and temperature of the control system according to different raw material characteristics, and synchronously acquires temperature and pressure data of each section of the synthesis monitored by the synthesis monitoring module and environmental influence data; The data analysis module dynamically calculates the synthetic pressure supplement coefficient , synthetic temperature supplement coefficient And the pressure warning value of the jth section , generate early warning logic; The parameter adjustment module calculates the synthetic pressure supplement coefficient based on the data analysis module , synthetic temperature supplement coefficient , adjusting the pressure and temperature control set points for the synthesis reaction; The early warning module monitors the pressure warning value in real time According to the numerical range of the data, real-time graded warnings are issued and corresponding measures are taken; The human-computer interaction interface module is used to display the system operation status, key parameters and warning information, and receive instructions from operators to achieve human-computer interaction; The adaptive optimization module automatically adjusts the control strategy and optimizes system performance based on historical data and real-time monitoring data; The advantages are: by establishing a synthesis monitoring module, a multi-source data acquisition module, a parameter adjustment module, an early warning module, a human-computer interaction interface module and an adaptive optimization module, each module cooperates with each other, so that the system can achieve precise pressure control and safety monitoring of the entire process of trans-dichloroethylene synthesis. Among them, the synthesis monitoring module can capture the key parameters of each section in real time and provide basic data support for the system; the multi-source data acquisition module will automatically integrate the raw material characteristics and environmental data to make the control more targeted, and the pressure supplement unit, temperature supplement unit and safety margin assessment unit in the data analysis module calculate the synthesis pressure supplement coefficient , synthetic temperature supplement coefficient And the pressure warning value of the jth section , which will provide the system with a basis for decision-making; the parameter adjustment module and the adaptive optimization module dynamically optimize the control strategy according to the calculation and analysis results, and finally enable the system to achieve stable control of the synthesis process pressure, timely warning and processing of abnormal situations, and greatly improve the safety and efficiency of production.

[0025] The synthesis monitoring module includes a raw material pretreatment monitoring unit, a catalytic reaction monitoring unit, a separation monitoring unit and a distillation monitoring unit. The raw material pretreatment monitoring unit is used to monitor the pretreatment process of the raw materials (acetylene and chlorine), including the temperature, pressure, flow rate and impurity content parameters during the gas cabinet buffering, water-soluble impurity removal of the water washing tank, and sulfide and phosphide removal of the adsorption tank, to ensure that the raw materials meet the specified purity and quality standards before entering the reaction system; the catalytic reaction monitoring unit is used to monitor the key parameters of the catalytic reaction process, including the temperature, pressure, reaction rate, raw material feed rate (acetylene and chlorine), catalyst activity state and component concentration of the product in the reactor, and to evaluate the reaction progress and safety in real time to ensure that the reaction is carried out efficiently under the set process conditions and at the same time Abnormal conditions can be discovered in time to avoid the occurrence of side reactions; the separation monitoring unit is used to monitor various parameters in the product separation process, such as the liquid level of the gas-liquid separator, the condensing temperature and pressure of the condenser, the recovery flow rate of uncondensed gas (HCl / Cl2), and the concentration of trichloroethane, solvent and by-products in the crude liquid phase, to ensure the efficiency of the separation process and the purity of the product, while optimizing the operating efficiency of the recovery system; the distillation monitoring unit is used to monitor parameters such as temperature, pressure, flow rate, and component concentration at the top and bottom of the tower during the distillation process to ensure the normal operation of the light removal tower and distillation tower, achieve the removal of light components (such as acetylene and methyl chloride) and the collection of high-purity trichloroethane (>99%), and monitor the treatment process of light / heavy component residues in the intermittent tower to improve the recovery rate of trichloroethane and product quality.

[0026] The multi-source data acquisition module includes a raw material characteristic data acquisition unit, a work section data acquisition unit and an environmental data acquisition unit; the data analysis module includes a pressure supplement unit, a temperature supplement unit and a safety margin assessment unit.

