Raw material batching optimization control method for cement production based on setting time
Patent Information
- Application Number
- CN202611529698.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-09-30
- Publication Date
- 2026-11-03
Smart Images
Figure CN123029900A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of cement production control technology, and in particular to a method for optimizing the batching control of raw materials for cement production based on setting time. Background Technology
[0002] In the continuous cement production process, to ensure that the cement setting time meets construction requirements, the proportions of raw materials such as limestone, sandstone, iron powder, and slag are usually adjusted based on the setting time test results. When a setting time that is too long is detected, the control system implements corresponding batching corrections; if the subsequent setting time is still too long, the raw material proportions are adjusted again along the original correction direction.
[0003] However, after the raw material batching is adjusted, it still needs to go through raw material transportation, raw material homogenization, preheating, calcination, clinker formation, and sampling and testing. Its effects cannot be immediately reflected in the setting time test results. When a historical abnormal batching cycle causes a longer setting time, although batching correction has been implemented, as production continues, the material corresponding to the historical abnormal batching cycle may have gradually been removed from the production process. The setting time samples obtained later may still be affected by the tail end of the material corresponding to the historical abnormal batching cycle, and continue to show a longer setting time.
[0004] In this situation, if the current excessively long setting time is still considered as insufficient adjustment in the previous batching process, and batching adjustments in the same direction continue to be implemented, then batching adjustments that have not yet received feedback confirmation from the setting time will continue to accumulate. Once the materials corresponding to the historically abnormal batching cycles have largely disappeared, the effects of the existing batching adjustments will gradually become apparent, potentially causing the setting time to shift from being too long (exceeding the target range) to being too short, resulting in over-adjustment of raw material batching and repeated fluctuations in setting time. Therefore, the existing technology still faces the problem of difficulty in reasonably controlling subsequent raw material batching based on the residual effects of materials corresponding to historically abnormal batching cycles and the unfeeded effects of existing batching adjustments. Summary of the Invention
[0005] In view of this, in order to solve the problems mentioned in the background art, the present invention proposes a method for optimizing and controlling the batching of raw materials for cement production based on setting time.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: a method for optimizing and controlling the batching of raw materials for cement production based on setting time, comprising the following steps: determining the historical abnormal batching cycle and the mass proportion of the corresponding material in the current setting time sample based on the sampling period of the setting time sample, the raw material batching record and the batching cycle transmission interval, and determining the remaining amount of historical abnormal effects in combination with the intensity of setting action.
[0007] After the historical abnormal batching cycle is determined, the same-direction batching correction is executed. The cumulative amount of unconfirmed batching correction is determined based on the condensation correction amount of each same-direction batching correction and the proportion of the corresponding material entering the sample at the current condensation time.
[0008] Subtract the accumulated amount of unconfirmed batching corrections from the remaining amount of historical anomalies to obtain the net amount of anomalies to be processed. When the setting time is still too long and the net amount of anomalies to be processed is not greater than zero, the batching correction in the same direction is locked.
[0009] After the corresponding material for a historically abnormal batching cycle is removed and the existing batching correction meets the feedback confirmation conditions, the locking is released. The raw material ratio for the next batching cycle is adjusted based on the settling time deviation after the locking is released. Compared with existing technologies, the beneficial effects of this invention are as follows: This invention traces multiple historical batching cycles using settling time samples and raw material batching records, and determines historically abnormal batching cycles by combining the mass proportion of materials corresponding to each historical batching cycle and the intensity of settling in each historical batching cycle. This method avoids judging the source of settling time abnormalities based on material proportions or fixed time correspondences, enabling subsequent batching control to address historical batching cycles where the current settling time deviation plays a major role.
[0010] This invention determines the remaining amount of historical anomalies and the accumulated amount of unconfirmed batching corrections, and obtains the net amount of anomalies to be processed by the difference between the two. This method can identify situations where the current setting time is still too long but the batching corrections already implemented have not been fully reflected, avoiding the erroneous assumption that setting time feedback lag is insufficient batching correction and thus continuously increasing batching corrections in the same direction.
