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

Abstract

The present invention relates to the technical field of fluidized bed roasting furnaces, and in particular to an intelligent anti-blocking system, method and device for a gas distribution plate of a fluidized bed roasting furnace. Two groups of nozzle arrays are installed on the side wall of the fluidized bed roasting furnace, and the nozzle spray direction is adjusted to align with the small hole area of ​​the distribution plate; high-precision temperature and pressure sensors are installed at the edges and corners of the distribution plate where blockage is likely to occur, to achieve real-time and continuous monitoring of temperature-pressure data, and provide key supporting data for system diagnosis and control; an integrated programmable logic controller system is introduced, and when the sensor captures signals such as an abnormal drop in temperature or a significant increase in pressure, indicating that the small hole may be blocked, the PLC will immediately determine the existence and location of the blockage and trigger a preset clearing program, driving the nozzle to spray a high-pressure pulse airflow to efficiently clear the blockage. The present invention has the characteristics of intelligence, automation, and high efficiency, and can prevent and control the blockage problem of the gas distribution plate of a fluidized bed roasting furnace, ensuring the efficiency and stability of the equipment operation.

Description

Technical Field

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

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

[0003] Prior art 1, Chinese patent application number 202210189303.7, discloses a fluidized bed air distribution structure comprising a plate with a plurality of holes evenly distributed. A first air cap is mounted upwardly on each hole in the feed portion of the plate, while a second air cap is mounted upwardly on each hole in the discharge portion. The first air cap comprises a first cylinder having a plurality of upper air distribution holes evenly distributed along the circumference. Each upper air distribution hole is arranged with a higher outer portion and a lower inner portion, tilted to form an upward air outlet direction. The second air cap comprises a second cylinder having a plurality of horizontal air distribution holes evenly distributed along the circumference. The tops of the first and second cylinders are provided with first and second caps, respectively. A fluidized bed roaster using this air distribution structure and a method for its use are also disclosed. While roasting efficiency is improved by extending the airborne time of the ore and shortening the sedimentation time before entering the furnace, significantly reducing energy consumption, and by utilizing ineffective vibration to prevent screen clogging, it provides a basis for installing a screen at the furnace gas outlet to coarsely scatter dust particles, thereby reducing energy consumption in the dust removal process, screen clogging can occur, making it easy for dust or material to accumulate and cause small hole blockage.

[0004] Prior art 2, Chinese patent application number 202310306978.X, discloses a continuous reforming mixed feed anti-blocking coiled tube heat exchanger, comprising a shell, the lower end of which is connected to a mixed feed box via a lower tube box flange. The mixed feed box is divided by a tube sheet and a gas distribution plate, and is penetrated by a crude oil center tube. Gas nozzles are distributed on the gas distribution plate, and liquid nozzles are provided on the wall of the crude oil center tube above the gas distribution plate. The liquid sprayed by the liquid nozzles and the gas sprayed by the gas nozzles can be cross-mixed and evenly mixed, so that the mixed materials enter the heat exchange tubes together. Although the gas nozzles allow the injected gas to fully mix with the liquid at a certain speed and then quickly enter the heat exchange tubes, the mixed material has a short residence time in the lower tube box. The liquid nozzles accelerate the liquid injection speed through grooved tangential swirl, making the liquid fully refined. The liquid droplets are fully mixed with the rapidly injected gas before entering the heat exchange tubes, avoiding the phenomenon of material crystallization and blockage caused by the mixed material staying on the gas distribution plate for a long time. However, in actual industrial operations, the gas distribution plate is easily affected by factors such as material particle characteristics, fluid dynamics behavior, and improper operation and maintenance, which destroys the uniform distribution of gas in the furnace, resulting in a decrease in the roasting furnace's processing capacity, an unnecessary increase in energy consumption, and a degradation of product quality.

