Energy-saving and efficient combustion control method and system for industrial furnace

Abstract

This invention relates to an energy-saving and efficient combustion control method and system for industrial furnaces, belonging to the field of industrial furnace automatic control technology. The method includes: acquiring the industrial furnace zone number; obtaining the corresponding target temperature and current temperature based on the industrial furnace zone number; calculating the temperature difference based on the target temperature and current temperature; when the temperature difference is less than a preset temperature difference threshold, finding the corresponding PID parameter based on the industrial furnace zone number; calculating a first required fuel amount based on the temperature difference and the PID parameter; controlling the zone corresponding to the industrial furnace zone number to add fuel according to the first required fuel amount; when the temperature difference is greater than the preset temperature difference threshold, finding a proportionality coefficient based on the industrial furnace zone number; calculating a second required fuel amount based on the temperature difference and the proportionality coefficient; and controlling the zone corresponding to the industrial furnace zone number to add fuel according to the second required fuel amount. This invention effectively reduces energy waste in industrial furnaces.

Description

Technical Field

[0001] This invention relates to the field of automatic control technology for industrial furnaces, and in particular to an energy-saving and efficient combustion control method and system for industrial furnaces. Background Technology

[0002] Industrial furnaces are an indispensable piece of equipment in industrial production and are widely used in many industries such as metallurgy, machinery, building materials, and chemicals. As a core device for heat energy conversion and processing, industrial furnaces generate high temperatures through fuel combustion or electrical energy conversion to realize processes such as smelting, heating, sintering, heat treatment, or chemical reactions of materials.

[0003] In related technologies, common combustion control often adopts PID regulation based on total load or overall temperature feedback, which controls the total supply of fuel and combustion air by monitoring the overall temperature or key point temperature in the furnace.

[0004] Regarding the aforementioned technologies, industrial furnaces often exhibit significant uneven temperature distribution. Existing control methods struggle to detect and respond to these localized differences in real time, failing to precisely adjust fuel supply according to actual regional needs. This can lead to fuel surplus in certain areas, resulting in energy waste. Summary of the Invention

[0005] To reduce energy waste in industrial furnaces, this invention provides an energy-saving and efficient combustion control method and system for industrial furnaces.

[0006] In a first aspect, the present invention provides an energy-saving and efficient combustion control method for an industrial furnace, employing the following technical solution: An energy-saving and efficient combustion control method for an industrial furnace includes: Step S1: Obtain the industrial furnace area number; Step S2: Obtain the corresponding target temperature and current temperature based on the industrial furnace area number; Step S3: Calculate the temperature difference based on the target temperature and the current temperature; Step S4: When the temperature difference is less than the preset temperature difference threshold, find the corresponding PID parameter based on the industrial furnace area number; Step S5: Calculate the first amount of fuel to be added based on the temperature difference and PID parameters; Step S6: Control the area corresponding to the industrial furnace area number to add fuel according to the first required amount of fuel; Step S7: When the temperature difference is greater than the preset temperature difference threshold, look up the proportional coefficient based on the industrial furnace area number; Step S8: Calculate the second required amount of fuel based on the temperature difference and the proportionality coefficient; Step S9: Control the area corresponding to the industrial furnace area number to add fuel according to the second required fuel amount.

[0007] By adopting the above technical solution, the corresponding target temperature and current temperature are accurately obtained by acquiring the numbers of each area of ​​the industrial furnace, and the temperature difference is calculated accordingly. Based on the comparison between the temperature difference and a preset threshold, different control strategies are flexibly selected. When the temperature difference is small, the first amount of fuel to be added is accurately calculated using PID parameters to achieve fine adjustment. When the temperature difference is large, the second amount of fuel to be added is quickly calculated using a proportional coefficient to respond rapidly to temperature changes.

[0008] Optionally, optimized methods for calculating the required amount of fuel include: Step S10: Calculate the precision heating temperature based on the target temperature and the temperature difference threshold; Step S11: Calculate the rough heating temperature difference based on the precise heating temperature and the current temperature; Step S12: Calculate the approximate amount of fuel to be added based on the approximate heating temperature difference and the proportionality coefficient; Step S13: Calculate the precise amount of fuel to be added based on the temperature difference threshold and PID parameters; Step S14: Obtain the required amount of fuel to be added based on the rough amount of fuel to be added and the precise amount of fuel to be added; Step S15: Control the area corresponding to the industrial furnace area number to add fuel according to the required amount of fuel.

[0009] By adopting the above technical solution, and by calculating the difference between precise and coarse heating temperatures, combined with proportional coefficients and PID parameters, the coarse and precise fuel addition amounts are obtained respectively. These two values ​​are then combined to arrive at the final required fuel addition amount. This method considers both the need for rapid response to temperature changes and ensures the accuracy of adjustment, thereby further optimizing the fuel addition calculation process and improving the efficiency and energy-saving effect of industrial furnace combustion control.

[0010] Optionally, methods for controlling the addition of fuel to the area corresponding to the industrial furnace area number according to the required fuel amount include: Step S150: Acquire control mode signal; Step S151: When the control mode signal is in automatic mode, determine whether the amount of fuel to be added falls within the preset normal fuel addition range; Step S152: When the amount of fuel to be added falls within the preset normal fuel addition range, control the area corresponding to the industrial furnace area number to add fuel according to the amount of fuel to be added; Step S153: When the amount of fuel to be added does not fall within the preset normal fuel addition range, output a fuel quantity abnormality signal; Step S154: When the control mode signal is manual mode, obtain the amount of fuel added manually, and determine whether the amount of fuel added manually falls within the preset normal fuel addition range. Step S155: When the amount of fuel added manually falls within the preset normal fuel addition range, control the area corresponding to the industrial furnace area number to add fuel according to the amount of fuel added manually; Step S156: When the amount of fuel added manually does not fall within the preset normal fuel addition range, output a fuel quantity abnormality signal.

[0011] By adopting the above technical solution and introducing the judgment of control mode signals, two different control modes, automatic and manual, are realized. In automatic mode, the system can automatically determine whether the amount of fuel to be added is within the normal range and make precise control or output an abnormal signal accordingly. In manual mode, the system judges and controls the fuel addition based on the user's input and can also output an abnormal signal to remind the user. This design improves the system's flexibility and safety, making the combustion control of the industrial furnace more in line with actual needs.