[0011] This invention locks the same-direction batching correction when the current setting time is still too long and the net amount of anomalies to be processed is not greater than zero. The lock is released after the corresponding material of the historical abnormal batching cycle is removed and the existing batching correction meets the feedback confirmation conditions. It does not rely on a fixed waiting time to determine the timing of the readjustment, which can reduce the over-adjustment and repeated fluctuations of setting time caused by the concentrated manifestation of existing batching correction after the historical abnormality effect is removed. Attached Figure Description
[0012] Figure 1 This is a schematic diagram of the raw material batching optimization control process in S1 to S6 of the present invention; Figure 2 This is a schematic diagram of the process for confirming historical abnormal batching cycles in steps S101 to S103 of this invention; Figure 3 This is a schematic diagram of the process for determining the cumulative amount of unconfirmed ingredient corrections in steps S301 to S303 of the present invention; Figure 4 This is a schematic diagram illustrating the changes in coagulation time, material mass percentage corresponding to historical abnormal batching cycles, cumulative amount of unconfirmed batching corrections, net amount of abnormalities to be processed, and batching correction status over sampling time in this invention. Detailed Implementation
[0013] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0014] The following examples illustrate the method for optimizing and controlling the batching of raw materials for cement production based on setting time.
[0015] Example 1: like Figure 1 As shown, this embodiment performs raw material batching optimization control according to S1 to S6. S1 determines the historical abnormal batching cycle based on the sampling period of the setting time sample, the raw material batching record, and the batching cycle transfer interval; S2 determines the remaining amount of historical abnormal effects based on the mass ratio of the material corresponding to the historical abnormal batching cycle and the intensity of the setting effect; S3 determines the accumulated amount of unconfirmed batching correction based on the setting correction amount of the same direction batching correction and the proportion of the corresponding material entering the current setting time sample; S4 calculates the net amount of abnormalities to be processed; S5 locks the same direction batching correction when the current setting time is still too long and the net amount of abnormalities to be processed is not greater than zero; S6 unlocks the lock after the material corresponding to the historical abnormal batching cycle exits and the existing batching correction meets the feedback confirmation conditions, and adjusts the raw material ratio of the next batching cycle according to the setting time deviation after unlocking.
[0016] This embodiment uses a continuous cement production line as the application object, and each batching cycle is divided according to the actual batching rhythm of the production line. The setting time samples are tested using uniform sample preparation conditions, that is, cement samples are prepared using the same grinding conditions and the same gypsum addition ratio for the corresponding clinker, and the setting time, as a control quantity, is obtained using the same testing method. The target setting time is predetermined according to the process control requirements of the current cement variety being produced; during a single control process, the definition of setting time, testing conditions, and target setting time remain consistent. In this embodiment, a longer setting time refers to a measured setting time that is higher than the target setting time, and the difference between the two exceeds the repeated testing fluctuation range, which is determined according to the method described in S6. The raw material batching record includes at least the start time, end time, actual limestone addition ratio, actual sandstone addition ratio, actual iron powder addition ratio, actual slag addition ratio, and the execution time of each batching correction for each batching cycle.
[0017] After the raw material ratio is adjusted, the materials sequentially undergo raw material conveying, raw material homogenization, preheating, calcination, and clinker formation, followed by setting time monitoring. There is a material transfer lag between batching correction and setting time feedback. The same setting time sample may also contain materials corresponding to multiple historical batching cycles. Therefore, when materials corresponding to historically abnormal batching cycles have not yet been removed and existing batching corrections have not yet been completed, the current setting time is not directly used as the basis for additional batching corrections in the same direction.
[0018] This embodiment first traces the historical batching cycle corresponding to the current setting time sample and identifies historical abnormal batching cycles. Then, it determines the remaining amount of historical abnormal effects and the accumulated amount of unconfirmed batching corrections, and calculates the net amount of anomalies to be processed. When the setting time is still too long and the net amount of anomalies to be processed is not greater than zero, the actual addition ratio of the corresponding raw material after the most recent batching correction is maintained. When the material corresponding to the historical abnormal batching cycle is removed and the existing batching correction meets the feedback confirmation conditions, the raw material ratio of the next batching cycle is adjusted according to the new setting time deviation.
[0019] In this embodiment, the condensation intensity is characterized by the change in the relative deviation of condensation time. The condensation intensity of historical abnormal batching cycles is used to calculate the remaining amount of historical abnormality; the condensation intensity of the corresponding raw material is used to calculate the condensation correction amount for batching correction. The condensation intensity of the corresponding raw material is the comprehensive condensation intensity determined based on historical batching correction records that have completed material transfer and obtained condensation time feedback, under the condition that the raw material is adjusted and the other raw materials are compensated in reverse according to a predetermined relative ratio.
[0020] S1. Based on the sampling period of the solidification time sample, the raw material batching record, and the batching cycle transfer interval, trace the historical batching cycle to determine the historical abnormal batching cycle that caused the solidification time deviation.
