High-efficiency annealing furnace waste heat recovery control system

Abstract

The invention discloses a high-efficiency annealing furnace waste heat recovery control system, and relates to the technical field of annealing process control, the high-efficiency annealing furnace waste heat recovery control system comprises a control unit, a circulating water pump, a regulating valve, a heat exchanger and a plurality of water consuming devices, the intelligent self-adaptive water flow regulation and control mechanism is composed of a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module. And the control unit is connected to the heat exchanger, the circulating water pump, the regulating valve and the water consumption equipment through signal lines. By designing an intelligent self-adaptive water flow regulation and control mechanism, the dynamic detection and optimization regulation function of the water flow is achieved, the problem that a traditional waste heat recovery control system cannot distribute the water flow in real time to optimize the heat exchange efficiency is solved, the flexibility of equipment operation is improved, and the heat exchange requirements under various working conditions are met.

Description

Technical Field

[0001] The invention relates to the technical field of annealing process control, and in particular to a high-efficiency annealing furnace waste heat recovery control system. Background Art

[0002] In modern industrial production, especially in the metal processing and heat treatment industries, annealing furnace is a key equipment, which is widely used to improve the performance of metal materials. With the increasing requirements for energy conservation, emission reduction and resource utilization efficiency, waste heat recovery has become an important technical means. Annealing furnaces generate a lot of heat energy during operation, a considerable part of which is lost in the form of waste gas and hot water, resulting in energy waste.

[0003] However, the design and implementation of waste heat recovery systems face many challenges. Different water-using equipment has different water demands, work priorities, process requirements, and safety requirements, which makes flow distribution and priority management complicated. In actual operation, when the flow is limited, how to dynamically adjust the water flow of each water-using equipment to ensure the stable operation of high-priority equipment has become an urgent problem that the industry needs to solve. In addition, traditional waste heat recovery systems often lack intelligent control and cannot adapt to process changes and equipment status in real time, resulting in energy efficiency that is not optimal.

[0004] Therefore, it is particularly important to build a highly efficient annealing furnace waste heat recovery control system, combined with an intelligent user priority allocation mechanism, to achieve dynamic sorting and flow priority management of water-using equipment. The implementation of this system will greatly improve waste heat recovery efficiency, reduce production costs, and contribute to the sustainable development of industry.

[0005] 1. Patent document CN116793098B discloses a method for recovering waste heat from the slow cooling section of the annealing process of ductile iron pipes. The above patent realizes the reuse of waste heat from the slow cooling section of the annealing process in the cast pipe production process, which not only reduces the waste of recovered steam, but also effectively improves the strength and uniformity of the cement lining in the cast pipe, and reduces the unqualified rate of the cement lining of the ductile iron pipe. However, the above patent cannot realize the dynamic detection, optimization and adjustment function of the water flow.

[0006] 2. Patent document CN107686881B discloses a waste heat recovery device for an annealing system. The above patent realizes that while gradually annealing the workpiece, the heat in the heating section is transported to the isothermal section and the slow cooling section respectively through the setting of the waste heat utilization unit in the heating section, thereby completing the utilization of the heat in the annealing furnace. The waste heat utilization rate is high, the temperature distribution is uniform, and the automatic coordination of the device is realized. However, the above patent cannot realize the dynamic sorting and flow regulation functions of the water-using equipment.

[0007] 3. Patent document CN111286598B discloses a method, device and system for controlling the temperature of the preheating section of an annealing furnace. The above patent achieves the goal of avoiding low heat utilization due to too low a fan speed setting, or excessively high a fan speed, which leads to exceeding the maximum waste heat recovery amount and increasing additional power consumption. However, the above patent cannot achieve the functions of load monitoring of the heat exchanger and water flow distribution optimization.

[0008] 4. Patent document CN116573843B discloses an annealing kiln for waste heat recycling. The above patent achieves the effect of optimal waste heat utilization of high-temperature gas, but the above patent cannot achieve the advance prediction of heat load and water flow distribution function.

[0009] In summary, the above patents cannot realize the functions of dynamic detection, optimization and regulation of water flow, dynamic sorting and flow regulation of water-using equipment, load monitoring and water flow distribution optimization of heat exchangers, and advance prediction of heat load and water flow distribution, resulting in poor heat exchange efficiency, low energy utilization, unstable system operation and poor economic benefits. To this end, the present application proposes a high-efficiency annealing furnace waste heat recovery control system that can realize dynamic detection, optimization and regulation of water flow, dynamic sorting and flow regulation of water-using equipment, load monitoring and water flow distribution optimization of heat exchangers, and advance prediction of heat load and water flow distribution. Summary of the invention

[0010] The object of the present invention is to provide a high-efficiency annealing furnace waste heat recovery control system to solve the technical problems proposed in the above background technology that the dynamic detection and optimization adjustment function of water flow, the dynamic sorting and flow adjustment function of water-using equipment, the load monitoring and water flow distribution optimization function of the heat exchanger, and the advance prediction of the heat load and the water flow distribution function cannot be realized, resulting in poor heat exchange efficiency, low energy utilization, unstable system operation and poor economic benefits.