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

[0006] Currently, existing technologies 1, 2, and 3 suffer from the fact that gas distribution plates are susceptible to factors such as material particle characteristics, fluid dynamics, and improper operation and maintenance. This leads to frequent pore blockage, especially at the edges and corners of the distribution plate, where weak airflow easily accumulates dust or material, causing pore blockage. This disrupts uniform gas distribution within the furnace, resulting in reduced furnace processing capacity, unwarranted energy consumption, and degraded product quality. When distribution plate pores become clogged, manual cleaning, high-pressure air injection from below, and chemical cleaning are employed. However, these methods are complex, costly, and prone to damage to the equipment structure, with limited effectiveness for stubborn blockages. Currently, there is a lack of efficient and accurate online monitoring technology to assess the status of distribution plate pores in real time, resulting in a delayed response mechanism to blockages. Therefore, this study proposes an intelligent system that integrates real-time monitoring and immediate response. This system can provide high-precision and continuous monitoring of the distribution plate pore status and automatically triggers an efficient clearing strategy when blockage occurs, thereby maintaining uniform airflow distribution and ensuring the long-term stable operation of the fluidized bed roaster. Summary of the Invention

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

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

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

[0010] The intelligent detection sensor component installs high-precision temperature and pressure sensors at the edges and corners of the distribution plate, which are prone to clogging. This enables real-time and continuous monitoring of temperature and pressure data in these areas, records the data, and transmits the collected data to the PLC automatic control component for analysis.

[0011] The PLC automatic control component is responsible for receiving signals from sensors and quickly processing data to identify and determine whether the distribution plate holes are blocked. Once blockage is confirmed, the PLC will automatically activate the nozzle and perform high-pressure pulse airflow cleaning operations to promptly resolve the blockage problem. It is also connected to the display screen to accurately transmit various data and status information to the display unit in real time.

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

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

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

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

[0016] The instruction sending module, upon receiving the start signal from the analysis and judgment module, warns on the display screen that the gas distribution plate may be blocked, and sends a start instruction to the side wall high-pressure air nozzle assembly; upon receiving the stop signal from the blockage recheck module, the warning is canceled, and a stop instruction is sent to the side wall high-pressure air nozzle assembly;

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

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

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

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

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

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

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

[0024] Temperature and pressure sensors installed in potential blockage areas of the gas distribution plate continuously monitor the temperature and pressure parameters within the roaster and transmit the collected data in real time to the PLC automatic control component. Simultaneously, the PLC transmits temperature and pressure data and system status information to the display screen for intuitive and real-time monitoring of the system. Under normal operating conditions, the data recorded by the sensors remains within the preset safety threshold range.

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

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

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

[0028] During the operation of a fluidized bed roaster, the charge particles are in a boiling state due to the injection of gas, and the gas and solid charge are in full contact. This is a typical gas-solid two-phase flow, which allows for in-depth analysis and accurate prediction of particle behavior using computational fluid dynamics. Simulating the particle motion trajectory, velocity distribution, and interaction in a complex flow field provides a basis for the design of key injection parameters for the gas distribution plate clearing system.

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

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

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

[0032] The PLC automatic control component pre-processes the temperature and pressure data to obtain a data set; a blockage location determination model is constructed and trained based on historical data. Real-time data is input into the blockage location determination model for simulation, and the blockage location is determined by comparing the maximum and minimum indicator values ​​under normal operating conditions with the indicator values ​​under simulated blockage conditions.

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

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

[0035] The collected temperature and pressure data are processed to unify the time frequency and outliers, and the data are processed into the average value within a period of time. The data is stored according to the time series structure, and the data with abnormalities are directly eliminated.

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

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

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

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

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

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

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

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

[0044] Figure 1 This is a functional module diagram of an embodiment of the intelligent anti-blocking system for the gas distribution plate of a fluidized bed roaster according to the present invention;

[0045] Figure 2This is a schematic diagram of the pulse cycle of a high-efficiency high-pressure pulse air source module of an embodiment of the intelligent anti-clogging system for the gas distribution plate of a fluidized bed roaster according to the present invention;

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

[0047] Figure 4 This is a schematic diagram of an embodiment of the intelligent anti-blocking method for the gas distribution plate of a fluidized bed roaster according to the present invention;

[0048] Figure 5 This is a basic principle diagram of the gas-solid two-phase coupling solution of an embodiment of the intelligent anti-clogging method for the gas distribution plate of a fluidized bed roaster according to the present invention;

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

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

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

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

[0053] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

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

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

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

[0057] The intelligent detection sensor component installs high-precision temperature and pressure sensors at the edges and corners of the distribution plate, which are prone to clogging. This enables real-time and continuous monitoring of temperature and pressure data in these areas, records the data, and transmits the collected data to the PLC automatic control component for analysis.