[0021] like Figure 2 As shown, S1 further includes S101 to S103. S101 screens historical batching cycles that may enter the current setting time sample based on the sampling period and batching cycle transfer interval of the current setting time sample, and determines the material mass and mass ratio of each historical batching cycle entering the sample based on the transfer distribution; S102 determines the relative deviation of setting time based on the measured setting time and the target setting time, selects adjacent setting time samples where the material mass ratio of the historical batching cycle to be evaluated changes, the other historical batching cycles use the same raw material ratio and no new batching correction is implemented during the period, and determines the intensity of condensation based on the change in the relative deviation of setting time and the change in mass ratio; S103 determines the current condensation amount based on the mass ratio and condensation intensity of each historical batching cycle, and determines the historical abnormal batching cycle accordingly.
[0022] A sample at the same settling time may contain materials corresponding to multiple historical batching cycles. Therefore, the source of the anomaly is determined based on the mass percentage of materials corresponding to each historical batching cycle entering the current settling time sample and the intensity of their coagulation.
[0023] Specifically, the start and end times of sampling are recorded for each condensation time sample. Before production operation, a period in which no new batching modifications are implemented and the feed rate per unit time remains stable is selected. The actual addition ratio of the corresponding raw material in a known batching cycle is changed, and the change in the actual addition ratio is within the range covered by the historical stable production records of the corresponding raw material. Subsequently, X-ray fluorescence analyzer is used to detect the changes in the content of characteristic elements of the corresponding raw material in subsequent condensation time samples. The characteristic elements are selected as elements that have a high content in the corresponding raw material or have a significant content difference relative to other raw materials, and whose content change in the condensation time sample can stably exceed the normal production fluctuation range when the actual addition ratio of the corresponding raw material changes. Their identifiability is confirmed by historical stable production records.
[0024] The detection threshold is determined based on the normal fluctuation range of the characteristic element content of the raw material before calibration. The moment when the characteristic element content first stably exceeds the detection threshold is designated as the first occurrence moment; the moment when the sample reaches its peak value is designated as the maximum occurrence moment; and the moment when the characteristic element content falls back to the normal fluctuation range and remains stable in subsequent continuous samples is designated as the disappearance moment. The batching cycle transfer interval under the current production load is determined based on the first occurrence moment, the maximum occurrence moment, and the disappearance moment.
[0025] Under the condition that the material conveying path and equipment operating status remain unchanged, when the production load changes, the batching cycle transfer interval is scaled by the ratio of the feed rate per unit time at the calibration time to the current feed rate per unit time; when the material conveying path or equipment operating status changes, the batching cycle transfer interval is recalibrated. Based on the overlap between the material arrival time period after correction by the batching cycle transfer interval for each historical batching cycle and the sampling time period of the condensation time sample, the material mass entering the condensation time sample for the corresponding historical batching cycle is determined according to the feed rate per unit time within the overlap interval; after determining the material mass corresponding to each historical batching cycle, a transfer distribution is formed.
[0026] S101. For the current setting time sample, screen the historical batching cycles that may enter the current setting time sample based on the sampling period and the transfer interval of the batching cycle; determine the material mass of each historical batching cycle that enters the current setting time sample based on the transfer distribution, and calculate the corresponding mass percentage.
[0027] The mass percentage is the ratio of the mass of the material entering the current condensation time sample in the corresponding historical batching cycle to the sum of the mass of the material entering the sample in each historical batching cycle. The value ranges from zero to one, and the sum of the mass percentages of the corresponding materials in each historical batching cycle is one.
[0028] S102. Determine the intensity of condensation in each historical batching cycle. Divide the difference between the measured condensation time and the target condensation time of the condensation time sample by the target condensation time to obtain the relative deviation of condensation time; a relative deviation of condensation time greater than zero indicates that the condensation time is too long, and a relative deviation of less than zero indicates that the condensation time is too short.
[0029] For the historical batching cycle to be evaluated, adjacent setting time samples are selected where the corresponding material mass ratio changed, no new batching adjustments were implemented during the period, and the other historical batching cycles that participated in the formation of the adjacent setting time samples used the same raw material ratio. The relative deviation of setting time of adjacent samples is divided by the change in the mass ratio of the corresponding material in the historical batching cycle to be evaluated to obtain the unit mass ratio condensation effect. Then, a weighted average is performed according to the absolute value of each mass ratio change to obtain the condensation intensity of that historical batching cycle. A positive unit mass ratio condensation effect corresponds to the direction of increased setting time, and a negative value corresponds to the direction of decreased setting time.
[0030] S103. Multiply the mass percentage of each historical batching cycle in the current setting time sample by the corresponding setting intensity to obtain the current setting amount of each historical batching cycle; screen the historical batching cycles whose setting direction is the same as the current setting time deviation direction, and determine the historical batching cycle with the largest absolute value of the current setting amount as the historical abnormal batching cycle.