[0011] To achieve the above object, the present invention provides the following technical solutions: a high-efficiency annealing furnace waste heat recovery control system, comprising a control unit, a circulating water pump, a regulating valve, a heat exchanger and a plurality of water-using equipment, wherein the control system is designed with an intelligent adaptive water flow control mechanism, and the intelligent adaptive water flow control mechanism is composed of a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module; The multi-point sensor network is arranged at key nodes of the circulating water pump, water-using equipment and heat exchanger to collect water pressure, water temperature and flow data. The dynamic feedback control algorithm regulates the frequency of the circulating water pump and the opening of each regulating valve based on the data collected by the multi-point sensor network. The variable frequency water pump control module adjusts the water flow rate by adjusting the speed of the circulating water pump through frequency conversion, thereby maximizing the heat exchange efficiency under different working conditions; The control unit is connected to the heat exchanger, the circulating water pump, the regulating valve and the water-using equipment through a signal line.

[0012] Preferably, the control system includes an intelligent user priority allocation system, which is used to dynamically sort multiple water-using equipment based on the frequency of use of the water-using equipment, key process requirements and safety priorities, and the control unit allocates water flow through a flow priority adjustment algorithm according to the sorting scheme; When the system water flow is limited, priority is given to ensuring the water supply to high-priority water-using equipment, and when necessary, flow limitation / cut-off is implemented for low-priority water-using equipment to ensure the continuous operation of key process equipment.

[0013] Preferably, the control system is equipped with a distributed flue gas-water heat exchanger flow distribution optimization system, which includes a plurality of distributed heat exchanger units, which are respectively arranged on a plurality of water branches, and an independent intelligent regulating valve and a heat load sensor are provided at the inlet of each heat exchanger unit; The control unit dynamically adjusts the water flow of each heat exchanger branch according to the real-time heat load and flow demand of each heat exchanger unit through the allocation optimization algorithm to adapt to the actual heat load fluctuations, ensure that each heat exchanger unit operates efficiently under different load conditions, and optimize the overall heat exchange efficiency.

[0014] Preferably, the control system also includes a waste heat recovery data prediction and load distribution system, which uses a machine learning model to train historical water-using equipment heat load data and flow data, and estimates the waste heat to be generated in real time through a time series prediction method; When the control unit predicts that the heat load is about to arrive, it pre-adjusts the water flow of the circulating water pump and the heat exchanger branch to distribute the load in advance, optimize the water flow distribution, reduce the system pressure caused by the instantaneous waste heat peak, and improve the heat recovery stability and energy utilization efficiency.

[0015] Preferably, an adaptive expansion interface is designed in the control system, which realizes convenient access to each heat exchange branch / water-using equipment through a modular structure. The adaptive expansion interface includes a new device identification module and an adaptive water flow control module. When a new device is connected, the control unit automatically reads the flow demand and priority parameters of the new device through the new device identification module, and adjusts the water flow parameters based on the adaptive water flow control module, so as to seamlessly integrate the new device into the flow optimization and control system, thereby ensuring the plug-and-play function of the control system.

[0016] Preferably, the intelligent adaptive water flow control mechanism includes: a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module; The multi-point sensor network is a system where sensors are placed at the outlet of the circulating water pump, the inlet of each water-using device, and the inlet and outlet of the heat exchanger to collect real-time water pressure, water temperature and flow data at a frequency of 10 times / s; The dynamic feedback control algorithm is that the control unit runs the PID control algorithm based on the data collected by the multi-point sensor network, adjusts the frequency of the circulating water pump and the opening of the regulating valve in real time, and performs dynamic optimization by combining historical data and adaptive adjustment algorithm; The variable frequency water pump control module controls the variable frequency regulation of the circulating water pump to accurately control the flow output, avoid system water flow fluctuations, and ensure the system heat exchange efficiency.

[0017] Preferably, the intelligent user priority allocation system includes: a priority classification module and a traffic priority adjustment algorithm; The priority classification module prioritizes each water-using equipment through a multi-parameter algorithm, and sets the priority based on the equipment usage frequency, process criticality and safety demand indicators. When the water demand is higher than the current total water volume of the system, high-priority equipment is given priority. The flow priority adjustment algorithm and control unit adjust the water flow of each water-using equipment through a dynamic allocation algorithm, and limit / cut off the flow of low-priority equipment according to the actual water pressure and flow conditions to ensure stable water supply to high-priority water-using equipment in the system.