[0027] The raw material characteristic data acquisition unit collects raw material characteristic data through online analyzers and sensors, including raw material (acetylene / chlorine) purity, temperature, pressure, flow, component concentration and impurity content (such as sulfide and phosphide concentration).

[0028] The process data acquisition unit obtains data on each synthesis process section through the sensors and online monitoring equipment of the synthesis monitoring module, including temperature (reactor, condenser and regeneration tower), pressure (gas cabinet, reactor inlet / outlet), flow (acetylene / chlorine feed rate), component concentration (trichloroethane, by-products), liquid level (separator, storage tank) and pH value (aqueous phase reaction).

[0029] The environmental data acquisition unit collects environmental data through temperature and humidity sensors, atmospheric pressure gauges, and gas detectors, including workshop temperature, humidity, atmospheric pressure, and combustible gas concentration in the air (such as acetylene leak monitoring).

[0030] The pressure supplement unit calculates a synthetic pressure supplement coefficient according to raw material characteristic data and environmental data The calculation formula is: ; In the formula, represents the synthetic pressure supplement coefficient, represents the target pressure, represents the actual pressure, represents the pressure of the i-th raw material, represents the weight of the i-th raw material, represents the environmental pressure, represents the weight of the environmental pressure, represents the number of raw material types; The advantage is that the synthetic pressure supplement coefficient is calculated , which is used as the basis for pressure parameter adjustment and is substituted into the pressure control algorithm of the parameter adjustment module for real-time dynamic correction of the pressure parameter, so that the system can adapt to the influence of different raw material characteristics and environmental pressure changes, ensuring that the synthetic reaction is stable within the preset pressure range, thereby solving the problem of insufficient pressure control accuracy caused by raw material fluctuations and environmental changes, which easily leads to safety hazards.

[0031] The temperature supplement unit calculates a synthetic temperature supplement coefficient according to raw material characteristic data and environmental data The calculation formula is: ; In the formula, represents the synthetic temperature supplement coefficient, represents the target temperature, represents the actual temperature, represents the temperature of the i-th raw material, represents the weight of the i-th raw material, represents the environmental temperature, represents the weight of the environmental temperature, represents the number of raw material types; The advantage is that the synthetic temperature supplement coefficient is calculated , which is used as an important basis for temperature adjustment and is substituted into the temperature control model of the parameter adjustment module for real-time compensation and correction of the temperature, so that the system can accurately respond to the influence of raw material temperature differences and environmental temperature changes on the reaction temperature, ensuring that the synthesis of trans-dichloroethylene is efficiently carried out under suitable temperature conditions, thereby solving the problems of decreased reaction selectivity, increased by-products, and increased safety risks caused by excessive temperature fluctuations.

[0032] The safety margin evaluation unit calculates a pressure warning value for the j-th section according to synthetic data of each section This value is the pressure warning value of one section. The specific warning values ​​of other sections need to be substituted into the data of each section to calculate. The calculation formula is the same, which is: ; In the formula, Indicates the pressure warning value of the j-th section, represents the static safety threshold of the j-th section, It represents the periodic fluctuation coefficient of the jth process section (dimensionless), with a value range of 0.02-0.08, which is determined by the process characteristics. Indicates the fluctuation frequency (rad / min) of the jth section, based on historical data fitting, Indicates the cumulative running time since the system was started. represents the phase angle (rad) of the jth process section, which is determined by the process start time and is determined by Fourier analysis. It represents the pressure change rate coefficient of the jth section (dimensionless), with a value range of 0.1~0.3. Indicates the pressure change rate of the j-th section (MPa / min), represents the historical extreme value coefficient of the j-th section (dimensionless), It represents the maximum pressure fluctuation of the jth section in the past 24 hours; The advantage is: by calculating the pressure warning value of the jth section , and use it as the standard for judging whether the pressure of the section is in a safe state. When the calculated pressure warning value of the j-th section is within the normal range (lower than a certain proportion of the static safety threshold), the system maintains normal operation; when the calculated pressure warning value of the j-th section is close to the static safety threshold, the warning module issues a primary warning to remind the operator to pay close attention; when the calculated pressure warning value of the j-th section exceeds the static safety threshold, the warning module issues an advanced warning and triggers corresponding emergency measures. Finally, the system solves the problem that the traditional fixed threshold warning method is difficult to adapt to process fluctuations and is prone to false alarms or missed alarms, thereby improving the accuracy and timeliness of the system pressure warning.