[0012] Optionally, the method for controlling the addition of fuel to the area corresponding to the industrial furnace area number according to the required fuel amount also includes: Step S157: Obtain the real-time temperature and maximum single fuel addition amount corresponding to the industrial furnace area number; Step S158: Obtain the real-time temperature difference based on the real-time temperature and the target temperature; Step S159: When the real-time temperature difference is greater than the preset temperature difference threshold, control the area corresponding to the industrial furnace area number to add fuel according to the maximum single fuel addition amount, and accumulate the amount of fuel added; Step S160: When the real-time temperature difference is less than the preset temperature difference threshold, obtain the amount of fuel added at low power.

[0013] Step S161: Control the area corresponding to the industrial furnace area number to add fuel according to the low power fuel addition amount.

[0014] By adopting the above technical solution, the system can flexibly adjust the fuel addition strategy according to the real-time temperature changes in different areas of the industrial furnace. When the real-time temperature difference exceeds a preset threshold, the system rapidly increases the temperature with the maximum single fuel addition amount, while recording the cumulative addition amount for subsequent monitoring. When the temperature approaches the target value, the system switches to a low-power addition mode for fine adjustment. This dynamic response mechanism avoids energy waste caused by excessive temperature fluctuations and ensures the temperature stability required by the process, effectively improving combustion control efficiency.

[0015] Optional, also includes: Step S162: When the amount of fuel to be added is less than the preset minimum amount, obtain the adjacent area number based on the industrial furnace area number; Step S163: Obtain the temperature of the adjacent region corresponding to the adjacent region number; Step S164: Filter out the adjacent area temperatures that are higher than the current temperature, and obtain the corresponding high-temperature area valve number; Step S165: Open the valve corresponding to the valve number in the high-temperature area until the real-time temperature equals the target temperature, then close the valve corresponding to the valve number in the high-temperature area.

[0016] By adopting the above technical solution, when the amount of fuel needed in a certain area is lower than the preset lower limit, the system locates adjacent areas by area number and obtains their temperature data. By filtering adjacent areas with temperatures higher than the current temperature, the system can accurately locate the high-temperature heat source and obtain the corresponding valve number. By opening the valve in the high-temperature area, heat sharing is achieved through heat conduction, allowing the low-temperature area to quickly rise to the target temperature before automatically closing the valve.

[0017] Optional, also includes: Step S166: Obtain the temperature difference between adjacent regions based on the temperature of adjacent regions and the target temperature; Step S167: When the temperature difference between adjacent temperatures is greater than the preset overheating temperature value, filter out the low temperature region with a current temperature lower than the current temperature and obtain the corresponding low temperature region number. Step S168: Obtain the target temperature of the low-temperature region corresponding to the low-temperature region number; Step S169: When the current temperature in the low-temperature region is lower than the target temperature of the low-temperature region, define the valve number corresponding to the low-temperature region number as the adjustable valve number; Step S170: While opening the valve corresponding to the valve number in the high-temperature zone, open the adjustable valve number until the real-time temperature is equal to the target temperature, then close the valve corresponding to the valve number in the high-temperature zone and the valve corresponding to the adjustable valve number.

[0018] By adopting the above technical solution, when the temperature difference between adjacent areas exceeds a preset overheating threshold, the system achieves gradient utilization of thermal energy through a dual temperature screening mechanism. First, it identifies the low-temperature area with a temperature lower than the current area and verifies whether its current temperature is below the set target value, marking the valves in the qualified areas as adjustable valves. While opening the valves in the high-temperature area to transfer heat, the adjustable valves are simultaneously opened to form a bidirectional heat flow channel, allowing excess heat from the high-temperature area to flow directionally to the low-temperature area through the conduction medium. When the real-time temperature parameter reaches the target value, the system automatically executes a linkage shutdown command, ensuring that the heat energy distribution process avoids the risk of local overheating while achieving precise temperature compensation in the low-temperature area.

[0019] Optional, also includes: Step S171: Obtain the superheat temperature based on the real-time temperature and the target temperature; Step S172: When the overheating temperature is greater than the preset overheating temperature threshold, obtain the number of working area numbers; Step S173: When the number of working area numbers is not 0, control the area corresponding to the industrial furnace area number to stop adding fuel.

[0020] By adopting the above technical solution, when the system detects that the overheating temperature exceeds the preset threshold, it first confirms whether there is an area currently in operation. If such an area exists, the system will immediately cut off the fuel supply to the area with the excessively high temperature to prevent the temperature from rising further and avoid equipment damage or process accidents caused by temperature runaway.

[0021] Optional, also includes: Step S174: When the number of working area numbers is 0, obtain the non-working area numbers; Step S175: Execute steps S1 to S15 based on the area corresponding to the non-working area number, and control the area corresponding to the industrial furnace area number to stop adding fuel.

[0022] By adopting the above technical solution, when the system confirms that all areas are in a non-working state, it allows the non-working areas to be heated, while cutting off the fuel supply channel to the areas with excessively high temperatures, thereby preventing overheating while continuing to heat the industrial furnace.

[0023] Optionally, methods for obtaining the corresponding target temperature and current temperature based on the industrial furnace zone number include: Step S20: Obtain the provisional target temperature and provisional current temperature based on the industrial furnace area number; Step S21: When the provisional target temperature falls within the preset normal target temperature range, the provisional target temperature is defined as the target temperature; Step S22: When the provisional target temperature does not fall within the preset normal target temperature range, output a target temperature abnormality signal; Step S23: When the provisional current temperature falls within the preset normal current temperature range, the provisional current temperature is defined as the current temperature; Step S24: When the current temperature does not fall within the preset normal current temperature range, output a current temperature abnormality signal.