[0018] Preferably, the distributed flue gas-water heat exchanger flow distribution optimization system comprises: a heat exchanger inlet independent adjustment module, a heat load detection module and a dynamic flow optimization algorithm; The heat exchanger inlet independent regulation module means that each heat exchanger unit inlet is equipped with an intelligent regulating valve, and the user independently controls the water flow to ensure efficient heat exchange in the distributed heat exchange structure; The heat load detection module is equipped with temperature sensors at the inlet and outlet of each heat exchanger unit to detect the real-time temperature difference. The control unit automatically adjusts the flow rate according to the detection data to ensure the balanced distribution of the heat load of each heat exchanger unit. The dynamic flow optimization algorithm calculates the actual heat load of each heat exchanger unit, and the control unit optimizes the water flow distribution of different branches in real time to ensure that each heat exchanger can work efficiently under different load conditions and optimize the heat exchange efficiency of the overall system.

[0019] Preferably, the waste heat recovery data prediction and load distribution system comprises: a data prediction module and a load pre-regulation module; The data prediction module uses time series analysis and machine learning algorithms to predict future waste heat based on historical water use data and waste heat load data, and obtains a heat load estimate for the next 5-10 minutes in advance; When the load pre-regulation module predicts that a large heat load is about to arrive, the control unit adjusts the frequency of the circulating water pump and the water flow of the heat exchanger branch in advance to avoid the impact of instantaneous heat load on the system pressure and optimize the system energy utilization efficiency.

[0020] Preferably, the adaptive and modular design of the adaptive expansion interface includes: a modular expansion interface, a new equipment automatic identification module and an adaptive water flow control module; The modular expansion interface is to configure an independent flow control valve and sensor for each expansion interface. The modular expansion interface supports a standard plug-and-play structure design, so that new equipment / heat exchange branches can be connected without changing the main system. The new device automatic identification module, i.e., the control unit detects the type, flow demand and priority parameters of the access device through the new device automatic identification module, automatically configures the operating parameters, and incorporates the new device into the flow control system; The adaptive water flow control module optimizes the flow distribution immediately after the new equipment automatic identification module detects the new equipment, adjusts the working parameters of the flow control valve and the circulating water pump, and ensures that the new equipment operates efficiently and stably in the system.

[0021] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention realizes the dynamic detection and optimization of water flow by designing an intelligent adaptive water flow control mechanism, solves the problem that the traditional waste heat recovery control system cannot allocate water flow in real time to optimize heat exchange efficiency, improves the flexibility of equipment operation, and meets the heat exchange requirements under various working conditions; 2. The present invention realizes the dynamic sorting and flow regulation functions of water-using equipment by designing an intelligent user priority allocation system, which solves the problem that the traditional system is difficult to accurately regulate the water use priority of different equipment when the water flow is limited or the process load is at peak, which easily leads to the problem that key equipment cannot operate normally due to insufficient water. It significantly improves the operation continuity and reliability of process equipment and avoids shutdown or efficiency reduction caused by unstable water flow; 3. The present invention realizes the load monitoring and water flow distribution optimization functions of the heat exchanger by designing a distributed flue gas-water heat exchanger flow distribution optimization system, solves the problem of being unable to flexibly distribute water flow according to the load demand of the heat exchanger, resulting in low heat exchange efficiency and low energy utilization, improves the overall efficiency of waste heat recovery, and reduces energy consumption; 4. The present invention realizes the advance prediction of heat load and water flow distribution function by designing a waste heat recovery data prediction and load distribution system, solves the problem of system overload caused by sudden heat load peak, reduces heat load impact, optimizes heat utilization efficiency, and improves system stability and load fluctuation resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the waste heat recovery control process of the present invention. DETAILED DESCRIPTION