[0031] S2. Determine the remaining amount of historical abnormal effects based on the mass percentage of materials corresponding to the historical abnormal batching cycle in the continuous condensation time sample and the intensity of condensation.
[0032] Once the historical abnormal batching cycle is determined, the mass percentage of the material corresponding to that historical batching cycle is updated according to the sampling order of the subsequent condensation time samples, and the remaining amount of the historical abnormal effect is calculated in combination with the condensation intensity of that historical batching cycle.
[0033] For the i-th condensation time sample, the remaining amount of historical anomalies is determined according to the following formula: .
[0034] In the formula, This represents the remaining amount of historical anomalies corresponding to the i-th condensation time sample; This represents the mass percentage of the material corresponding to the historical abnormal batching cycle in the sample at the i-th condensation time, with a value ranging from zero to one. This indicates the intensity of coagulation during historically abnormal batching cycles.
[0035] The remaining amount of historical anomalies varies with the mass percentage of the material corresponding to the historical anomaly batching cycle, and is used to characterize the condensation effect that has not yet exited in the current condensation time sample of that historical batching cycle.
[0036] Continuous setting time samples were selected based on historical abnormal batching cycles where the material mass percentage consistently decreased and no new batching corrections were implemented during that period. The mass percentage of each sample was determined by the material mass of the corresponding material entering the setting time sample, and the relative deviation of the setting time was calculated from the measured setting time and the target setting time.
[0037] The intensity of condensation in this historically abnormal batching cycle is determined according to S102. For samples with subsequent condensation times, the mass percentage of the corresponding material is substituted into the formula for calculating the remaining amount of the historically abnormal effect to obtain the current remaining amount of the historically abnormal effect.
[0038] S3. Obtain the same-direction batching corrections executed after the historical abnormal batching cycle is determined. Based on the condensation correction amount of each same-direction batching correction and the proportion of the corresponding material entering the sample at the current condensation time, determine the cumulative amount of unconfirmed batching corrections.
[0039] like Figure 3 As shown, S3 further includes S301 to S303. S301 determines the change in the actual addition ratio based on the actual addition ratio of the corresponding raw materials before and after each batching correction, and determines the magnitude and direction of the condensation correction amount in combination with the condensation intensity of the corresponding raw materials; S302 takes the first batching correction performed after the historical abnormal batching cycle is determined as the benchmark batching correction, and determines the subsequent batching corrections with the same condensation correction direction as batching corrections in the same direction; S303 determines the unreflected condensation effect based on the proportion of the corresponding material of each batching correction in the same direction entering the sample at the current condensation time, and adds up the unreflected condensation effects to obtain the cumulative amount of unconfirmed batching corrections.
[0040] Once the historical abnormal batching cycle is determined, the executed batching corrections are obtained. For batching corrections that have not yet fully entered the current setting time sample, the unrealized setting effect is calculated based on the proportion that has not yet entered the sample, and batching corrections in the same direction are accumulated.
[0041] S301. Based on the historical abnormal batching cycle determined at the execution time and the current sample sampling start time, record the actual addition ratio of the corresponding raw material before and after each batching correction, and use the difference between the actual addition ratio after correction and the actual addition ratio before correction as the change in the actual addition ratio for that batching correction. When the actual addition ratio of a corresponding raw material is adjusted, the remaining raw materials are compensated in reverse according to their relative ratios before adjustment, so that the sum of the actual addition ratios of all raw materials remains unchanged.
[0042] For batching corrections that have been confirmed and whose actual addition ratio changes are within the range of the corresponding raw material's historical stable production records, the relative deviation of the setting time is divided by the actual addition ratio change of the corresponding raw material to obtain the unit ratio setting action, retaining both positive and negative directions; then, a weighted average is performed according to the absolute values of each actual addition ratio change to obtain the setting action intensity of the corresponding raw material.
[0043] The amount of the coagulation correction for each batching adjustment is determined by multiplying the absolute value of the change in the actual addition ratio of the corresponding raw material by the absolute value of the coagulation intensity of the corresponding raw material. Its direction is determined by the direction of the actual addition ratio change and the sign of the coagulation intensity of the corresponding raw material. The coagulation correction amount represents the coagulation effect that can occur after the corresponding material has fully entered the coagulation time sample in this batching adjustment.
[0044] S302. The first batching correction performed after the historical abnormal batching cycle is determined shall be used as the baseline batching correction. Subsequent batching corrections with the same direction of condensation correction as the baseline batching correction shall be determined as batching corrections in the same direction. If a batching correction with the opposite direction of condensation correction occurs during the period, the reverse batching correction shall not be included in the batching correction in the same direction.