[0033] The early warning module monitors the pressure warning value in real time The system will provide real-time graded warnings and take corresponding measures according to the numerical range of the data. The specific levels and response measures are as follows: (1) Level 1 warning (minor abnormality): When the pressure warning value of the jth section When the static safety threshold of the jth section is between 80% and 90%, the system automatically records the abnormal parameters and issues a yellow warning signal on the human-machine interface module, prompting the operator to strengthen monitoring without suspending production. (2) Second level warning (moderate abnormality): When the pressure warning value of the jth section When the static safety threshold of the jth section is between 90% and 100%, the early warning module issues an orange warning signal. The parameter adjustment module automatically fine-tunes the pressure and temperature, displays adjustment suggestions on the human-machine interface module, and notifies relevant technical personnel to conduct on-site evaluation. (3) Level 3 warning (serious abnormality): When the pressure warning value of the jth section When the static safety threshold of the jth working section is exceeded, the response measure is that the early warning module sends a red warning signal accompanied by an audible and visual alarm. The system automatically activates the emergency shut-off valve to stop the raw material feed. At the same time, the abnormal information is sent to the mobile phone of the relevant person in charge to ensure that emergency measures are taken in time.

[0034] The advantages are: through the hierarchical early warning mechanism, precise response measures corresponding to different levels and the coordinated cooperation of various modules, the system can finally achieve scientific handling of pressure abnormalities of different degrees. It can not only effectively avoid production interruptions caused by excessive handling of minor abnormalities, but also respond in time to serious abnormalities, minimize safety risks, and thus ensure the stability and safety of the trans-dichloroethylene synthesis process.

[0035] The system of the present invention is applied to practical scenarios in Examples 1-3, and the traditional system is applied to Comparative Examples 1-3. The specific scenarios are as follows: Example 1 (Verification of system adaptability under fluctuating raw material characteristics) During the synthesis of trans-dichloroethylene at a chemical plant, the purity of the batch raw material acetylene fluctuated by 1.2% (from 99.5% to 98.3%). At the same time, the concentration of sulfide impurities in the chlorine briefly rose to 0.005%. In this case, the raw material characteristic data acquisition unit of the multi-source data acquisition module captured the above changes in real time and transmitted the data to the data analysis module. The pressure replenishment unit calculated the synthesis pressure replenishment coefficient as 1.03 based on the formula, and the temperature replenishment unit simultaneously calculated the synthesis temperature replenishment coefficient as 1.02. The parameter adjustment module immediately substituted these two coefficients into the control algorithm, making a dynamic correction of +3% to the reactor pressure set point and a compensation correction of +2% to the reaction temperature. Throughout the process, the catalytic reaction monitoring unit showed that the reaction pressure was stable at 0.31±0.01MPa, the reaction temperature was maintained at 85±1℃, the trichloroethane component concentration remained above 99.2%, and there was no abnormal increase in by-products.