[0023] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0024] See also Figure 1 , an embodiment provided by the present invention: a high-efficiency annealing furnace waste heat recovery control system, including a control unit, a circulating water pump, a regulating valve, a heat exchanger and a plurality of water-using equipment, wherein the control system is designed with an intelligent adaptive water flow control mechanism, and the intelligent adaptive water flow control mechanism is composed of a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module; The multi-point sensor network is arranged at key nodes of the circulating water pump, water-using equipment and heat exchanger to collect water pressure, water temperature and flow data. The dynamic feedback control algorithm regulates the frequency of the circulating water pump and the opening of each regulating valve based on the data collected by the multi-point sensor network. The variable frequency water pump control module adjusts the water flow rate by adjusting the speed of the circulating water pump through frequency conversion, thereby maximizing the heat exchange efficiency under different working conditions; The control unit is connected to the heat exchanger, the circulating water pump, the regulating valve and the water-using equipment through a signal line; The intelligent adaptive water flow control mechanism includes: a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module; The multi-point sensor network is a system where sensors are placed at the outlet of the circulating water pump, the inlet of each water-using device, and the inlet and outlet of the heat exchanger to collect real-time water pressure, water temperature and flow data at a frequency of 10 times / s; The dynamic feedback control algorithm is that the control unit runs the PID control algorithm based on the data collected by the multi-point sensor network, adjusts the frequency of the circulating water pump and the opening of the regulating valve in real time, and performs dynamic optimization by combining historical data and adaptive adjustment algorithm; The variable frequency water pump control module controls the frequency regulation of the circulating water pump to accurately control the flow output, avoid system water flow fluctuations, and ensure the system heat exchange efficiency; Furthermore, after the system is started, the control unit performs self-inspection on the multi-point sensor network, circulating water pump, regulating valve and other key equipment in turn to ensure that the sensors and actuators are working properly, and sets the initial values ​​of various control parameters (including the frequency of the circulating water pump and the initial opening of the regulating valve, etc.); the multi-point sensor network collects real-time data such as water pressure, water temperature and flow at a frequency of 10 times / s, and these data are transmitted to the control unit through the signal line. The control unit receives and analyzes the collected data from the multi-point sensor network in real time, calculates and processes the data, checks the pressure data at the outlet of the circulating water pump, ensures that it is within the set range, avoids excessively high or low pressure fluctuations, monitors the water temperature difference at the inlet and outlet of the heat exchanger, ensures that the waste heat can be effectively recovered when the water flows through the heat exchanger, and adjusts the flow of each branch through the regulating valve in combination with the water flow requirements of each water-using equipment to meet the actual water demand; The control unit runs a dynamic feedback control algorithm based on real-time monitoring data. The core is PID control. By adjusting the speed of the circulating water pump, a stable water flow output is maintained to achieve a dynamic balance between water pressure and flow. According to the needs of different water-using equipment, the opening of each branch regulating valve is adjusted to finely control the water flow to ensure that the water needs of different equipment are met. The variable frequency water pump control module will automatically adjust the pump speed according to the adjustment signal of the control unit. In the case of load increase or decrease, the variable frequency water pump automatically responds through variable frequency speed regulation to ensure that the water flow can adapt to the instantaneous change of water-using equipment and avoid the reduction of system efficiency due to water flow fluctuations. According to the real-time needs of each water-using equipment, the control unit will dynamically adjust the opening of the regulating valve of each branch. High-priority water-using equipment can obtain priority water supply when demand increases, and the control unit will temporarily reduce the water supply of low-priority equipment to ensure the operating stability of key equipment.

[0025] See also Figure 1 , an embodiment of the present invention provides: a high-efficiency annealing furnace waste heat recovery control system, the control system includes an intelligent user priority allocation system, the intelligent user priority allocation system is used to dynamically sort multiple water-using equipment based on the frequency of use of water-using equipment, key process requirements and safety priorities, and the control unit allocates water flow through a flow priority adjustment algorithm according to the sorting scheme; When the system water flow is limited, priority is given to ensuring the water supply to high-priority water-using equipment, and when necessary, flow restriction / cut-off is implemented for low-priority water-using equipment to ensure the continuous operation of key process equipment; The intelligent user priority allocation system includes: a priority classification module and a traffic priority adjustment algorithm; The priority classification module prioritizes each water-using equipment through a multi-parameter algorithm, and sets the priority based on the equipment usage frequency, process criticality and safety demand indicators. When the water demand is higher than the current total water volume of the system, high-priority equipment is given priority. The flow priority adjustment algorithm and control unit adjust the water flow of each water-using device through a dynamic allocation algorithm, and limit / cut off the flow of low-priority devices according to the actual water pressure and flow conditions to ensure stable water supply to high-priority water-using devices in the system; Furthermore, the system evaluates the frequency of use of each water-using equipment based on historical water use data. Frequently used equipment is given a higher priority. The importance of each water-using equipment in the production process is evaluated. Key process equipment (such as heat exchangers, annealing furnace cooling water, etc.) is given a higher priority. Some equipment may be closely related to production safety (such as emergency cooling systems, pressure protection equipment, etc.). These equipment will be given a higher priority, and a priority sorting scheme for water-using equipment is generated; The system monitors the actual water flow demand of each water-using device in real time through a multi-point sensor network (such as water pressure, flow, temperature sensors, etc.). The demand value of each device is dynamically adjusted based on its current process status, equipment usage frequency and priority classification. At the same time, the system monitors the total water supply capacity of the water pump and pipe network in real time. The current total water flow is obtained through sensors to determine whether it meets the needs of all devices. If the total water flow of the system is lower than the total demand of all devices, it enters a water flow restricted state and needs to adjust the flow distribution; The system first ensures that high-priority devices have sufficient water flow. The control unit allocates the required water flow to these devices based on their actual needs and priorities. For low-priority devices, the system controls the flow through the following measures: For some low-priority devices, the control unit will dynamically reduce their water flow to ensure that these devices receive a certain degree of water supply, but will not affect the operation of high-priority devices; when the system water flow is seriously insufficient and cannot meet the needs of all devices, the control unit will cut off the flow to some low-priority devices, that is, completely cut off their water source, to ensure the stability of the water flow of high-priority devices and avoid the impact of low-priority devices on the system; The system monitors the operating status of each water-using device in real time through a sensor network, including flow, pressure, temperature, etc. After the sensor data is fed back to the control unit, the control unit will adjust the flow distribution plan based on the actual needs and priorities of the equipment.

