A high-efficiency annealing furnace waste heat recovery control system

Abstract

The application discloses a kind of high-efficiency annealing furnace waste heat recovery control systems, it is related to annealing process control technical field, including control unit, circulating water pump, regulating valve, heat exchanger and multiple water-using equipment, the control system in design by intelligent self-adapting water flow regulation mechanism, the intelligent self-adapting water flow regulation mechanism is by multipoint sensor network, dynamic feedback control algorithm and frequency conversion water pump control module constitute;The control unit is connected to heat exchanger, circulating water pump, regulating valve and water-using equipment by signal line.This application has intelligent self-adapting water flow regulation mechanism by design, realizes the dynamic detection optimization adjustment function of water flow, solves the problem that traditional waste heat recovery control system cannot carry out distribution optimization heat exchange efficiency to water flow in real time, improves the flexibility of equipment operation, satisfies the heat exchange demand under a variety of working conditions.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of annealing process control, in particular to a high-efficiency annealing furnace waste heat recovery control system. BACKGROUND

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

[0003] However, the design and implementation of waste heat recovery system face many challenges. The water demand, work priority, process requirements and safety requirements of different water-using equipment are different, making the flow distribution and priority management complex. In actual operation, under the condition of flow limitation, how to dynamically adjust the water flow of each water-using equipment to ensure the stable operation of high-priority equipment has become a problem that the industry needs to solve. In addition, the traditional waste heat recovery system often lacks intelligent control and cannot adapt to process changes and equipment status in real time, resulting in suboptimal energy efficiency.

[0004] Therefore, it is particularly important to build a high-efficiency annealing furnace waste heat recovery control system combined with an intelligent user priority allocation mechanism to realize dynamic sequencing and flow priority management of water-using equipment. The implementation of this system will greatly improve the 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 and utilizing waste heat in the slow cooling section of the annealing process of ductile cast iron pipe. The above-mentioned patent realizes the recycling of waste heat in the slow cooling section of the annealing process in the cast pipe production process, 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 cast iron pipe. However, the above-mentioned patent cannot realize the function of dynamic detection and optimization adjustment of water flow.

[0006] 2. Patent document CN107686881B discloses a waste heat recovery device for annealing system. The above-mentioned patent realizes the gradual annealing of workpieces while the heat in the heating section is transported to the isothermal section and the slow cooling section through the setting of the waste heat utilization unit in the heating section, completing the utilization of heat in the annealing furnace, with high waste heat utilization rate, uniform temperature distribution, and automatic cooperation of the device. However, the above-mentioned patent cannot realize the functions of dynamic sequencing and flow adjustment of water-using equipment.

[0007] 3. Patent document CN111286598B discloses a kind of annealing furnace preheating section temperature control method, device and system, above-mentioned patent has realized the low speed setting of fan due to the fact that it is avoided, cause heat utilization rate is low, or fan speed is too high, lead to exceed maximum waste heat recovery, increase additional power consumption, but above-mentioned patent cannot realize the load monitoring and water flow distribution optimization function of heat exchanger.

[0008] 4. Patent document CN116573843B discloses a kind of waste heat recycling annealing furnace, above-mentioned patent realizes the effect of optimal waste heat utilization of high-temperature gas, but above-mentioned patent cannot realize the early prediction and water flow distribution function of thermal load.

[0009] In summary, above-mentioned patent cannot realize the dynamic detection optimization regulation function of water flow, the dynamic sequencing and flow regulation function of water-using equipment, the load monitoring and water flow distribution optimization function of heat exchanger and the early prediction and water flow distribution function of thermal load, lead to the problems of poor heat exchange efficiency, low energy utilization rate, unstable system operation and poor economic benefit;

[0010] Therefore, the present application proposes a kind of high-efficiency annealing furnace waste heat recovery control system, which can realize the dynamic detection optimization regulation function of water flow, the dynamic sequencing and flow regulation function of water-using equipment, the load monitoring and water flow distribution optimization function of heat exchanger and the early prediction and water flow distribution function of thermal load. SUMMARY

[0011] The present application aims to provide a kind of high-efficiency annealing furnace waste heat recovery control system to solve the technical problems of above-mentioned background art, which cannot realize the dynamic detection optimization regulation function of water flow, the dynamic sequencing and flow regulation function of water-using equipment, the load monitoring and water flow distribution optimization function of heat exchanger and the early prediction and water flow distribution function of thermal load, lead to the problems of poor heat exchange efficiency, low energy utilization rate, unstable system operation and poor economic benefit.