[0024] By adopting the above technical solution and introducing a temperature range verification mechanism, the system immediately performs dual verification after acquiring the provisional temperature parameter. When the provisional target temperature is within the preset normal range, the system confirms it as a valid target value; if it exceeds the range, an abnormal alarm is triggered. Similarly, the same verification process is performed on the current temperature parameter to ensure that all temperature data meets process requirements before proceeding to subsequent control stages. This data preprocessing mechanism effectively filters abnormal parameters, avoids control errors caused by sensor malfunctions or data transmission errors, and provides a reliable data foundation for subsequent precise adjustments.

[0025] Secondly, this invention provides an energy-saving and high-efficiency combustion control system for an industrial furnace, employing the following technical solution: An energy-saving and high-efficiency combustion control system for an industrial furnace, comprising: The acquisition module is used to obtain the industrial furnace area number; A memory for storing a program for an energy-saving and efficient combustion control method for an industrial furnace as described above; The processor loads and executes programs from memory.

[0026] By adopting the above technical solution and constructing a control system architecture including an acquisition module, a memory, and a processor, an intelligent upgrade of industrial furnace combustion control has been achieved. The acquisition module is responsible for real-time collection of area numbering information, providing basic data for subsequent temperature parameter matching; the memory uses non-volatile storage media to completely store the program code of the combustion control method and preset parameter thresholds; the processor, as the core computing unit, loads and executes program instructions from the memory to complete the entire process control, including temperature difference calculation, control strategy selection, and dynamic fuel quantity adjustment. This system architecture modularizes data acquisition, storage, and processing functions, ensuring the independent operational stability of each component while achieving high-speed collaborative data processing through a bus communication mechanism, providing reliable technical support for industrial furnace combustion control.

[0027] In summary, the present invention has at least one of the following beneficial technical effects: 1. By independently monitoring and adjusting the temperature of each zone, and using PID control to ensure stability when the temperature is close to the target value, and proportional control to achieve rapid heating when the temperature difference is large, the system balances control accuracy and response speed, effectively reduces temperature overshoot and oscillation, and improves combustion efficiency. 2. By setting up automatic and manual dual-mode control, and performing fuel quantity range verification in both modes, an alarm signal is output in a timely manner when an abnormality occurs, to prevent equipment failure or safety accidents caused by abnormal fuel supply. Attached Figure Description

[0028] Figure 1 This is a flowchart of an energy-saving and efficient combustion control method for an industrial furnace according to an embodiment of this application. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0030] This invention discloses an energy-saving and efficient combustion control method for industrial furnaces. (Refer to...) Figure 1 An energy-saving and efficient combustion control method for industrial furnaces includes: Step S1: Obtain the industrial furnace area number.

[0031] Industrial furnace zone numbers are pre-defined numbers used to uniquely identify different heating zones within an industrial furnace system. Each number corresponds to a specific spatial location within the furnace, and these locations exhibit varying temperature differences due to factors such as design structure, fuel supply, and air circulation. Industrial furnace zone numbers are obtained by having staff pre-number each designated zone within the furnace, such as Zone 1, Zone 2, etc., and then entering this numbering information into the system.

[0032] Step S2: Obtain the corresponding target temperature and current temperature based on the industrial furnace area number.

[0033] The target temperature refers to the temperature that needs to be achieved for the current industrial furnace zone number. For example, if zone number one needs to be heated to 1000 degrees Celsius, then the target temperature for zone number one is 1000 degrees Celsius. The target temperature is obtained by having staff pre-set the target temperature for each zone according to the production process requirements. This target temperature data is then associated with the corresponding industrial furnace zone number and stored in the system. When the industrial furnace zone number is obtained, the system retrieves the corresponding target temperature from the stored data.

[0034] The current temperature refers to the actual temperature corresponding to the current industrial furnace zone number. For example, if the actual temperature of zone number one is detected to be 200 degrees Celsius at a certain moment, then the current temperature corresponding to zone number one is 200 degrees Celsius. The current temperature is obtained by installing temperature sensors in various zones of the industrial furnace. These temperature sensors can monitor the temperature of the corresponding zone in real time and transmit the monitored temperature data to the system. The system determines the current temperature corresponding to each industrial furnace zone number based on the received data.

[0035] Step S3: Calculate the temperature difference based on the target temperature and the current temperature.

[0036] Temperature difference refers to the difference between the target temperature and the current temperature, reflecting the degree of deviation between the current temperature and the desired temperature. The temperature difference is calculated by subtracting the current temperature from the target temperature. For example, if the target temperature for region 1 is 1000 degrees Celsius and the current temperature for region 1 is 200 degrees Celsius, then the temperature difference for region 1 is the difference between the target temperature of 1000 degrees Celsius and the current temperature of 200 degrees Celsius, which is 800 degrees Celsius.

[0037] Step S4: When the temperature difference is less than the preset temperature difference threshold, find the corresponding PID parameter based on the industrial furnace area number.

[0038] PID parameters are important parameters used to control the fuel addition amount in industrial furnaces. They include Kp, Ki, and Kd parameters. Each zone in an industrial furnace has its own independently set PID parameters (Kp, Ki, Kd). PID parameters are obtained by operators who pre-set the corresponding PID parameters for each zone of the industrial furnace based on its characteristics and actual operating experience, and then store these parameters in the system.

[0039] When the temperature difference is less than the preset temperature difference threshold, it means that the current temperature is close to the target temperature. At this time, it is necessary to control the amount of fuel added more precisely to avoid excessive temperature fluctuations.

[0040] Step S5: Calculate the first amount of fuel to be added based on the temperature difference and PID parameters.

[0041] The first required fuel amount refers to the amount of fuel that needs to be added when the temperature difference is less than a preset threshold, calculated by the PID control algorithm. The first required fuel amount is calculated by combining the proportional, integral, and derivative calculations of the PID parameters (Kp, Ki, Kd) and the temperature difference. It is obtained using the formula: Kp × temperature difference + Ki × temperature difference integral term + Kd × temperature difference derivative term. This value directly reflects the amount of fuel required when the current temperature is close to the target temperature.

[0042] Step S6: Control the area corresponding to the industrial furnace area number to add fuel according to the first required amount of fuel.

[0043] The control system adds fuel to the area corresponding to the industrial furnace area number according to the first required fuel amount, thereby raising the current temperature of the area corresponding to the industrial furnace area number to the target temperature.