[0026] See also Figure 1 , an embodiment provided by the present invention: a high-efficiency annealing furnace waste heat recovery control system, the control system is equipped with a distributed flue gas-water heat exchanger flow distribution optimization system, the distributed flue gas-water heat exchanger flow distribution optimization system comprises a plurality of distributed heat exchanger units, the heat exchanger units are respectively arranged on a plurality of water branches, and an independent intelligent regulating valve and a heat load sensor are arranged at the inlet of each heat exchanger unit; The control unit dynamically adjusts the water flow of each heat exchanger branch according to the real-time heat load and flow demand of each heat exchanger unit through the allocation optimization algorithm to adapt to the actual heat load fluctuation, ensure that each heat exchanger unit operates efficiently under different load conditions, and optimize the overall heat exchange efficiency; The distributed flue gas-water heat exchanger flow distribution optimization system includes: a heat exchanger inlet independent adjustment module, a heat load detection module and a dynamic flow optimization algorithm; The heat exchanger inlet independent regulation module means that each heat exchanger unit inlet is equipped with an intelligent regulating valve, and the user independently controls the water flow to ensure efficient heat exchange in the distributed heat exchange structure; The heat load detection module is equipped with temperature sensors at the inlet and outlet of each heat exchanger unit to detect the real-time temperature difference. The control unit automatically adjusts the flow rate according to the detection data to ensure the balanced distribution of the heat load of each heat exchanger unit. The dynamic flow optimization algorithm calculates the actual heat load of each heat exchanger unit, and the control unit optimizes the water flow distribution of different branches in real time to ensure that each heat exchanger can work efficiently under different load conditions and optimize the heat exchange efficiency of the overall system; Furthermore, the temperature sensors at the inlet and outlet of each heat exchanger unit collect data in real time to obtain the inlet and outlet temperatures of the water flow. By comparing the temperature difference between the inlet and outlet, the system can determine the heat load (heat exchange efficiency) of the current heat exchanger unit. The control unit calculates the actual heat load of each heat exchanger unit based on the temperature difference data combined with the flow information. For example, a unit with a larger temperature difference means that the unit carries a larger heat load and has a better heat exchange effect; conversely, a small temperature difference means that the heat exchange effect is poor. The control unit obtains the heat load data of each heat exchanger unit in real time and evaluates whether the designed heat exchange target is achieved; The control unit dynamically optimizes the water flow distribution of each branch by analyzing the heat load data of each heat exchanger unit. The goal of the flow distribution optimization algorithm is to allocate more water flow to the heat exchanger unit with higher heat load, and reduce the water flow to the heat exchanger unit with lower heat load to ensure the heat exchange efficiency of the overall system. For the heat exchanger unit with higher heat load, increase the flow to improve its heat exchange efficiency, and for the heat exchanger unit with lower heat load, reduce the flow to avoid energy waste. Each heat exchanger unit has an independent intelligent regulating valve at the inlet, and the control unit dynamically adjusts the flow of each heat exchanger unit through these intelligent regulating valves. The opening of the regulating valve is adjusted in real time according to the dynamic flow optimization algorithm to ensure that the water flow distribution of each heat exchanger unit meets the optimal heat exchange requirements. For example, if the heat load of a heat exchanger unit is high, the regulating valve will automatically open more to increase the water flow; if the heat load is low, the regulating valve will appropriately reduce the flow to avoid excessive heat exchange in the system.