[0012] To achieve the above-mentioned purpose, the present application provides the following technical solution: a kind of high-efficiency annealing furnace waste heat recovery control system, comprising control unit, circulating water pump, regulating valve, heat exchanger and multiple water-using equipment, the control system is designed by intelligent adaptive water flow control mechanism, the intelligent adaptive water flow control mechanism is constituted by multipoint sensor network, dynamic feedback control algorithm and variable frequency water pump control module;

[0013] The multipoint sensor network is arranged at the key nodes of circulating water pump, water-using equipment and heat exchanger, for collecting water pressure, water temperature and flow data, the dynamic feedback control algorithm regulates the frequency of circulating water pump and the opening of each regulating valve based on the data collected by multipoint sensor network.

[0014] The variable frequency water pump control module adjusts the water flow by adjusting the rotating speed of the circulating water pump, and realizes the maximization of heat exchange efficiency under different working conditions.

[0015] The control unit is connected to the heat exchanger, circulating water pump, regulating valve and water using equipment through a signal line.

[0016] Preferably, the control system comprises an intelligent user priority allocation system, which is used for dynamically sorting a plurality of water using equipment based on the use frequency of the water using equipment, critical process requirements and safety priority, and the control unit allocates water flow according to the sorting scheme through a flow priority regulation algorithm.

[0017] In the case of limited system water flow, the water supply of high-priority water using equipment is ensured, and if necessary, the flow limiting / flow cutting of low-priority water using equipment is performed to ensure the continuous operation of critical process equipment.

[0018] Preferably, the control system is equipped with a distributed flue gas-water heat exchanger flow distribution optimization system, which comprises a plurality of distributed heat exchanger units, each heat exchanger unit being arranged on a plurality of water using branches, and each heat exchanger unit inlet being provided with an independent intelligent regulating valve and a heat load sensor.

[0019] The control unit dynamically adjusts the water flow of each heat exchanger branch through a distribution optimization algorithm according to the real-time heat load and flow demand of each heat exchanger unit, adapts to actual heat load fluctuations, ensures the efficient operation of each heat exchanger unit under different load conditions, and optimizes the overall heat exchange efficiency.

[0020] Preferably, the control system further comprises 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.

[0021] When the control unit predicts that the heat load is about to come, it adjusts the water flow of the circulating water pump and the heat exchanger branch in advance to distribute the load in advance, optimize water flow distribution, reduce the system pressure caused by instantaneous waste heat peak, and improve heat recovery stability and energy utilization efficiency.

[0022] Preferably, the control system is designed with an adaptive expansion interface, which realizes the convenient access of each heat exchange branch / water using equipment through a modular structure. The adaptive expansion interface comprises a new equipment identification module and an adaptive water flow control module. When a new equipment is connected, the control unit automatically reads the flow demand and priority parameters of the new equipment through the new equipment identification module, adjusts the water flow parameters based on the adaptive water flow control module, seamlessly integrates the new equipment into the flow optimization control system, and ensures the plug-and-play function of the control system.

[0023] Preferably, the intelligent self-adaptive water flow regulation mechanism comprises a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module.

[0024] The multi-point sensor network is that sensors are arranged 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 collection frequency of 10 times / s.

[0025] The dynamic feedback control algorithm is that a PID control algorithm is run by the control unit based on the data collected by the multi-point sensor network to adjust the frequency of the circulating water pump and the opening degree of the regulating valve in real time, and dynamic optimization is performed in combination with historical data and a self-adaptive adjustment algorithm.

[0026] The variable frequency water pump control module precisely controls the flow output by controlling the variable frequency adjustment of the circulating water pump, avoids system water flow fluctuation and ensures system heat exchange efficiency.

[0027] Preferably, the intelligent user priority allocation system comprises a priority classification module and a flow priority regulation algorithm.

[0028] The priority classification module sorts the priority of each water-using device by a multi-parameter algorithm, sets the priority according to the device use frequency, process criticality and safety requirement index, and ensures high-priority devices when the water-using needs are higher than the current total water quantity of the system.