[0045] S303. Based on the execution time of each unidirectional batching correction and the sampling start and end times of the current setting time sample, combined with the batching cycle transfer interval and transfer distribution determined in S1, determine the proportion of the material corresponding to each unidirectional batching correction entering the current setting time sample. The entry proportion is a dimensionless proportion value; the larger the proportion, the higher the degree to which the batching correction has been reflected in the current setting time sample.
[0046] For each directional batching correction, the proportion of unreflected condensation effect is determined based on the percentage of the corresponding material that has not yet entered the current setting time sample. The condensation correction amount for this batching correction is then multiplied by the unreflected proportion to obtain the condensation effect not yet reflected in this batching correction. When the corresponding material has not yet entered the current setting time sample, the entire condensation correction amount is included in the unreflected condensation effect; when the corresponding material has fully entered the current setting time sample, the condensation correction amount is no longer included in the unreflected condensation effect.
[0047] The cumulative amount of unconfirmed ingredient corrections is obtained by adding up the coagulation effects that have not yet been reflected in each batching correction in the same direction.
[0048] For each batching correction in the same direction, the amount of coagulation correction is determined based on the change in the actual addition ratio of the corresponding raw materials before and after the correction and the coagulation intensity of the corresponding raw materials; then the entry ratio of the corresponding materials is determined based on the execution time of the batching correction, the current coagulation time sample sampling period, and the batching cycle transfer distribution.
[0049] The unreflected coagulation effect is determined by the coagulation correction amount of each batching correction and the proportion of samples that have not entered the current coagulation time. The unreflected coagulation effects are then added together to obtain the current unconfirmed cumulative batching correction amount.
[0050] S4. Subtract the accumulated amount of unconfirmed ingredient corrections from the remaining amount of historical abnormal actions to obtain the net amount of abnormalities to be processed.
[0051] like Figure 4 As shown, from top to bottom, the graph represents the setting time, the mass percentage of materials corresponding to historical abnormal batching cycles, the cumulative amount of unconfirmed batching corrections, the net amount of abnormalities to be processed, and the changes in batching correction status during the sampling process. The horizontal dashed line in the setting time curve represents the target setting time. Figure 4 The vertical dashed lines in the figure correspond to the sampling moments when the batching correction state changes, and are only used to distinguish adjacent control states. The cumulative amount of unconfirmed batching corrections and the net amount of anomalies to be processed are shown as dimensionless percentages in the figure; the batching correction state curves sequentially represent normal batching, performing batching correction in the same direction, locking batching correction in the same direction, batching adjustment after unlocking, and returning to normal batching. Each vertical position is only used to distinguish the control state and does not represent the numerical value.
[0052] exist Figure 4 Within the sampling interval shown, the materials corresponding to the historical abnormal batching cycles have entered the condensation time samples and are gradually removed as production continues. The mass percentage of the materials corresponding to the historical abnormal batching cycles in each condensation time sample is determined according to S1, and the remaining amount of historical abnormal effects is updated according to S2; as the mass percentage decreases, the remaining amount of historical abnormal effects decreases accordingly.
[0053] Once the historical abnormal batching cycle is determined, the production line performs unidirectional batching correction based on the current setting time deviation. Before locking, the accumulated amount of unconfirmed batching corrections can increase with the addition of new unidirectional batching corrections; after entering the locked state, no new unidirectional batching corrections are added. As the materials corresponding to the existing batching corrections gradually enter the subsequent setting time samples, the setting effect that has not yet been reflected in each batching correction decreases, and the accumulated amount of unconfirmed batching corrections decreases accordingly.
[0054] For each newly obtained setting time sample, subtract the current unconfirmed batch correction accumulation from the current remaining amount of historical anomalies according to S4 to obtain the net anomaly to be treated. When the remaining amount of historical anomalies is greater than the unconfirmed batch correction accumulation, the net anomaly to be treated is greater than zero; when the unconfirmed batch correction accumulation reaches or exceeds the remaining amount of historical anomalies, the net anomaly to be treated is not greater than zero.
[0055] when Figure 4If the settling time shown is still higher than the target settling time, and the net amount of anomalies to be processed is no greater than zero, the batching correction status is switched to locked status according to S5. The actual addition ratio of the corresponding raw material after the most recent batching correction is maintained, and no further batching corrections in the same direction are added. During the locked period, new settling time samples continue to be acquired, and the remaining amount of historical anomalies and the accumulated amount of unconfirmed batching corrections are updated according to S2 and S3 respectively.