[0027] See also Figure 1, an embodiment provided by the present invention: a high-efficiency annealing furnace waste heat recovery control system, the control system also includes a waste heat recovery data prediction and load distribution system, the waste heat recovery data prediction and load distribution system uses a machine learning model to train historical water-using equipment heat load data and flow data, and estimates the waste heat to be generated in real time through a time series prediction method; When the control unit predicts that the heat load is about to arrive, it pre-adjusts the water flow of the circulating water pump and the heat exchanger branch to distribute the load in advance, optimize the water flow distribution, reduce the system pressure caused by the instantaneous waste heat peak, and improve the heat recovery stability and energy utilization efficiency; The waste heat recovery data prediction and load distribution system includes: a data prediction module and a load pre-regulation module; The data prediction module uses time series analysis and machine learning algorithms to predict future waste heat based on historical water use data and waste heat load data, and obtains a heat load estimate for the next 5-10 minutes in advance; When the load pre-regulation module predicts that a large heat load is about to arrive, the control unit adjusts the frequency of the circulating water pump and the water flow of the heat exchanger branch in advance to avoid the impact of instantaneous heat load on the system pressure and optimize the energy utilization efficiency of the system; Furthermore, the data prediction module will regularly obtain real-time data, including the current water flow, the status of the water-using equipment, the waste heat, and the operation of the heat exchanger. Based on these real-time data and combined with the historical heat load pattern, the system runs the prediction model every minute to estimate the waste heat in the next 5-10 minutes. This prediction enables the system to perceive the upcoming heat load fluctuations in advance. The prediction results of the data prediction module will be fed back to the control unit and display the upcoming heat load trend. For example, if a significant heat load peak is predicted in the next few minutes, the system will pass this information to the load pre-regulation module to make adjustments in advance to cope with the upcoming load fluctuations.

[0028] After receiving the heat load forecast data, the load pre-regulation module will adjust the frequency of the circulating water pump and the branch water flow distribution of the heat exchanger in advance according to the predicted heat load demand, and perform load pre-distribution. The system will increase the water flow to the optimal level based on the upcoming heat load forecast to ensure that the heat exchanger enters the optimal heat exchange state in advance. For example, if it is predicted that there will be a water consumption peak within 5 minutes, the load pre-regulation module will increase the frequency of the water pump to increase the heat exchange capacity of the system. The control unit will adjust the speed of the circulating water pump through frequency conversion according to the instructions of the load pre-regulation module. Specific operations include increasing the circulating water flow rate and increasing the flow of the high-load branch to ensure that when the heat load increases, the system is already in an efficient operating state in advance. Before the heat load arrives, the preparatory adjustment of the water pump and the heat exchanger can effectively reduce the instantaneous load impact, avoid overload, and reduce equipment wear and pressure peaks; By predicting and distributing the load in advance, the system can effectively reduce the instantaneous heat load peak, relieve the pressure on the circulating water pump and heat exchanger, and achieve smooth energy recovery. At the same time, this optimization method reduces system energy consumption and improves the overall waste heat recovery efficiency.

[0029] See also Figure 1 , an embodiment provided by the present invention: a high-efficiency annealing furnace waste heat recovery control system, wherein the control system is designed with an adaptive expansion interface, and convenient access to each heat exchange branch / water-using equipment is achieved through a modular structure, and the adaptive expansion interface includes a new device identification module and an adaptive water flow control module. When a new device is connected, the control unit automatically reads the flow demand and priority parameters of the new device through the new device identification module, and adjusts the water flow parameters based on the adaptive water flow control module, so as to seamlessly incorporate the new device into the flow optimization control system, thereby ensuring the plug-and-play function of the control system; The adaptive and modular design of the adaptive expansion interface includes: a modular expansion interface, a new equipment automatic identification module and an adaptive water flow control module; The modular expansion interface is to configure an independent flow control valve and sensor for each expansion interface. The modular expansion interface supports a standard plug-and-play structure design, so that new equipment / heat exchange branches can be connected without changing the main system. The new device automatic identification module, i.e., the control unit detects the type, flow demand and priority parameters of the access device through the new device automatic identification module, automatically configures the operating parameters, and incorporates the new device into the flow control system; The adaptive water flow control module optimizes the flow distribution immediately after the new equipment automatic identification module detects the new equipment, adjusts the working parameters of the flow control valve and the circulating water pump, and ensures that the new equipment operates efficiently and stably in the system; Furthermore, when a new device is connected to the system through a modular interface, the new device automatic identification module will immediately detect the physical access signal of the device. The module reads the basic information of the new device through the sensor in the interface, such as device type, flow requirements, priority parameters, temperature and pressure requirements, etc. The automatic identification module analyzes the frequency of use, key process requirements and safety priorities of the new device according to the system's preset priority classification standards. According to the actual needs of the new device, the identification module sets the initial flow and priority configuration for it, providing reference data for subsequent flow control; Once the new equipment is identified, the adaptive water flow control module will immediately start the flow optimization calculation, automatically adjust the working parameters of the flow control valve and the circulating water pump, and the control unit will adjust the flow valve of the modular interface to meet the real-time flow requirements of the new equipment, while ensuring that the flow distribution of other branches and equipment in the main system is not significantly affected, so as to achieve efficient operation of the new equipment. The adaptive water flow control module allocates an appropriate amount of water flow in the overall system according to the needs of the new equipment, and controls the working frequency of the circulating water pump through frequency conversion regulation to maintain the stability of the total water pressure and flow of the system. In this way, the new equipment can operate stably in the system without affecting the normal operation of other equipment; Based on the modular adaptive expansion interface design, the system is highly flexible and scalable, meeting the user's needs for rapid device access and plug-and-play. Even if the number of devices continues to grow in the later stage, the system can still ensure the coordinated operation of the devices and ensure the continuous optimization of water flow distribution.