[0029] The flow priority regulation algorithm and the control unit regulate the water flow of each water-using device by a dynamic distribution algorithm, limit / stop the flow of low-priority devices according to the actual water pressure and flow conditions, and ensure stable water supply for high-priority water-using devices in the system.

[0030] Preferably, the distributed flue gas-water heat exchanger flow distribution optimization system comprises a heat exchanger inlet independent regulation module, a heat load detection module and a dynamic flow optimization algorithm.

[0031] The heat exchanger inlet independent regulation module is that an intelligent regulating valve is configured at the inlet of each heat exchanger unit, and the water flow is independently controlled by the user to ensure efficient heat exchange in the distributed heat exchange structure.

[0032] The heat load detection module is that temperature sensors are arranged at the inlet and outlet of each heat exchanger unit to detect the real-time temperature difference, and the control unit automatically adjusts the flow according to the detection data to ensure balanced distribution of the heat load of each heat exchanger unit.

[0033] The dynamic flow optimization algorithm is that the actual heat load of each heat exchanger unit is calculated, the water flow distribution of different branches is optimized in real time by the control unit to ensure that each heat exchanger can work efficiently under different loads, and the overall system heat exchange efficiency is optimized.

[0034] Preferably, the waste heat recovery data prediction and load distribution system comprises a data prediction module and a load pre-regulation module.

[0035] The data prediction module predicts future waste heat based on historical water consumption data and waste heat load data using time series analysis and machine learning algorithms, obtaining a heat load estimate for the next 5-10 minutes in advance.

[0036] When the load pre-regulation module predicts that a large heat load is approaching, the control unit adjusts the circulating water pump frequency and the water flow of the heat exchanger branch in advance to avoid the impact of instantaneous heat load on system pressure and optimize system energy utilization efficiency.

[0037] Preferably, the adaptive and modular design of the self-adaptive expansion interface comprises a modular expansion interface, a new device automatic identification module and a self-adaptive water flow control module.

[0038] The modular expansion interface is configured with an independent flow regulating valve and sensor for each expansion interface, and the modular expansion interface supports a standard plug-and-play structure design, allowing new devices / heat exchanger branches to be connected without changing the main system.

[0039] The new device automatic identification module detects the type, flow demand and priority parameters of the connected device through the new device automatic identification module, automatically configures the operating parameters and integrates the new device into the flow control system.

[0040] The self-adaptive water flow control module optimizes the flow distribution immediately after the new device automatic identification module detects the new device, adjusts the working parameters of the flow regulating valve and circulating water pump to ensure efficient and stable operation of the new device in the system.

[0041] Compared with the prior art, the present application has the following advantages:

[0042] 1. The present application has an intelligent self-adaptive water flow control mechanism, which realizes dynamic detection and optimization of water flow, solves the problem of traditional waste heat recovery control systems that cannot optimize heat exchange efficiency by real-time distribution of water flow, improves the flexibility of equipment operation and meets the heat exchange needs of various working conditions.

[0043] 2. The present application has an intelligent user priority allocation system, which realizes dynamic sorting and flow regulation of water-consuming devices, solves the problem of traditional systems that cannot accurately control the water priority of different devices when water flow is limited or during peak process load, and avoids the problem of key equipment not being able to operate normally due to insufficient water flow, significantly improving the operation continuity and reliability of process equipment and avoiding downtime or efficiency reduction caused by unstable water flow.

[0044] 3. The present application realizes the load monitoring and water flow distribution optimization function of the heat exchanger by designing a distributed flue gas-water heat exchanger flow distribution optimization system, solves the problem of low heat exchange efficiency and low energy utilization caused by the problem of unable to flexibly distribute water flow according to the load demand of the heat exchanger, improves the overall efficiency of waste heat recovery, and reduces energy consumption;

[0045] 4. The present application realizes the functions of early prediction of thermal load and water flow distribution by designing a waste heat recovery data prediction and load distribution system, solves the problem of system overload caused by sudden thermal load peak, reduces thermal load impact, optimizes heat utilization efficiency, and improves system stability and load fluctuation resistance. BRIEF DESCRIPTION OF DRAWINGS

[0046] Figure 1 The present application is a waste heat recovery control process schematic diagram. DETAILED DESCRIPTION