[0058] The PLC automatic control component is responsible for receiving signals from sensors and quickly processing data to identify and determine whether the distribution plate holes are blocked. Once blockage is confirmed, the PLC will automatically activate the nozzle and perform high-pressure pulse airflow cleaning operations to promptly resolve the blockage problem. It is also connected to the display screen to accurately transmit various data and status information to the display unit in real time.

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

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

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

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

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

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

[0065] The instruction sending module, upon receiving the start signal from the analysis and judgment module, warns on the display screen that the gas distribution plate may be blocked, and sends a start instruction to the side wall high-pressure air nozzle assembly; upon receiving the stop signal from the blockage recheck module, the warning is canceled, and a stop instruction is sent to the side wall high-pressure air nozzle assembly;

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

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

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

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

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

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

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

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

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

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

[0076] Step S1: Temperature and pressure sensors installed in potential blockage areas of the gas distribution plate continuously monitor the temperature and pressure parameters within the roasting furnace and transmit the collected data in real time to the PLC automatic control component. Simultaneously, the PLC transmits the temperature and pressure data and system status information to the display screen for intuitive and real-time monitoring of the system. Under normal operating conditions, the data recorded by the sensors remains within the preset safety threshold range.

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

[0078]

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

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

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

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

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

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

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

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

[0087] S13: Each sensor channel is equipped with an automatic calibration function, which calibrates the sensor's working status in real time during the data acquisition process. The automatic calibration function detects and corrects sensor drift and errors. Before the data is transmitted to the central control unit, each sensor channel compresses the collected raw data in real time.

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

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

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

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

[0092]

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

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

[0095]

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

[0097] Preferably, in step S11 of this embodiment, a distributed sensor network is established. Through the distributed sensor network, each sensor node is responsible for monitoring environmental parameters in a specific area, ensuring comprehensive coverage and accurate monitoring of potential congestion areas. Each sensor node operates independently and does not interfere with each other, reducing data conflicts and delays, and improving the stability and reliability of data acquisition. Step S12 involves high-speed data acquisition and parallel processing. The high-speed data acquisition module collects data at a sampling rate of thousands of times per second, ensuring detailed and real-time data and capturing subtle environmental changes. Multiple sensor channels operate simultaneously, each collecting and performing preliminary data processing. The central control unit uses parallel processing technology to simultaneously receive and process data from multiple channels, greatly improving the efficiency of data acquisition and processing. Step S13 involves automatic calibration and data compression. Each sensor channel is equipped with an automatic calibration function that can calibrate the sensor's operating status in real time during data acquisition, detect and correct sensor drift and errors, and ensure the accuracy and reliability of the collected data. Before data is transmitted to the central control unit, each sensor channel compresses the collected raw data in real time, using an efficient compression algorithm. This significantly reduces the bandwidth required for data transmission without compromising data accuracy, thereby improving data transmission efficiency.

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

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

[0100] During the operation of a fluidized bed roaster, the charge particles are in a boiling state due to the injection of gas, and the gas and solid charge are in full contact. This is a typical gas-solid two-phase flow, which allows for in-depth analysis and accurate prediction of particle behavior using computational fluid dynamics. Simulating the particle motion trajectory, velocity distribution, and interaction in a complex flow field provides a basis for the design of key injection parameters for the gas distribution plate clearing system.