[0030] Working principle: The system first uses the intelligent flow control module to collect key data such as flow and water temperature of water-using equipment in real time using a multi-point sensor network, and adjusts the frequency of the circulating water pump and the opening of each regulating valve based on a dynamic feedback control algorithm. The control unit combines the heat load data and uses the flow priority adjustment algorithm to prioritize the water supply to key equipment, ensuring the stability and heat exchange efficiency of the system under load fluctuations; Through the machine learning model of historical data, the system estimates the future trend of heat load changes. When a large heat load is predicted to come, the system pre-adjusts the parameters of the water pump and regulating valve in advance to reduce the pressure on the system caused by sudden heat peaks, realize load pre-distribution, and optimize water flow and thermal energy utilization efficiency; When new water-using equipment is connected, the automatic identification module of the adaptive expansion interface will detect the flow and priority requirements of the new equipment and automatically incorporate it into the flow control system. The control unit adjusts the parameters of each valve and pump through the adaptive water flow control module to ensure the stable operation of the new equipment. This modular interface supports plug-and-play functions, allowing the system to flexibly respond to equipment expansion and continuously maintain the efficiency and stability of the overall operation.

[0031] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A high-efficiency annealing furnace waste heat recovery control system, comprising a control unit, a circulating water pump, a regulating valve, a heat exchanger and a plurality of water-using equipment, characterized in that: The control system is designed with an intelligent adaptive water flow control mechanism, which is composed of a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module; The multi-point sensor network is arranged at key nodes of the circulating water pump, water-using equipment and heat exchanger to collect water pressure, water temperature and flow data. The dynamic feedback control algorithm regulates the frequency of the circulating water pump and the opening of each regulating valve based on the data collected by the multi-point sensor network. The variable frequency water pump control module adjusts the water flow rate by adjusting the speed of the circulating water pump through frequency conversion, thereby maximizing the heat exchange efficiency under different working conditions; The control unit is connected to the heat exchanger, the circulating water pump, the regulating valve and the water-using equipment through signal lines.

2. According to claim 1, a high-efficiency annealing furnace waste heat recovery control system is characterized in that: The control system includes an intelligent user priority allocation system, which is used to dynamically sort multiple water-using equipment based on the frequency of use of the water-using equipment, key process requirements and safety priorities, and the control unit allocates water flow through a flow priority adjustment algorithm according to the sorting scheme; When the system water flow is limited, priority is given to ensuring the water supply to high-priority water-using equipment, and when necessary, flow limitation / cut-off is implemented for low-priority water-using equipment to ensure the continuous operation of key process equipment.

3. According to claim 1, a high-efficiency annealing furnace waste heat recovery control system is characterized in that: The control system is equipped with a distributed flue gas-water heat exchanger flow distribution optimization system, which includes a plurality of distributed heat exchanger units, which are respectively arranged on a plurality of water branches, and an independent intelligent regulating valve and a heat load sensor are arranged at the inlet of each heat exchanger unit; The control unit dynamically adjusts the water flow of each heat exchanger branch according to the real-time heat load and flow demand of each heat exchanger unit through the allocation optimization algorithm to adapt to the actual heat load fluctuations, ensure that each heat exchanger unit operates efficiently under different load conditions, and optimize the overall heat exchange efficiency.

4. According to claim 1, a high-efficiency annealing furnace waste heat recovery control system is characterized in that: The control system also includes a waste heat recovery data prediction and load distribution system, which uses a machine learning model to train historical water-using equipment heat load data and flow data, and estimates the waste heat to be generated in real time through a time series prediction method; When the control unit predicts that the heat load is about to arrive, it pre-adjusts the water flow of the circulating water pump and the heat exchanger branch to distribute the load in advance, optimize the water flow distribution, reduce the system pressure caused by the instantaneous waste heat peak, and improve the heat recovery stability and energy utilization efficiency.