[0047] The technical solutions in the embodiments of the present application will be described in detail below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0048] Please refer to Figure 1 , the present application provides an embodiment: 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, the control system is designed by an intelligent adaptive water flow control mechanism, 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;

[0049] The multi-point sensor network is arranged at the key nodes of the circulating water pump, the water-using equipment and the heat exchanger, for collecting water pressure, water temperature and flow data, the dynamic feedback control algorithm adjusts 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;

[0050] The variable frequency water pump control module adjusts the water flow by adjusting the rotating speed of the circulating water pump, and realizes the maximum heat exchange efficiency under different working conditions;

[0051] The control unit is connected to the heat exchanger, the circulating water pump, the regulating valve and the water-using equipment through signal lines;

[0052] The intelligent adaptive water flow control mechanism comprises a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module;

[0053] Multi-point sensor network, i.e. sensors are arranged at the outlet of the circulating water pump, the inlet of each water-using equipment, and the inlet and outlet of the heat exchanger, to collect real-time water pressure, water temperature and flow data, with a collection frequency of 10 times / s;

[0054] Dynamic feedback control algorithm, i.e. the control unit runs the PID control algorithm based on the data collected by the multi-point sensor network, to adjust the frequency of the circulating water pump and the opening of the regulating valve in real time, and dynamically optimizes in combination with historical data and self-adaptive adjustment algorithm;

[0055] Variable frequency water pump control module precisely controls the flow output by controlling the variable frequency adjustment of the circulating water pump, avoids system flow fluctuation, and ensures system heat exchange efficiency;

[0056] Further, after the system is started, the control unit performs self-checking on the multi-point sensor network, the circulating water pump, the regulating valve and other key equipment in turn, to ensure that the sensors and actuators are working normally, and to set 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, which are transmitted to the control unit through signal lines, the control unit receives and analyzes the collected data from the multi-point sensor network in real time, and calculates and processes the data, checks the pressure data at the outlet of the circulating water pump to ensure that it is within the set range and avoid excessive or low pressure fluctuation, monitors the water temperature difference between the inlet and outlet of the heat exchanger to ensure that the water flow can effectively recover waste heat when passing through the heat exchanger, adjusts the flow of each branch through the regulating valve to adapt to the actual water demand in combination with the flow demand of each water-using equipment;

[0057] The control unit runs the dynamic feedback control algorithm according to the real-time monitored data, the core of which is the PID control, to maintain stable water flow output by adjusting the speed of the circulating water pump, to realize dynamic balance of water pressure and flow, to adjust the opening of each branch regulating valve to finely control water flow to ensure that the water demand of different equipment is met, and the variable frequency water pump control module will automatically adjust the speed of the water pump 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 demand of the water-using equipment, avoid system efficiency reduction due to flow fluctuation, and dynamically regulate the opening of each branch regulating valve according to the real-time demand of each water-using equipment. High-priority water-using equipment can obtain priority water supply when the demand increases, and the control unit will temporarily reduce the water supply of low-priority equipment to ensure the operation stability of key equipment.

[0058] Please refer to Figure 1The application provides an embodiment of a high-efficiency annealing furnace waste heat recovery control system, wherein the control system comprises an intelligent user priority allocation system, the intelligent user priority allocation system is used for dynamically sequencing a plurality of water-using devices based on water-using device use frequency, key process requirements and safety priority, and a control unit allocates water flow through a flow priority adjustment algorithm according to the sequencing scheme;

[0059] In the case that the system water flow is limited, the water supply of high-priority water-using devices is ensured, and if necessary, the flow limiting / flow cutting of low-priority water-using devices is performed, so that the continuous operation of key process devices is ensured.

[0060] The intelligent user priority allocation system comprises a priority classification module and a flow priority adjustment algorithm.

[0061] The priority classification module sequences the priority of each water-using device through a multi-parameter algorithm, sets the priority according to the device use frequency, process criticality and safety requirement index, and ensures the high-priority devices when the water-using needs more than the current total water amount of the system.

[0062] The flow priority adjustment algorithm and the control unit adjust the water flow of each water-using device through a dynamic allocation algorithm, limit / stop the flow of low-priority devices according to the actual water pressure and flow, and ensure the stable water supply of high-priority water-using devices in the system.