[0044] Step S7: When the temperature difference is greater than the preset temperature difference threshold, look up the proportional coefficient based on the industrial furnace area number.

[0045] The proportionality coefficient is a parameter used to quickly adjust the fuel addition amount when there is a large temperature difference. Each zone in the industrial furnace has a corresponding independently set proportionality coefficient. The proportionality coefficient is obtained by the staff, who pre-determine an appropriate proportionality coefficient for each zone of the industrial furnace based on the actual operating conditions of each zone and historical experimental data, and then store it in the system.

[0046] Step S8: Calculate the second amount of fuel to be added based on the temperature difference and the proportionality coefficient.

[0047] The second required fuel amount refers to the amount of fuel that needs to be added when the temperature difference exceeds a preset threshold, calculated using a proportional control algorithm. This second required fuel amount is calculated directly by multiplying the temperature difference by a proportional coefficient. For example, when the temperature difference is 500 degrees Celsius and the proportional coefficient is 0.1, the second required fuel amount is 50 units of fuel. This value reflects the amount of rapid fuel replenishment needed when the current temperature differs significantly from the target temperature.

[0048] Step S9: Control the area corresponding to the industrial furnace area number to add fuel according to the second required fuel amount.

[0049] By controlling the fuel supply to the area corresponding to the industrial furnace zone number according to the second required fuel amount, the current temperature of that area can be rapidly brought closer to the target temperature, thereby reducing problems such as reduced production efficiency or affected product quality caused by excessive temperature differences.

[0050] The optimized methods for calculating the required amount of fuel include: Step S10: Calculate the precision heating temperature based on the target temperature and the temperature difference threshold.

[0051] Precision heating temperature refers to the temperature at which more precise heating is required, specifically the temperature at which the amount of fuel to be added needs to be calculated using PID parameters. The precision heating temperature is calculated by subtracting a temperature difference threshold from the target temperature. For example, if the target temperature is 1000 degrees Celsius and the temperature difference threshold is 100 degrees Celsius, then the precision heating temperature is 1000 degrees Celsius minus 100 degrees Celsius, resulting in 900 degrees Celsius.

[0052] Step S11: Calculate the rough heating temperature difference based on the precise heating temperature and the current temperature.

[0053] The rough heating temperature difference is the difference in temperature required for rough heating, and it also refers to the temperature difference used to calculate the amount of fuel to be added. The rough heating temperature difference is calculated by subtracting the precision heating temperature from the current temperature. For example, if the precision heating temperature is 900 degrees Celsius and the current temperature is 200 degrees Celsius, then the rough heating temperature difference is 900 degrees Celsius minus 200 degrees Celsius, resulting in 700 degrees Celsius.

[0054] Step S12: Calculate the approximate amount of fuel to be added based on the approximate heating temperature difference and the proportionality coefficient.

[0055] The rough fuel addition amount refers to the amount of fuel required to heat the current temperature to the precision heating temperature. The rough fuel addition amount is calculated by multiplying the rough heating temperature difference by a proportionality factor. For example, if the rough heating temperature difference is 700 degrees Celsius and the proportionality factor is 0.1, then the rough fuel addition amount is 70 units of fuel, calculated as 700 multiplied by 0.1.

[0056] Step S13: Calculate the precise amount of fuel to be added based on the temperature difference threshold and PID parameters.

[0057] Precision fuel addition refers to the amount of fuel required to be added, calculated more precisely using PID parameters. It also refers to the amount of fuel needed to heat the vehicle to the target temperature. The precision fuel addition is calculated by substituting the temperature difference threshold into the PID control algorithm formula: (Kp × temperature difference threshold + Ki × temperature difference threshold integral term + Kd × temperature difference threshold derivative term).

[0058] Step S14: Obtain the required amount of fuel to be added based on the rough amount of fuel to be added and the precise amount of fuel to be added.

[0059] The required fuel amount refers to the total amount of fuel needed to heat the current temperature to the target temperature. It is calculated by adding the approximate fuel amount to the precise fuel amount. For example, if the approximate fuel amount is 70 units and the precise fuel amount is 30 units, then the required fuel amount is 70 + 30 = 100 units.

[0060] Step S15: Control the area corresponding to the industrial furnace area number to add fuel according to the required amount of fuel.

[0061] The method for adding fuel to the area corresponding to the industrial furnace area number according to the required fuel amount includes: Step S150: Obtain the control mode signal.

[0062] The control mode signal is a signal used to indicate the current fuel addition control mode of the industrial furnace, including manual mode and automatic mode. The control mode signal is obtained by setting a mode selection button on the industrial furnace control panel and sending the control mode signal. The system receives and identifies the signal to determine whether it is currently in manual mode or automatic mode.

[0063] Step S151: When the control mode signal is in automatic mode, determine whether the amount of fuel to be added falls within the preset normal fuel addition range.

[0064] When the control mode signal is in automatic mode, it means that the fuel addition control of the industrial furnace is automatically performed by the system. At this time, the system will further determine whether the calculated amount of fuel to be added is within the preset normal fuel addition range.

[0065] The normal fuel addition range refers to a pre-set reasonable range of values ​​during the operation of an industrial furnace to ensure that the amount of fuel added meets heating requirements while avoiding waste. The normal fuel addition range is obtained by staff in advance based on the rated power of the industrial furnace, the design heat load of each area, historical operating data, and actual production process requirements. For example, a range of 5 to 100 units is the normal fuel addition range.

[0066] Step S152: When the amount of fuel to be added falls within the preset normal fuel addition range, control the area corresponding to the industrial furnace area number to add fuel according to the amount of fuel to be added.

[0067] When the required amount of fuel falls within the preset normal fuel addition range, it indicates that the currently calculated required amount of fuel is within a reasonable range, which can meet the heating needs of the industrial furnace and will not cause fuel waste. At this time, the system directly controls the area corresponding to the industrial furnace area number to add fuel according to the required amount of fuel, so as to achieve precise fuel supply and gradually bring the temperature of each area of ​​the industrial furnace to the target temperature. For example, if the required amount of fuel is 50 units and the normal fuel addition range is 5 to 100 units, then the required amount of fuel falls within the preset normal fuel addition range.