[0036] Comparative Example 1 (traditional method) During the synthesis of trans-dichloroethylene, a similar chemical plant also encountered a 1.2% fluctuation in the purity of the raw material acetylene (from 99.5% to 98.3%), as well as a brief rise in the concentration of sulfide impurities in the chlorine gas to 0.005%. The plant used a traditional fixed-threshold control system and lacked the multi-source data acquisition module, data analysis module, and dynamic calculation-based parameter adjustment mechanism of the present invention. When raw material properties fluctuate, the traditional system, unable to detect subtle changes in real time and make corresponding adjustments, relies solely on fixed control parameters to maintain operation. Changes in acetylene purity and the concentration of sulfide impurities in chlorine caused the reactor pressure to fluctuate by 0.05 MPa and the reaction temperature to fluctuate by 3°C. These fluctuations destabilized the reaction process, causing the trichloroethane concentration to drop to around 97.5% and significantly increasing byproducts. This impacted product quality and production efficiency, while also posing potential safety risks.

[0037] Summary: Example 1 compares the 0.05 MPa pressure fluctuation and 3°C temperature fluctuation of the traditional control system of Comparative Example 1 under the same raw material fluctuation. The present invention effectively proves its ability to accurately adapt to the fluctuation of raw material characteristics.

[0038] Example 2 (Verification of Control Stability in a Scenario of Sudden Changes in Environmental Conditions) A production workshop encountered a sudden environmental change. Within 30 minutes, the atmospheric pressure dropped from 101.3kPa to 99.8kPa, and the workshop temperature rose from 25℃ to 30℃. After the environmental data acquisition unit collected these changes in real time, the data analysis module responded quickly: the pressure supplement unit calculated the supplement coefficient of 0.98 based on the environmental pressure change and corrected the system pressure by -2%. The temperature supplement unit calculated the supplement coefficient of 0.97 based on the ambient temperature fluctuation and implemented a -3% compensation for the reaction temperature. Through real-time tracking by the synthesis monitoring module, the pressure of each section (the gas cabinet pressure was stable at 1.2±0.02kPa, the reactor outlet pressure was stable at 0.3±0.01MPa) and the temperature (the reactor temperature was stable at 82±0.5℃) did not fluctuate beyond the allowable range of the process. The separation monitoring unit showed that the condensation efficiency of the condenser remained stable, and the fluctuation of the uncondensed gas recovery flow was controlled within 5%.

[0039] Comparative Example 2 Another chemical plant production workshop using a traditional control system encountered the same sudden environmental change. Within 30 minutes, the atmospheric pressure dropped from 101.3kPa to 99.8kPa, and the workshop temperature rose from 25°C to 30°C. Because the traditional system lacked the ability to collect and dynamically analyze environmental data in real time, it was unable to adjust control parameters in time according to the environmental changes. After the sudden change in environmental conditions, the reactor pressure deviated by 0.03MPa and the reaction temperature fluctuated by 2°C. Such deviation and fluctuation significantly affected the operation of each work section. The gas tank pressure fluctuated to 1.2±0.05kPa and the reactor outlet pressure fluctuated to 0.3±0.03MPa, exceeding the allowable range of the process. At the same time, the reactor temperature fluctuated to 82±1.5°C, affecting the normal progress of the reaction. The separation monitoring unit showed that the condensation efficiency of the condenser had dropped significantly, and the uncondensed gas recovery flow rate fluctuated by about 15%, seriously affecting the stability of the production process and product quality.

[0040] Summary: Compared with the 0.03 MPa pressure deviation and 2°C temperature deviation of the conventional system in Example 2 under the same environmental changes, the present invention greatly improves the system stability when the environment changes suddenly.

[0041] Example 3 (Verification of the accuracy of early warning in the case of abnormal fluctuations in process parameters) In the distillation section of trans-dichloroethylene synthesis, transient fluctuations in the feed rate caused abnormal pressure fluctuations in the distillation column. Based on real-time data collected from this section (the pressure change rate reached 0.02 MPa / min, with a maximum fluctuation of 0.05 MPa over the past 24 hours), the safety margin assessment unit calculated a pressure warning value of 0.45 MPa for this section, combining the process-specific periodic fluctuation coefficient of 0.05 and phase angle of 0.3 rad. This calculated a pressure warning value of 0.45 MPa, reaching 90% of the static safety threshold (0.5 MPa). The early warning module immediately triggered a secondary warning, displaying an orange warning signal on the human-computer interface. Simultaneously, the parameter adjustment module automatically fine-tuned the distillation column pressure by 0.02 MPa. After the operator intervened according to the suggested adjustments on the interface, the pressure returned to 0.42 MPa within 15 minutes, without causing any production interruptions.