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

[0102]

[0103]

[0104] Step S22: Newton's second law is used to solve the particle motion, which is expressed as follows:

[0105]

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

[0107]

[0108] Step S23: Solve the particle collision using the discrete element method, and the expression is as follows:

[0109]

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

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

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

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

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

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

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

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

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

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

[0120] Step S251: The collected temperature and pressure data are processed to unify the time frequency and outlier values, and the data are processed into an average value within a period of time. The data is stored according to the time series structure, and any abnormal data is directly removed.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0140] The above detailed description of the specific embodiments of the invention is intended to be illustrative only, and the present invention is not limited to the specific embodiments described above. For those skilled in the art, any equivalent modifications or substitutions to the invention are also within the scope of the present invention. Therefore, equivalent changes, modifications, and improvements made without departing from the spirit and scope of the present invention are also encompassed within the scope of the present invention.

Claims

1. An intelligent anti-blocking system for a gas distribution plate of a fluidized bed roaster, comprising: Intelligent detection sensor components are used to install temperature and pressure sensors at the edges and corners of the distribution plate in areas prone to clogging. This enables real-time and continuous monitoring of temperature and pressure data in these areas, records the data, and transmits the collected data to the PLC automatic control component for analysis; The PLC automatic control component is used to receive signals from sensors and perform data processing to identify and determine whether the distribution plate holes are blocked. Once blockage is confirmed, the PLC will automatically activate the nozzle and perform high-pressure pulse airflow cleaning operations to solve the blockage problem in a timely manner; And it is connected to the display screen to transmit various data and status information to the display screen in real time and accurately; Side wall high-pressure air nozzle assembly, used to evenly distribute the nozzles on the side wall of the roaster, with the spray direction aimed at the small hole area of ​​the gas distribution plate; The efficient high-pressure pulse air source provides high-pressure pulse airflow, responds quickly after receiving the command of the PLC automatic control component, and provides strong wind support for the nozzle; PLC automatic control components, including: The data receiving module is used by the PLC automatic control component to receive the temperature and pressure data collected by the intelligent detection sensor component in real time, pre-process the received data for the next step of analysis and judgment; and visualize the pre-processed data on the display screen; The analysis and judgment module is used to set thresholds for temperature and pressure based on historical data. When the temperature is lower than the threshold after pre-processing, a start signal is sent to the instruction sending module; if the temperature is higher than the threshold, the detection continues; when the pressure value is higher than the threshold after pre-processing, a start signal is sent to the instruction sending module; if the pressure value is lower than the threshold, the detection continues; The command sending module is used to, upon receiving a start signal from the analysis and judgment module, issue a warning on the display screen that the gas distribution plate may be blocked, and send a start command to the side wall high-pressure air nozzle assembly; upon receiving a stop signal from the blockage recheck module, cancel the warning and send a stop command to the side wall high-pressure air nozzle assembly; The blockage recheck module is used to continue to collect temperature and pressure data in real time after sending the instruction to the side wall high-pressure air nozzle assembly. When the collected temperature is higher than the preset threshold and the pressure value is lower than the preset threshold, a stop signal is sent to the instruction sending module; Side wall high pressure air nozzle assembly, including: The instruction receiving module is used to receive instructions from the PLC automatic control component and control the start or stop of the high-efficiency high-pressure pulse air source module according to the instruction information; The side wall nozzle array module is used to evenly distribute the nozzles on the side wall of the roaster. The nozzle direction is aimed at the small hole area of ​​the gas distribution plate. It has the ability to spray high-pressure pulse airflow to clear the blockage of the small holes; The high-efficiency high-pressure pulse air source module is used to respond to the high-pressure pulse air source under the instruction of the PLC automatic control component to provide wind support for the nozzle.