[0068] Step S153: When the amount of fuel to be added does not fall within the preset normal fuel addition range, output a fuel quantity abnormality signal.

[0069] If the amount of fuel to be added does not fall within the preset normal fuel addition range, it indicates that the currently calculated amount of fuel to be added exceeds the reasonable range, which may not meet the heating requirements of the industrial furnace or may cause fuel waste, or may even have an adverse effect on the normal operation of the industrial furnace. At this time, the system outputs a fuel quantity abnormality signal.

[0070] An abnormal fuel level signal is a warning signal indicating that the required amount of fuel exceeds the normal fuel addition range. This signal is displayed through audible alarms, flashing lights, or warning messages on the user interface.

[0071] Step S154: When the control mode signal is in manual mode, obtain the amount of fuel added manually, and determine whether the amount of fuel added manually falls within the preset normal fuel addition range.

[0072] Manually added fuel amount refers to the amount of fuel added by the operator in manual control mode. The manual fuel added amount is obtained by the operator entering the corresponding fuel added value on the control panel in manual control mode; the system receives this value as the manually added fuel amount.

[0073] When the control mode signal is in manual mode, it means that the fuel addition control of the industrial furnace is performed manually by the operator. At this time, the system will obtain the amount of fuel manually added by the operator and further determine whether the amount of fuel manually added is within the preset normal fuel addition range.

[0074] Step S155: When the amount of fuel added manually falls within the preset normal fuel addition range, control the area corresponding to the industrial furnace area number to add fuel according to the amount of fuel added manually.

[0075] When the manually added fuel amount falls within the preset normal fuel addition range, it indicates that the manually added fuel amount entered by the operator is within a reasonable range, which can meet the heating needs of the industrial furnace and will not cause fuel waste. For example, if the operator enters a manually added fuel amount of 80 units through the control panel, this manually added fuel amount is within the normal fuel addition range (such as 5 to 100 units), and the system will add fuel accordingly.

[0076] Step S156: When the amount of fuel added manually does not fall within the preset normal fuel addition range, output a fuel quantity abnormality signal.

[0077] If the manually added fuel amount does not fall within the preset normal fuel addition range, it indicates that the manually added fuel amount entered by the operator exceeds the reasonable range. This may fail to meet the heating requirements of the industrial furnace, cause fuel waste, or even adversely affect the normal operation of the industrial furnace. In this case, the system will also output a fuel quantity abnormality signal to remind the operator to adjust the manually added fuel amount in a timely manner to ensure the safe operation of the industrial furnace.

[0078] The method for adding fuel to the area corresponding to the industrial furnace area number according to the required fuel amount also includes: Step S157: Obtain the real-time temperature and maximum single fuel addition amount corresponding to the industrial furnace area number.

[0079] Real-time temperature refers to the real-time temperature value corresponding to the industrial furnace zone number. This value reflects the temperature status of each zone in the industrial furnace in real time. Real-time temperature is obtained through temperature sensors installed in each zone of the industrial furnace. These sensors continuously monitor the temperature and transmit the data to the system, which then determines the real-time temperature corresponding to each industrial furnace zone number.

[0080] The maximum single fuel addition amount refers to the maximum amount of fuel that can be added to an industrial furnace in a single operation. This value is set to ensure the safe operation of the industrial furnace and avoid safety hazards caused by excessive fuel addition. The maximum single fuel addition amount is obtained by operators who pre-set it based on the industrial furnace's design parameters, combustion characteristics, and safety regulations, and then store it in the system.

[0081] Step S158: Obtain the real-time temperature difference based on the real-time temperature and the target temperature.

[0082] The real-time temperature difference refers to the difference between the real-time temperature and the target temperature. It reflects the degree of difference between the current temperature and the desired temperature of the industrial furnace. The real-time temperature difference is calculated by subtracting the real-time temperature from the target temperature. For example, if the target temperature is set to 1000 degrees Celsius and the real-time temperature is 600 degrees Celsius, then the real-time temperature difference is 1000 degrees Celsius minus 600 degrees Celsius, resulting in 400 degrees Celsius.

[0083] Step S159: When the real-time temperature difference is greater than the preset temperature difference threshold, control the area corresponding to the industrial furnace area number to add fuel according to the maximum single fuel addition amount, and accumulate the amount of fuel added.

[0084] The amount of fuel added refers to the total amount of fuel recorded and accumulated during the process of adding fuel to the industrial furnace. The method for accumulating the amount of fuel added is to add the amount of fuel added each time fuel is added to the previously added amount of fuel.

[0085] Step S160: When the real-time temperature difference is less than the preset temperature difference threshold, obtain the amount of fuel added at low power.

[0086] Low-power fuel addition refers to a relatively small amount of fuel added to ensure that the industrial furnace temperature rises slowly and steadily to the target temperature when the real-time temperature difference is less than a preset threshold. The low-power fuel addition amount is obtained by operators who pre-determine an appropriate low-power fuel addition amount for each industrial furnace zone based on the furnace's combustion efficiency, thermal inertia, and the accuracy requirements of the target temperature, and then store this information in the system.

[0087] Step S161: Control the area corresponding to the industrial furnace area number to add fuel according to the low power fuel addition amount.

[0088] This also includes: Step S162: When the amount of fuel to be added is less than the preset minimum amount, obtain the adjacent area number based on the industrial furnace area number.

[0089] The minimum fuel addition amount refers to the lower limit of fuel addition set in advance to ensure stable operation of the industrial furnace and efficient fuel utilization. The minimum fuel addition amount is obtained by the staff in advance based on the minimum stable combustion load of the industrial furnace and the minimum flow requirement of the fuel supply system, thereby avoiding risks such as unstable combustion or flameout caused by insufficient fuel.

[0090] The adjacent area number refers to the number of other areas that are spatially adjacent to the current industrial furnace area number. The adjacent area number is obtained by the system based on the pre-set industrial furnace area layout information (industrial furnace area layout information refers to data stored in the system in advance about the spatial distribution and adjacency relationships of each area of ​​the industrial furnace).

[0091] Step S163: Obtain the temperature of the adjacent region corresponding to the adjacent region number.