[0042] Comparative Example 3 A chemical plant used a traditional fixed-threshold early warning system in the distillation section of its trans-dichloroethylene synthesis process. When transient fluctuations in the feed rate caused abnormal changes in the distillation column pressure (the pressure change rate reached 0.02 MPa / min, with a maximum fluctuation of 0.05 MPa over the past 24 hours), the system relied solely on a fixed, static safety threshold (0.5 MPa) for its assessment, rather than dynamically adjusting the warning value based on process characteristics. In this scenario, traditional systems, unable to distinguish between normal fluctuations and abnormal trends, mistakenly identify fluctuations that do not reach the actual risk level as warning conditions, resulting in a false alarm rate of up to 30%. For example, when the pressure briefly fluctuates to 0.48MPa (not reaching the actual risk threshold), the system still triggers a level 1 warning. Operators intervene and find that no adjustment is required, resulting in wasted resources and production disruptions. In addition, the traditional system's warning response time is long (an average of 5 seconds) and does not provide specific adjustment suggestions. Operators are required to determine the treatment plan on their own, resulting in pressure recovery time extended to more than 20 minutes, increasing the risk of production interruption.

[0043] Summary: According to the statistical data of Example 3 and Comparative Example 3, the false alarm rate of the traditional fixed threshold warning system in Comparative Example 3 under this type of fluctuation is as high as 30%, while the present invention achieves zero false alarms through dynamic warning value calculation, and the warning response time is shortened to 2 seconds, which fully verifies the accuracy and timeliness of its warning.

[0044] In summary: The present invention uses a data-driven dynamic control strategy to solve the problems of insufficient adaptability, high false alarm rate and delayed response of traditional systems under complex working conditions, thereby providing reliable guarantees for the efficient and stable operation of chemical production processes.

[0045] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A pressure SIS control system for trans-dichloroethylene synthesis, characterized in that: It includes synthetic monitoring module, multi-source data acquisition module, parameter adjustment module, early warning module, human-computer interaction interface module and adaptive optimization module; The synthesis monitoring module monitors the key parameters of each section of the synthesis equipment in real time; The multi-source data acquisition module collects characteristic data of different raw materials and simultaneously obtains temperature and pressure data and environmental impact data of each synthesis process section monitored by the synthesis monitoring module; The data analysis module dynamically calculates the synthetic pressure supplement coefficient , synthetic temperature supplement coefficient And the pressure warning value of the jth section , generate early warning logic; The parameter adjustment module calculates the synthetic pressure supplement coefficient based on the data analysis module. , synthetic temperature supplement coefficient , adjusting the pressure and temperature control set points for the synthesis reaction; The early warning module monitors the pressure early warning value in real time According to the numerical range of the data, real-time graded warnings are issued and corresponding measures are taken; The human-computer interaction interface module is used to display the system operation status, key parameters and warning information, and receive instructions from operators to achieve human-computer interaction; The adaptive optimization module automatically adjusts the control strategy based on historical data and real-time monitoring data to optimize system performance.