[0056] When the mass percentage of materials corresponding to historical abnormal batching cycles decreases below the minimum identifiable mass percentage, and the proportion of materials corresponding to each existing batching correction entering the setting time sample reaches the feedback confirmation proportion, the same-direction batching correction lock is released according to S6. After the lock is released, the setting time deviation is recalculated based on the current setting time sample, and the actual addition ratio change for the next batching cycle is determined based on the setting time deviation and the setting effect intensity of the corresponding raw material. After the new batching adjustment is completed, subsequent setting time samples are obtained, and S1 to S6 are executed again.
[0057] The remaining amount of historical anomalies indicates the effects of materials that have not yet been removed from the corresponding historical anomaly batching cycle, while the accumulated amount of unconfirmed batching corrections indicates the effects of existing batching corrections in the same direction that have not yet been fed back. Both are compared using the same scale of relative deviation in setting time.
[0058] For the i-th condensation time sample, the net amount of anomalies to be treated is determined according to the following formula: .
[0059] In the formula, This represents the net amount of anomalies to be processed corresponding to the i-th condensation time sample. This represents the remaining amount of historical anomalies corresponding to the i-th condensation time sample; This represents the sum of the coagulation correction effects of each ingredient in the same direction that have not yet been fully reflected in the sample up to the i-th coagulation time, i.e., the cumulative amount of unconfirmed ingredient correction.
[0060] When the net amount of anomalies to be processed is greater than zero, the historical anomalies that have not been covered by existing same-direction batching corrections are retained; when the net amount of anomalies to be processed is not greater than zero, the effects that have not yet been reflected by existing same-direction batching corrections have reached or exceeded the remaining amount of the current historical anomalies.
[0061] When the mass percentage of the material corresponding to the historical abnormal batching cycle decreases, the remaining amount of the historical abnormal effect is updated according to the calculation formula of the remaining amount of the historical abnormal effect mentioned above; at the same time, the unconfirmed batching correction accumulation is updated according to S3, and the net amount of abnormality to be processed is calculated according to the calculation formula of the net amount of abnormality to be processed mentioned above.
[0062] When the setting time is still higher than the target setting time and the net amount of abnormality to be processed is not greater than zero, no further correction of the same direction of batching is added, and the process proceeds to S5.
[0063] S5. When the setting time is still too long and the net amount of abnormality to be processed is not greater than zero, lock the batching correction in the same direction.
[0064] When the setting time is higher than the target setting time and the net amount of anomalies to be processed is not greater than zero, determine the raw material corresponding to the batching correction in the same direction that forms the current unconfirmed batching correction accumulation, maintain the actual addition ratio of the corresponding raw material after the most recent batching correction, and stop increasing the batching correction in the same direction.
[0065] During the lockout period, whenever a new settling time sample is obtained, the remaining amount of historical abnormal effects is updated according to S2, and the cumulative amount of unconfirmed ingredient correction is updated according to S3.
[0066] During the lockout period, it is determined whether the materials corresponding to the historical abnormal batching cycles have been removed and whether the existing batching corrections have met the feedback confirmation conditions. If any condition is not met, the lockout continues; if all conditions are met, proceed to S6.
[0067] S6. After the corresponding material in the historical abnormal batching cycle is removed and the existing batching correction meets the feedback confirmation conditions, the lock is released, and the raw material ratio of the next batching cycle is adjusted according to the condensation time deviation after the lock is released.
[0068] When the mass percentage of materials corresponding to a historically abnormal batching cycle is lower than the minimum identifiable mass percentage, the corresponding materials are deemed to be excluded. The minimum identifiable mass percentage is determined during the calibration process of the batching cycle transfer interval: a reliable identification lower limit is determined based on the detection precision of the characteristic element content of the target raw material during normal production, and the reliable identification lower limit is converted into the minimum identifiable mass percentage based on the correspondence between the mass percentage of the corresponding raw material and the change in the characteristic element content during the calibration process; when there are multiple calibration results, the arithmetic mean of the calibration results is used.
[0069] The feedback confirmation ratio is determined based on historical batching correction records showing that the corresponding materials have fully passed through the production process and the setting time has returned to a stable state. Continuous setting time samples with a continuously increasing proportion of the corresponding material are selected. When the setting time changes of adjacent samples within a batching cycle are all within the repeated testing fluctuation range, the proportion of the corresponding material that first meets this condition is determined as the feedback confirmation ratio. The repeated testing fluctuation range is determined during stable production stages where no new batching corrections have been implemented and sample preparation conditions are identical, through repeated setting time testing of continuous cement samples.
[0070] When the mass percentage of the material corresponding to the historical abnormal batching cycle is lower than the minimum identifiable mass percentage, and the proportion of the material corresponding to each existing batching correction entering the solidification time sample reaches the feedback confirmation proportion, the same-direction batching correction lock is released.