[0092] The adjacent area temperature refers to the temperature value of the industrial furnace area corresponding to the adjacent area number. The adjacent area temperature is obtained by temperature sensors installed in the adjacent areas. These sensors monitor the temperature of the adjacent areas in real time and transmit the temperature data to the system, which then determines the adjacent area temperature corresponding to each adjacent area number.

[0093] Step S164: Filter out the adjacent area temperatures that are higher than the current temperature, and obtain the corresponding high-temperature area valve number.

[0094] The valve number for the high-temperature zone refers to the valve number corresponding to the selected adjacent zones with temperatures higher than the current temperature. These valve numbers are obtained by the system based on a pre-established correspondence between industrial furnace zones and valves. After selecting adjacent zones that meet the specified temperature criteria, the system searches for and extracts the valve numbers corresponding to these high-temperature zones from the correspondence. For example, if the temperature of the adjacent zone with adjacent zone number A is higher than the current temperature, and the valve number corresponding to the adjacent zone with adjacent zone number A is V1, then the system will obtain V1 as the high-temperature zone valve number.

[0095] Step S165: Open the valve corresponding to the valve number in the high-temperature area until the real-time temperature equals the target temperature, then close the valve corresponding to the valve number in the high-temperature area.

[0096] Open the valve corresponding to the high-temperature zone valve number to allow air circulation between the industrial furnace zone number and the adjacent zone number, thereby transferring heat from the adjacent zone number to the industrial furnace zone number until the real-time temperature equals the target temperature. Then close the valve corresponding to the high-temperature zone valve number to stop the heat transfer.

[0097] This also includes: Step S166: Obtain the temperature difference between adjacent areas based on the temperature of adjacent areas and the target temperature.

[0098] The adjacent temperature difference refers to the difference between the temperature of an adjacent area and the target temperature. The adjacent temperature difference is obtained by subtracting the target temperature from the adjacent area temperature. For example, if the temperature of an adjacent area is 1000 degrees Celsius and the target temperature is 800 degrees Celsius, then the adjacent temperature difference is 1000 degrees Celsius minus 800 degrees Celsius, which is 200 degrees Celsius.

[0099] Step S167: When the temperature difference between adjacent temperatures is greater than the preset overheating temperature value, filter out the low temperature region with a current temperature lower than the current temperature and obtain the corresponding low temperature region number.

[0100] The superheat temperature value refers to the temperature at which opening the valve corresponding to the adjacent zone number in the industrial furnace could cause the temperature to rise too rapidly. The superheat temperature value is obtained by operators who pre-set it based on the industrial furnace's design parameters, combustion characteristics, and safety regulations, and then store it in the system. For example, if the superheat temperature value is 150 degrees Celsius and the adjacent temperature difference is 300 degrees Celsius, then opening the valve corresponding to the adjacent zone number could cause the temperature in that zone to rise too rapidly, exceeding the target temperature.

[0101] The current temperature of a low-temperature region refers to the temperature among adjacent regions that is lower than the current temperature. The current temperature of a low-temperature region is obtained by the system comparing the current temperature with the temperatures of all adjacent regions one by one, and filtering out the temperatures of adjacent regions that are lower than the current temperature. These filtered temperatures are the current temperature of the low-temperature region.

[0102] The low-temperature zone number refers to the number corresponding to the adjacent zone whose temperature is lower than the current temperature. The low-temperature zone number is obtained by filtering all adjacent zones to find those with temperatures lower than the current temperature and determining their corresponding numbers. For example, if there are adjacent zones numbered B, C, and D, where zone B has a temperature of 900 degrees Celsius, zone C has a temperature of 800 degrees Celsius, and zone D has a temperature of 600 degrees Celsius, and the current temperature is 750 degrees Celsius, then the selected low-temperature zone number is D.

[0103] Step S168: Obtain the target temperature of the low-temperature region corresponding to the low-temperature region number.

[0104] The target temperature for the low-temperature zone refers to the desired temperature value for the industrial furnace zone corresponding to the low-temperature zone number. The target temperature for the low-temperature zone is obtained by staff who pre-set it based on the overall production process requirements of the industrial furnace, the allocation of heating tasks for each zone, and the actual operating conditions, and then store it in the system.

[0105] Step S169: When the current temperature in the low-temperature region is lower than the target temperature of the low-temperature region, define the valve number corresponding to the low-temperature region number as the adjustable valve number.

[0106] The adjustable valve number refers to the number of the valve corresponding to the low-temperature region number, which can control heat transfer by adjustment when the current temperature in the low-temperature region is lower than the target temperature of the low-temperature region.

[0107] Step S170: While opening the valve corresponding to the valve number in the high-temperature zone, open the adjustable valve number until the real-time temperature is equal to the target temperature, then close the valve corresponding to the valve number in the high-temperature zone and the valve corresponding to the adjustable valve number.

[0108] While opening the valve corresponding to the high-temperature zone valve number, the adjustable valve number is also opened. As heat is transferred to the industrial furnace zone corresponding to the industrial furnace zone number through the valve corresponding to the high-temperature zone valve number, the heat in the industrial furnace zone corresponding to the industrial furnace zone number can simultaneously be transferred to the low-temperature zone corresponding to the low-temperature zone number through the valve corresponding to the adjustable valve number, thereby slowing down the rate of temperature rise in the industrial furnace zone corresponding to the industrial furnace zone number.

[0109] This also includes: Step S171: Obtain the superheat temperature based on the real-time temperature and the target temperature.

[0110] The superheat temperature refers to the temperature value that has exceeded the target temperature. The superheat temperature is obtained by subtracting the target temperature from the real-time temperature. For example, if the real-time temperature is 1200 degrees Celsius and the target temperature is 1000 degrees Celsius, then the superheat temperature is 200 degrees Celsius, which is 1200 degrees Celsius minus 1000 degrees Celsius.

[0111] Step S172: When the overheating temperature is greater than the preset overheating temperature threshold, obtain the number of working area numbers.

[0112] The overheating temperature threshold refers to the upper limit of the allowable overheating temperature that is preset to ensure the safe operation of an industrial furnace and prevent equipment damage or safety accidents caused by excessively high temperatures. The overheating temperature threshold is obtained by operators who preset and store it in the system based on the industrial furnace's design parameters, material temperature tolerance, and safety regulations.