2. A method for intelligently preventing blockage of a gas distribution plate of a fluidized bed roaster, which is applied to the intelligent anti-blockage system for a gas distribution plate of a fluidized bed roaster as claimed in claim 1, characterized in that: The intelligent anti-blocking method for the gas distribution plate of the fluidized bed roaster comprises: Temperature and pressure sensors installed in potential blockage areas of the gas distribution plate continuously monitor the temperature and pressure parameters within the roaster and transmit the collected data in real time to the PLC automatic control component. Simultaneously, the PLC transmits temperature and pressure data and system status information to the display screen for intuitive and real-time monitoring of the system. Under normal operating conditions, the data recorded by the sensors remains within the preset safety threshold range. When the small holes of the gas distribution plate are clogged due to dust or material accumulation, the PLC automatic control component processes the signals from the temperature and pressure sensors through a preset algorithm, detects that the temperature and pressure data exceed the safety threshold range, and determines the presence and location of the blockage; After determining the location of the blockage, the PLC automatic control component will automatically trigger the corresponding nozzle to spray high-pressure pulse airflow to clear the blockage in the small hole; after the cleaning is completed, if the monitored temperature-pressure data returns to the standard operating range, indicating that the blockage has been cleared, the PLC automatic control component stops the nozzle spraying operation and the system returns to the real-time monitoring state; if the monitoring data still shows abnormalities, the system automatically restarts the cleaning process until the blockage is completely cleared and the sensor signal returns to stability.

3. The intelligent anti-blocking method for the gas distribution plate of a fluidized bed roasting furnace according to claim 2, characterized in that: The process of calculating the degree of pore blockage includes: Simulate the motion trajectory, velocity distribution and interaction of particles in complex flow fields to provide a basis for the design of key injection parameters of the gas distribution plate clearing system; The flow of the gas phase is solved by the continuity equation, momentum equation and energy equation, and the turbulent pulsation is simulated by the Realizable ke turbulence model; the motion of the particles is solved by Newton's second law, and the collision of the particles is solved by the discrete element method.

4. The intelligent anti-blocking method for the gas distribution plate of a fluidized bed roasting furnace according to claim 2, characterized in that: The process of determining the blockage location includes: The temperature and pressure data of the gas distribution plate are collected in real time through temperature sensors and pressure sensors. Safety thresholds are preset based on historical data. The collected temperature and pressure data are compared with the safety thresholds. If the safety thresholds are exceeded, an alarm is issued and the data is transmitted to the PLC automatic control component. The PLC automatic control component pre-processes the temperature and pressure data to obtain a data set; a blockage location determination model is constructed and trained based on historical data. Real data is input into the blockage location determination model for simulation, and the blockage location is determined by comparing the maximum and minimum indicator values ​​under normal operating conditions with the indicator values ​​under simulated blockage conditions. According to the judgment result, the data collected by the pressure sensor at the corresponding position is retrieved and analyzed to obtain the blockage position; the obtained blockage position is transmitted to the PLC automatic control component; the PLC automatic control component performs corresponding operations according to the blockage position.

5. The intelligent anti-blocking method for the gas distribution plate of a fluidized bed roasting furnace according to claim 4, characterized in that: The process of determining the congestion location model includes: The collected temperature and pressure data are processed to unify the time frequency and outliers, and the data are processed into the average value within a period of time. The data is stored according to the time series structure, and the data with abnormalities are directly eliminated. The blockage location model is trained based on historical data. The pressure frequency index and standard deviation values ​​are collected under simulated blockage conditions. A blockage simulation test is performed using a valve. The blockage location is determined by comparing the maximum and minimum index values ​​under normal operating conditions with the index values ​​under simulated blockage conditions. Debug the blockage position determination model to ensure temperature control accuracy and stability, and optimize as needed; input real-time data into the blockage position determination model for judgment, and output blockage position data.

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

7. The intelligent anti-blocking device for the gas distribution plate of a fluidized bed roasting furnace according to claim 6, characterized in that: A funnel-shaped air chamber is set below the solid particles, with an air exhaust port directly below it and an air port on one side of the feed port.

8. The intelligent anti-blocking device for the gas distribution plate of a fluidized bed roasting furnace according to claim 6, characterized in that: include: Nozzles, gas distribution plates, wind chambers, nozzle arrays, temperature and pressure sensors, and fluidized bed roaster shells; Among them, on the shell of the fluidized bed roasting furnace above the gas distribution plate, a nozzle array is evenly distributed on its side wall, and temperature and pressure sensors are evenly installed on the gas distribution plate.

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