[0071] After unlocking, the relative deviation of the setting time is recalculated based on the current setting time sample. If the current setting time is still higher than the target setting time, raw materials that can reduce the current setting time deviation are selected from the corresponding raw materials of each batching in the same direction before unlocking, within the adjustable range covered by historical stable production records; if there are multiple candidate raw materials, the raw material with the largest absolute value of the setting effect intensity is selected as the raw material to be adjusted.
[0072] The absolute value of the recommended actual addition ratio change of the raw material to be adjusted is determined by dividing the absolute value of the current relative deviation of the setting time by the absolute value of the corresponding raw material's setting intensity. The adjustment direction is determined based on the direction of the setting time deviation and the sign of the corresponding raw material's setting intensity. If the recommended actual addition ratio change exceeds the maximum single adjustment amount in the historical stable production record of the raw material, the maximum single adjustment amount shall be followed. When adjusting the raw material to be adjusted, the remaining raw materials shall be compensated in reverse according to the relative ratio before adjustment, so that the sum of the actual addition ratios of all raw materials remains unchanged.
[0073] After completing the ingredient adjustment, maintain the adjusted raw material ratio until the material corresponding to the adjustment enters the subsequent setting time sample and obtains new setting time feedback, then re-execute S1 to S6.
[0074] Using the above method, repeated addition of batching corrections in the same direction is stopped while the feedback of existing batching corrections has not been completed, and the raw material ratio for the next batching cycle is re-determined after the historical anomaly has been resolved and the feedback of existing batching corrections has been completed.
[0075] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in the present invention, based on the method for optimizing and controlling the raw material batching for cement production based on setting time and the inventive concept, should be covered within the scope of protection of the present invention.
Claims
1. A method for optimizing and controlling the batching of raw materials for cement production based on setting time, characterized in that, Includes the following steps: Based on the sampling period of the condensation time sample, the raw material batching record and the batching cycle transmission interval, determine the historical abnormal batching cycle and the mass proportion of the corresponding material in the current condensation time sample, and determine the remaining amount of historical abnormal effects in combination with the intensity of condensation. After the historical abnormal batching cycle is determined, the same-direction batching correction is executed. The cumulative amount of unconfirmed batching correction is determined based on the condensation correction amount of each same-direction batching correction and the proportion of the corresponding material entering the sample at the current condensation time. Subtract the accumulated amount of unconfirmed batching correction from the remaining amount of historical anomalies to obtain the net amount of anomalies to be processed. When the setting time is still too long and the net amount of anomalies to be processed is not greater than zero, the batching correction in the same direction is locked. Once the material corresponding to the historical abnormal batching cycle is removed and the existing batching correction meets the feedback confirmation conditions, the lock is released, and the raw material ratio for the next batching cycle is adjusted according to the condensation time deviation after the lock is released.
2. The method for optimizing and controlling the batching of raw materials for cement production based on setting time according to claim 1, characterized in that, Determining the net amount of anomalies to be processed includes: The remaining amount of historical abnormal effects is determined based on the mass percentage of materials corresponding to the historical abnormal batching cycles and the intensity of coagulation. The amount of coagulation correction is determined based on the actual change in the proportion of corresponding raw materials added before and after the same direction of batching correction and the intensity of coagulation. Multiply the coagulation correction amount by the difference between the amount obtained by subtracting the proportion of the corresponding material entering the sample at the current coagulation time, to obtain the coagulation effect that has not yet been reflected, and sum them up to obtain the cumulative amount of unconfirmed batching correction. Subtract the accumulated amount of unconfirmed ingredient corrections from the remaining amount of historical anomalies to obtain the net amount of anomalies to be processed.
3. The method for optimizing and controlling the batching of raw materials for cement production based on setting time according to claim 1, characterized in that, The determination of the condensation intensity for each historical batching cycle includes: The relative deviation of the setting time is determined based on the measured setting time and the target setting time. The samples to be evaluated are adjacent setting time samples from other historical batching cycles that use the same raw material ratio, where the material mass ratio changes during the historical batching cycle to be evaluated, no new batching correction is implemented during the period, and the samples to be evaluated are selected. Divide the relative deviation of the setting time of samples with adjacent setting times by the change in the mass ratio of the material corresponding to the historical batching cycle to be evaluated to obtain the unit mass ratio of the setting effect. The coagulation intensity for the corresponding historical batching cycle is obtained by weighting the coagulation effect per unit mass percentage by the absolute value of the change in mass percentage.