[0113] The number of working area numbers refers to the total number of numbers corresponding to the areas in the industrial furnace that are currently undergoing heating operations. The number of working area numbers is obtained by the system identifying and counting the currently operating heating areas to determine the number of area numbers currently in operation. For example, if the industrial furnace has five areas, numbered 1 to 5, and at the current moment, areas 1, 3, and 5 are undergoing heating operations, then the number of working area numbers is 3.

[0114] Step S173: When the number of working area numbers is not 0, control the area corresponding to the industrial furnace area number to stop adding fuel.

[0115] When the number of working area numbers is not 0, it means that some areas in the industrial furnace are still in the heating operation state, but the area corresponding to the current industrial furnace area number has overheated. Its overheating temperature has exceeded the preset overheating temperature threshold. In order to prevent the temperature from rising further and causing damage to the equipment or causing a safety accident, the system will control the area corresponding to the industrial furnace area number to stop adding fuel, so that only other areas can heat the industrial furnace.

[0116] This also includes: Step S174: When the number of working area numbers is 0, obtain the non-working area numbers.

[0117] The non-working area number refers to the number corresponding to the area in the industrial furnace that is not currently being heated. The non-working area number is obtained by the system traversing all industrial furnace area numbers and identifying the areas not marked as working area numbers as non-working area numbers.

[0118] Step S175: Execute steps S1 to S15 based on the area corresponding to the non-working area number, and control the area corresponding to the industrial furnace area number to stop adding fuel.

[0119] The methods for obtaining the corresponding target temperature and current temperature based on the industrial furnace area number include: Step S20: Obtain the provisional target temperature and provisional current temperature based on the industrial furnace area number.

[0120] The provisional target temperature refers to the desired temperature value set for each industrial furnace zone number under the system's preset initial state. The provisional target temperature is obtained by the staff during system initialization based on the overall production process requirements of the industrial furnace, the heating task allocation for each zone, and the actual operating conditions. The system then directly retrieves the corresponding provisional target temperature from the stored data according to the industrial furnace zone number.

[0121] The provisional current temperature is the temperature currently obtained by the industrial furnace area number. It is obtained by the temperature sensor installed in the area corresponding to the industrial furnace area number. For example, if the temperature sensor installed in the area corresponding to the industrial furnace area number obtains a temperature value of 1500 degrees Celsius at this time, then the provisional current temperature is 1500 degrees Celsius.

[0122] Step S21: When the provisional target temperature falls within the preset normal target temperature range, the provisional target temperature is defined as the target temperature.

[0123] The normal target temperature range refers to a pre-set, reasonable target temperature range. This range is determined by the operators based on a comprehensive consideration of factors such as the industrial furnace's design parameters, production process requirements, and safety regulations. When the provisional target temperature falls within this range, it indicates that the temperature meets the requirements for normal operation of the industrial furnace. In this case, the system will directly define the provisional target temperature as the target temperature for subsequent combustion control operations. For example, if the preset normal target temperature range is 800 degrees Celsius to 1200 degrees Celsius, and the provisional target temperature is 1000 degrees Celsius, since it falls within this range, the target temperature will be determined as 1000 degrees Celsius.

[0124] Step S22: When the provisional target temperature does not fall within the preset normal target temperature range, output a target temperature abnormality signal.

[0125] The target temperature anomaly signal is a signal generated by the system to indicate an abnormality in the target temperature when the provisional target temperature exceeds the normal target temperature range. The output of the target temperature anomaly signal involves the system displaying corresponding abnormal information on the industrial furnace's operating interface after detecting that the provisional target temperature is outside the normal target temperature range. Simultaneously, an alarm will be triggered via an audible and visual alarm device to remind personnel to handle the situation promptly.

[0126] Step S23: When the provisional current temperature falls within the preset normal current temperature range, the provisional current temperature is defined as the current temperature.

[0127] When the provisional current temperature falls within the preset normal current temperature range, it indicates that the temperature is within the reasonable range set by the system and meets the temperature conditions allowed for the normal operation of the industrial furnace. At this time, the system will directly define the provisional current temperature as the current temperature corresponding to the target temperature. For example, if the preset normal current temperature range is 1000 degrees Celsius to 1200 degrees Celsius, and the provisional current temperature obtained by the temperature sensor is 1100 degrees Celsius, since it is within this range, the current temperature will be determined as 1100 degrees Celsius.

[0128] Step S24: When the current temperature does not fall within the preset normal current temperature range, output a current temperature abnormality signal.

[0129] The current temperature anomaly signal refers to a signal automatically generated and triggered by the system when the provisional current temperature obtained by the temperature sensor exceeds the system's preset normal current temperature range, indicating an abnormal temperature condition. The current temperature anomaly signal is output by displaying corresponding abnormal information on the industrial furnace's operating interface after the system detects that the provisional current temperature is outside the normal current temperature range. Simultaneously, an alarm is triggered via an audible and visual alarm device to remind personnel to handle the situation promptly.

[0130] Based on the same inventive concept, embodiments of the present invention provide an energy-saving and efficient combustion control system for industrial furnaces.

[0131] An energy-saving and high-efficiency combustion control system for an industrial furnace, comprising: The acquisition module is used to obtain the industrial furnace area number; A memory for storing a program for an energy-saving and efficient combustion control method for an industrial furnace; The processor loads and executes programs from memory.

[0132] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for energy-saving and efficient combustion control in an industrial furnace, characterized in that, include: Step S1: Obtain the industrial furnace area number; Step S2: Obtain the corresponding target temperature and current temperature based on the industrial furnace area number; Step S3: Calculate the temperature difference based on the target temperature and the current temperature; Step S4: When the temperature difference is less than the preset temperature difference threshold, find the corresponding PID parameter based on the industrial furnace area number; Step S5: Calculate the first amount of fuel to be added based on the temperature difference and PID parameters; Step S6: Control the area corresponding to the industrial furnace area number to add fuel according to the first required amount of fuel; Step S7: When the temperature difference is greater than the preset temperature difference threshold, look up the proportional coefficient based on the industrial furnace area number; Step S8: Calculate the second required amount of fuel based on the temperature difference and the proportionality coefficient; Step S9: Control the area corresponding to the industrial furnace area number to add fuel according to the second required fuel amount.