[0063] Further, the system evaluates the use frequency of each water-using device according to historical water-using data, and the frequently used devices are given higher priority, evaluates the importance of each water-using device in the production process, and the key process devices (such as heat exchangers, annealing furnace cooling water, etc.) are given higher priority, some devices may be closely related to production safety (such as emergency cooling systems, pressure protection devices, etc.), and these devices are given higher priority, and a priority sequencing scheme of water-using devices is generated.

[0064] 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 the current process state, device use frequency and priority classification, and at the same time, the system monitors the total water supply capacity of the water pump and the pipe network in real time. The current total water flow is obtained through the sensor, and it is judged whether the demand of all devices is met. If the total water flow of the system is lower than the total demand of all devices, the flow distribution adjustment is needed in the case that the water flow is limited.

[0065] The system first ensures that high-priority devices obtain sufficient water flow. The control unit allocates water flow to these devices according to their actual needs and priorities. For low-priority devices, the system controls the flow by dynamically reducing the water flow of some low-priority devices to ensure that these devices receive a certain degree of water supply, but does not affect the operation of high-priority devices. When the system water flow is severely insufficient to meet the needs of all devices, the control unit will cut off the flow of some low-priority devices, i.e., completely cut off their water supply, to ensure the stable water flow of high-priority devices and avoid the influence of low-priority devices on the system.

[0066] The system monitors the operating state 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 scheme according to the actual needs and priorities of the devices.

[0067] Please refer to Figure 1 An embodiment of the present application provides a high-efficiency annealing furnace waste heat recovery control system, which 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, and the heat exchanger units are arranged on a plurality of water-using branches. Each heat exchanger unit is provided with an independent intelligent regulating valve and a heat load sensor at the inlet thereof.

[0068] The control unit dynamically adjusts the water flow of each heat exchanger branch through a distribution optimization algorithm according to the real-time heat load and flow demand of each heat exchanger unit, so as to adapt to the actual heat load fluctuation, ensure the high-efficiency operation of each heat exchanger unit under different load conditions, and optimize the overall heat exchange efficiency.

[0069] The distributed flue gas-water heat exchanger flow distribution optimization system comprises a heat exchanger inlet independent regulating module, a heat load detection module and a dynamic flow optimization algorithm.

[0070] The heat exchanger inlet independent regulating module, i.e., the intelligent regulating valve is arranged at the inlet of each heat exchanger unit, so that the user can independently control the water flow, and high-efficiency heat exchange can be realized in the distributed heat exchange structure.

[0071] The heat load detection module, i.e., temperature sensors are arranged at the inlet and outlet of each heat exchanger unit to detect the real-time temperature difference. The control unit automatically adjusts the flow according to the detection data to ensure the balanced distribution of the heat load of each heat exchanger unit.

[0072] The dynamic flow optimization algorithm, i.e., the actual heat load of each heat exchanger unit is calculated, 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 overall system heat exchange efficiency.

[0073] Further, each heat exchanger unit inlet and outlet temperature sensor real-time data acquisition, access to water temperature and water temperature. By comparing the temperature difference between import and export, the system can determine the current heat load (heat exchange efficiency) of the heat exchanger unit, the control unit based on temperature difference data combined with flow information, calculate the actual heat load of each heat exchanger unit. For example, the unit with a large temperature difference means that the unit carries a large heat load, and the heat exchange effect is good; on the contrary, the temperature difference is small, which indicates that the heat exchange effect is poor, and 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 reached;

[0074] 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 heat exchanger units with high heat load, and reduce water flow to heat exchanger units with low heat load, to ensure the overall system heat exchange efficiency. For heat exchanger units with high heat load, increase the flow to improve the heat exchange efficiency, and for heat exchanger units with low heat load, reduce the flow to avoid energy waste;

[0075] 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 demand. For example, if a heat exchanger unit has a high heat load, 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.

[0076] Please refer to Figure 1 An embodiment of the present application provides a high-efficiency annealing furnace waste heat recovery control system, which further comprises 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 equipment heat load data and flow data, and estimates the waste heat to be generated in real time through a time series prediction method.

[0077] When the control unit predicts that the heat load is about to arrive, it adjusts the circulating water pump and the water flow of the heat exchanger branch in advance 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.