2. A pressure SIS control system for trans-dichloroethylene synthesis according to claim 1, characterized in that: The synthesis monitoring module includes a raw material pretreatment monitoring unit, a catalytic reaction monitoring unit, a separation monitoring unit and a distillation monitoring unit. The raw material pretreatment monitoring unit is used to monitor the raw material pretreatment process, including the temperature, pressure, flow rate and impurity content parameters during the gas cabinet buffering, water-soluble impurity removal of the water washing tank, and sulfide and phosphide removal operations of the adsorption tank; the catalytic reaction monitoring unit is used to monitor the key parameters of the catalytic reaction process, including the temperature, pressure, reaction rate, raw material feed rate, catalyst activity state and component concentration of the product in the reactor, and to evaluate the reaction progress and safety in real time; the separation monitoring unit is used to monitor various parameters in the product separation process, such as the liquid level of the gas-liquid separator, the condensing temperature and pressure of the condenser, the recovery flow rate of uncondensed gas, and the concentration of trichloroethane, solvent and by-products in the liquid phase crude product; the distillation monitoring unit is used to monitor the temperature, pressure, flow rate, component concentration parameters at the top and bottom of the tower during the distillation process, and monitor the treatment process of the light / heavy component residues in the intermittent tower.

3. The pressure SIS control system for trans-dichloroethylene synthesis according to claim 1, characterized in that: The multi-source data acquisition module includes a raw material characteristic data acquisition unit, a work section data acquisition unit and an environmental data acquisition unit; the data analysis module includes a pressure supplement unit, a temperature supplement unit and a safety margin assessment unit.

4. A pressure SIS control system for trans-dichloroethylene synthesis according to claim 3, characterized in that: The raw material characteristic data acquisition unit acquires raw material characteristic data, including raw material purity, temperature, pressure, flow, component concentration and impurity content, through online analyzers and sensors.

5. The pressure SIS control system for trans-dichloroethylene synthesis according to claim 3, characterized in that: The section data acquisition unit acquires data of each synthesis section through sensors of the synthesis monitoring module and online monitoring equipment, including temperature, pressure, flow, component concentration, liquid level and pH value.

6. A pressure SIS control system for trans-dichloroethylene synthesis according to claim 3, characterized in that: The environmental data acquisition unit collects environmental data, including workshop temperature, humidity, atmospheric pressure, and combustible gas concentration in the air, through temperature and humidity sensors, atmospheric pressure gauges, and gas detectors.

7. A pressure SIS control system for trans-dichloroethylene synthesis according to claim 3, characterized in that: The pressure supplement unit calculates the synthetic pressure supplement coefficient based on the raw material characteristic data and the environmental data , and its calculation formula is: ； In the formula, represents the composite pressure supplement coefficient, Indicates the target pressure, Indicates the actual pressure, represents the pressure of the i-th raw material, represents the weight of the i-th raw material, Indicates environmental pressure, represents the weight of environmental pressure, Indicates the number of raw material types.

8. The pressure SIS control system for trans-dichloroethylene synthesis according to claim 3, characterized in that: The temperature supplement unit calculates the synthetic temperature supplement coefficient based on the raw material characteristic data and the environmental data , and its calculation formula is: ； In the formula, represents the composite temperature supplement coefficient, Indicates the target temperature, Indicates the actual temperature, represents the temperature of the i-th raw material, represents the weight of the i-th raw material, Indicates the ambient temperature, represents the weight of the ambient temperature, Indicates the number of raw material types.

9. The pressure SIS control system for trans-dichloroethylene synthesis according to claim 3, characterized in that: The safety margin evaluation unit calculates the pressure warning value of the jth section based on the data of each section This value is the pressure warning value of one section. The specific warning values ​​of other sections need to be substituted into the data of each section to calculate. The calculation formula is the same, which is: ； In the formula, Indicates the pressure warning value of the j-th section, represents the static safety threshold of the j-th section, represents the periodic fluctuation coefficient of the j-th section, represents the fluctuation frequency of the jth section, Indicates the cumulative running time since the system was started. represents the phase angle of the jth section, represents the pressure change rate coefficient of the j-th section, represents the pressure change rate of the jth section, represents the historical extreme value coefficient of the j-th section, It represents the maximum pressure fluctuation of the jth section in the past 24 hours.

10. The pressure SIS control system for trans-dichloroethylene synthesis according to claim 1, characterized in that: The early warning module monitors the pressure early warning value in real time The system can provide real-time graded warnings and take corresponding measures according to the numerical range of the data.

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