2. The energy-saving and high-efficiency combustion control method for an industrial furnace according to claim 1, characterized in that, Optimal methods for calculating the required amount of fuel include: Step S10: Calculate the precision heating temperature based on the target temperature and the temperature difference threshold; Step S11: Calculate the rough heating temperature difference based on the precise heating temperature and the current temperature; Step S12: Calculate the approximate amount of fuel to be added based on the approximate heating temperature difference and the proportionality coefficient; Step S13: Calculate the precise amount of fuel to be added based on the temperature difference threshold and PID parameters; Step S14: Obtain the required amount of fuel to be added based on the rough amount of fuel to be added and the precise amount of fuel to be added; Step S15: Control the area corresponding to the industrial furnace area number to add fuel according to the required amount of fuel.

3. The energy-saving and high-efficiency combustion control method for an industrial furnace according to claim 2, characterized in that, The method for adding fuel to the industrial furnace zone corresponding to the zone number according to the required fuel amount includes: Step S150: Acquire control mode signal; Step S151: When the control mode signal is in automatic mode, determine whether the amount of fuel to be added falls within the preset normal fuel addition range; Step S152: When the amount of fuel to be added falls within the preset normal fuel addition range, control the area corresponding to the industrial furnace area number to add fuel according to the amount of fuel to be added; Step S153: When the amount of fuel to be added does not fall within the preset normal fuel addition range, output a fuel quantity abnormality signal; Step S154: When the control mode signal is manual mode, obtain the amount of fuel added manually, and determine whether the amount of fuel added manually falls within the preset normal fuel addition range. Step S155: When the amount of fuel added manually falls within the preset normal fuel addition range, control the area corresponding to the industrial furnace area number to add fuel according to the amount of fuel added manually; Step S156: When the amount of fuel added manually does not fall within the preset normal fuel addition range, output a fuel quantity abnormality signal.

4. The energy-saving and high-efficiency combustion control method for an industrial furnace according to claim 2, characterized in that, The method for adding fuel to the industrial furnace area according to the required amount also includes: Step S157: Obtain the real-time temperature and maximum single fuel addition amount corresponding to the industrial furnace area number; Step S158: Obtain the real-time temperature difference based on the real-time temperature and the target temperature; Step S159: When the real-time temperature difference is greater than the preset temperature difference threshold, control the area corresponding to the industrial furnace area number to add fuel according to the maximum single fuel addition amount, and accumulate the amount of fuel added; Step S160: When the real-time temperature difference is less than the preset temperature difference threshold, obtain the amount of fuel added for low power; Step S161: Control the area corresponding to the industrial furnace area number to add fuel according to the low power fuel addition amount.

5. The energy-saving and high-efficiency combustion control method for an industrial furnace according to claim 4, characterized in that, Also includes: Step S162: When the amount of fuel to be added is less than the preset minimum amount, obtain the adjacent area number based on the industrial furnace area number; Step S163: Obtain the temperature of the adjacent region corresponding to the adjacent region number; Step S164: Filter out the adjacent area temperatures that are higher than the current temperature, and obtain the corresponding high-temperature area valve number; Step S165: Open the valve corresponding to the valve number in the high-temperature area until the real-time temperature equals the target temperature, then close the valve corresponding to the valve number in the high-temperature area.

6. The energy-saving and high-efficiency combustion control method for an industrial furnace according to claim 5, characterized in that, Also includes: Step S166: Obtain the temperature difference between adjacent regions based on the temperature of adjacent regions and the target temperature; Step S167: When the temperature difference between adjacent temperatures is greater than the preset overheating temperature value, filter out the low temperature region with a current temperature lower than the current temperature and obtain the corresponding low temperature region number. Step S168: Obtain the target temperature of the low-temperature region corresponding to the low-temperature region number; Step S169: When the current temperature in the low-temperature region is lower than the target temperature of the low-temperature region, define the valve number corresponding to the low-temperature region number as the adjustable valve number; Step S170: While opening the valve corresponding to the valve number in the high-temperature zone, open the adjustable valve number until the real-time temperature is equal to the target temperature, then close the valve corresponding to the valve number in the high-temperature zone and the valve corresponding to the adjustable valve number.

7. The energy-saving and high-efficiency combustion control method for an industrial furnace according to claim 6, characterized in that, Also includes: Step S171: Obtain the superheat temperature based on the real-time temperature and the target temperature; Step S172: When the overheating temperature is greater than the preset overheating temperature threshold, obtain the number of working area numbers; Step S173: When the number of working area numbers is not 0, control the area corresponding to the industrial furnace area number to stop adding fuel.

8. The energy-saving and high-efficiency combustion control method for an industrial furnace according to claim 7, characterized in that, Also includes: Step S174: When the number of working area numbers is 0, obtain the non-working area numbers; Step S175: Execute steps S1 to S15 based on the area corresponding to the non-working area number, and control the area corresponding to the industrial furnace area number to stop adding fuel.

9. The energy-saving and high-efficiency combustion control method for an industrial furnace according to claim 1, characterized in that, Methods for obtaining the corresponding target temperature and current temperature based on the industrial furnace area number include: Step S20: Obtain the provisional target temperature and provisional current temperature based on the industrial furnace area number; Step S21: When the provisional target temperature falls within the preset normal target temperature range, the provisional target temperature is defined as the target temperature; Step S22: When the provisional target temperature does not fall within the preset normal target temperature range, output a target temperature abnormality signal; Step S23: When the provisional current temperature falls within the preset normal current temperature range, the provisional current temperature is defined as the current temperature; Step S24: When the current temperature does not fall within the preset normal current temperature range, output a current temperature abnormality signal.

10. An energy-saving and high-efficiency combustion control system for an industrial furnace, characterized in that, include: The acquisition module is used to obtain the industrial furnace area number; A memory for storing a program of an energy-saving and efficient combustion control method for an industrial furnace as described in any one of claims 1 to 9; The processor loads and executes programs from memory.

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