4. The method for optimizing and controlling the batching of raw materials for cement production based on setting time according to claim 1, characterized in that, The determination of historical abnormal ingredient batching cycles includes: Based on the sampling period of the condensation time sample, the raw material batching record, and the batching cycle transfer interval, multiple historical batching cycles and their corresponding material mass percentages were determined. Multiply the mass percentage of the material corresponding to each historical batching cycle by the corresponding coagulation intensity to obtain the current coagulation amount; Screen historical batching cycles whose condensation direction is the same as the current condensation time deviation direction, and determine the historical batching cycle with the largest absolute value of current condensation amount as the historical abnormal batching cycle.
5. The method for optimizing and controlling the batching of raw materials for cement production based on setting time according to claim 4, characterized in that, The determination of the remaining amount of historical anomalies includes: Multiply the mass percentage of the material corresponding to the historical abnormal batching cycle in the sample at the current condensation time by its condensation intensity to obtain the remaining amount of the historical abnormal effect. The mass percentage and remaining amount of historical anomalies are updated according to the sampling order of the condensation time samples.
6. The method for optimizing and controlling the batching of raw materials for cement production based on setting time according to claim 1, characterized in that, The determination of unidirectional ingredient correction includes: The actual addition ratio change is determined based on the actual addition ratio of the corresponding raw materials before and after each batching correction following the determination of historical abnormal batching cycles. The magnitude and direction of the coagulation correction amount are determined based on the actual change in the addition ratio and the coagulation intensity of the corresponding raw materials. The initial batching correction is used as the baseline batching correction. Subsequent batching corrections with the same direction of coagulation correction as the baseline batching correction are defined as batching corrections in the same direction.
7. The method for optimizing and controlling the batching of raw materials for cement production based on setting time according to claim 6, characterized in that, The determination of unconfirmed ingredient correction accumulation includes: Based on the execution time of each directional batching correction, the sampling period of the current setting time sample, and the batching cycle transfer interval, determine the proportion of the corresponding material entering the current setting time sample; Multiply the condensation correction by the difference obtained by subtracting the aforementioned ratio to obtain the condensation effect that has not yet been manifested. The cumulative amount of unconfirmed ingredient corrections is obtained by adding up all the coagulation effects that have not yet been manifested.
8. The method for optimizing and controlling the batching of raw materials for cement production based on setting time according to claim 1, characterized in that, Locking of ingredients in the same direction includes: When the setting time is still too long and it has not been confirmed that the cumulative amount of batch correction is not less than the remaining amount of the current historical abnormal effect, determine the raw material corresponding to the batch correction in the same direction. Maintain the actual addition ratio of the corresponding raw materials as determined by the most recent batching adjustment, and stop implementing further batching adjustments in the same direction. The system remains locked while the corresponding materials for the historical abnormal batching cycle have not yet been removed or the existing batching corrections have not yet met the feedback confirmation conditions.
9. The method for optimizing and controlling the batching of raw materials for cement production based on setting time according to claim 8, characterized in that, Methods to unlock include: During the lockout period, determine the mass percentage of materials corresponding to historical abnormal batching cycles and the proportion of materials corresponding to each existing batching correction entering the solidification time sample. The reliable identification limit is determined based on the detection precision of the corresponding raw material characteristic element content, and the minimum identifiable mass percentage is calculated based on the correspondence between the corresponding raw material mass percentage and the change in characteristic element content in the calibration of the batching cycle transfer interval; the feedback confirmation ratio is determined based on the historical batching correction records of materials that have completely passed through the production process and whose condensation time has entered a stable change state. When the mass percentage of the material corresponding to the historical abnormal batching cycle is lower than the minimum identifiable mass percentage, and the material entry ratio corresponding to each existing batching correction reaches the feedback confirmation ratio, the same-direction batching correction lock is released.
10. The method for optimizing and controlling the batching of raw materials for cement production based on setting time according to claim 9, characterized in that, Methods for adjusting the raw material ratio for the next batching cycle include: Based on the condensation time deviation after unlocking, select the raw materials to be adjusted from the corresponding raw materials of each batch in the same direction before unlocking, within the adjustable range covered by historical stable production records; when there are multiple raw materials to be adjusted, select the raw material with the largest absolute value of condensation intensity. The actual addition ratio change is determined based on the condensation time deviation and the condensation intensity of the raw material to be adjusted. When adjusting the raw material to be adjusted, the other raw materials are compensated in reverse according to the relative ratio before adjustment, so that the sum of the actual addition ratios of each raw material remains unchanged. Maintain the adjusted raw material ratio until the corresponding material enters the subsequent setting time sample and obtains new setting time feedback, then re-determine the remaining amount of historical abnormal effects and the cumulative amount of unconfirmed ingredient corrections.