5. The high-efficiency annealing furnace waste heat recovery control system according to claim 1 is characterized in that: The control system is designed with an adaptive expansion interface, which realizes convenient access to each heat exchange branch / water-using equipment through a modular structure. The adaptive expansion interface includes a new equipment identification module and an adaptive water flow control module. When a new device is connected, the control unit automatically reads the flow demand and priority parameters of the new device through the new equipment identification module, and adjusts the water flow parameters based on the adaptive water flow control module, so as to seamlessly integrate the new device into the flow optimization and control system, thereby ensuring the plug-and-play function of the control system.

6. The high-efficiency annealing furnace waste heat recovery control system according to claim 1 is characterized in that: The intelligent adaptive water flow control mechanism includes: a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module; The multi-point sensor network is a system where sensors are placed at the outlet of the circulating water pump, the inlet of each water-using device, and the inlet and outlet of the heat exchanger to collect real-time water pressure, water temperature and flow data at a frequency of 10 times / s; The dynamic feedback control algorithm is that the control unit runs the PID control algorithm based on the data collected by the multi-point sensor network, adjusts the frequency of the circulating water pump and the opening of the regulating valve in real time, and performs dynamic optimization by combining historical data and adaptive adjustment algorithm; The variable frequency water pump control module controls the variable frequency regulation of the circulating water pump to accurately control the flow output, avoid system water flow fluctuations, and ensure the system heat exchange efficiency.

7. The high-efficiency annealing furnace waste heat recovery control system according to claim 2 is characterized in that: The intelligent user priority allocation system includes: a priority classification module and a traffic priority adjustment algorithm; The priority classification module prioritizes each water-using equipment through a multi-parameter algorithm, and sets the priority based on the equipment usage frequency, process criticality and safety demand indicators. When the water demand is higher than the current total water volume of the system, high-priority equipment is given priority. The flow priority adjustment algorithm and control unit adjust the water flow of each water-using equipment through a dynamic allocation algorithm, and limit / cut off the flow of low-priority equipment according to the actual water pressure and flow conditions to ensure stable water supply to high-priority water-using equipment in the system.

8. The high-efficiency annealing furnace waste heat recovery control system according to claim 3 is characterized in that: The distributed flue gas-water heat exchanger flow distribution optimization system includes: a heat exchanger inlet independent adjustment module, a heat load detection module and a dynamic flow optimization algorithm; The heat exchanger inlet independent regulation module means that each heat exchanger unit inlet is equipped with an intelligent regulating valve, and the user independently controls the water flow to ensure efficient heat exchange in the distributed heat exchange structure; The heat load detection module is equipped with temperature sensors at the inlet and outlet of each heat exchanger unit to detect the real-time temperature difference. The control unit automatically adjusts the flow rate according to the detection data to ensure the balanced distribution of the heat load of each heat exchanger unit. The dynamic flow optimization algorithm calculates the actual heat load of each heat exchanger unit, and the control unit optimizes the water flow distribution of different branches in real time to ensure that each heat exchanger can work efficiently under different load conditions and optimize the heat exchange efficiency of the overall system.

9. The high-efficiency annealing furnace waste heat recovery control system according to claim 4, characterized in that: The waste heat recovery data prediction and load distribution system includes: a data prediction module and a load pre-regulation module; The data prediction module uses time series analysis and machine learning algorithms to predict future waste heat based on historical water use data and waste heat load data, and obtains a heat load estimate for the next 5-10 minutes in advance; When the load pre-regulation module predicts that a large heat load is about to arrive, the control unit adjusts the frequency of the circulating water pump and the water flow of the heat exchanger branch in advance to avoid the impact of instantaneous heat load on the system pressure and optimize the system energy utilization efficiency.

10. The high-efficiency annealing furnace waste heat recovery control system according to claim 5, characterized in that: The adaptive and modular design of the adaptive expansion interface includes: a modular expansion interface, a new equipment automatic identification module and an adaptive water flow control module; The modular expansion interface is to configure an independent flow control valve and sensor for each expansion interface. The modular expansion interface supports a standard plug-and-play structure design, so that new equipment / heat exchange branches can be connected without changing the main system. The new device automatic identification module, i.e., the control unit detects the type, flow demand and priority parameters of the access device through the new device automatic identification module, automatically configures the operating parameters, and incorporates the new device into the flow control system; The adaptive water flow control module optimizes the flow distribution immediately after the new equipment automatic identification module detects the new equipment, adjusts the working parameters of the flow control valve and the circulating water pump, and ensures that the new equipment runs efficiently and stably in the system.

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