[0078] The waste heat recovery data prediction and load distribution system comprises a data prediction module and a load pre-adjustment module.

[0079] The data prediction module predicts future waste heat based on historical water data and waste heat load data, using time series analysis and machine learning algorithms to obtain heat load estimates for the next 5-10 minutes in advance.

[0080] When the load pre-regulation module predicts that a large thermal load is about to arrive, the control unit adjusts the circulating water pump frequency and the water flow of the heat exchanger branch in advance to avoid the impact of instantaneous thermal load on system pressure and optimize system energy utilization efficiency;

[0081] Further, the data prediction module regularly obtains real-time data, including the current water flow, the state of the water-using equipment, the residual heat, and the operation of the heat exchanger. Based on these real-time data, combined with historical thermal load patterns, the system runs a prediction model every minute to estimate the residual heat in the next 5-10 minutes. This prediction enables the system to anticipate the upcoming thermal load fluctuation in advance. The prediction results of the data prediction module are fed back to the control unit and display the upcoming thermal load trend. For example, if a significant thermal load peak is predicted in the next few minutes, the system will pass this information to the load pre-regulation module for pre-adjustment to cope with the upcoming load fluctuation.

[0082] After receiving the thermal load prediction data, the load pre-regulation module adjusts the frequency of the circulating water pump and the distribution of the water flow of the heat exchanger branch in advance according to the predicted thermal load demand, performs load pre-distribution, and increases the water flow to the optimal level to ensure that the heat exchanger enters the optimal heat exchange state in advance. For example, if a water-using peak is predicted in 5 minutes, the load pre-regulation module will increase the water pump frequency to increase the system's heat exchange capacity. The control unit adjusts the speed of the circulating water pump according to the instructions of the load pre-regulation module. The specific operation includes increasing the circulating water flow and the flow of the high-load branch to ensure that the system is in an efficient operating state when the thermal load increases. The preparation adjustment of the water pump and the heat exchanger before the arrival of the thermal load can effectively reduce the impact of instantaneous load and avoid overload, reducing equipment wear and pressure peaks;

[0083] By predicting and distributing the load in advance, the system can effectively reduce the instantaneous thermal load peak, reduce the pressure on the circulating water pump and the heat exchanger, and realize smooth energy recovery. At the same time, this optimization method reduces system energy consumption and improves overall residual heat recovery efficiency.

[0084] Please refer to Figure 1The application provides an embodiment of a high-efficiency annealing furnace waste heat recovery control system, wherein a self-adaptive expansion interface is designed in the control system, and each heat exchange branch / water equipment is conveniently connected through a modular structure, the self-adaptive expansion interface comprises a new equipment identification module and a self-adaptive water flow control module, when new equipment is connected, the control unit automatically reads the flow demand and priority parameter of the new equipment through the new equipment identification module, and adjusts the water flow parameter based on the self-adaptive water flow control module, so that the new equipment is seamlessly integrated into the flow optimization control system, and the plug-and-play function of the control system is ensured;

[0085] The self-adaptive and modular design of the self-adaptive expansion interface comprises a modular expansion interface, a new equipment automatic identification module and a self-adaptive water flow control module;

[0086] The modular expansion interface is that an independent flow regulating valve and a sensor are configured for each expansion interface, the modular expansion interface supports a standard plug-and-play structure design, and new equipment / heat exchange branches can be connected without changing the main system;

[0087] The new equipment automatic identification module is that the control unit detects the type, flow demand and priority parameter of the connected equipment through the new equipment automatic identification module, automatically configures the operation parameter, and integrates the new equipment into the flow control system;

[0088] The self-adaptive water flow control module optimizes the flow distribution immediately after the new equipment is detected by the new equipment automatic identification module, adjusts the working parameter of the flow regulating valve and the circulating water pump, and ensures that the new equipment operates efficiently and stably in the system;

[0089] Further, when the new equipment is connected to the system through the modular interface, the new equipment automatic identification module immediately detects the physical connection signal of the equipment. The module reads the basic information of the new equipment, such as the equipment type, flow demand, priority parameter, temperature and pressure requirement, etc., through the sensor in the interface, and the automatic identification module analyzes the use frequency, critical process demand and safety priority of the new equipment according to the priority classification standard preset by the system. According to the actual demand of the new equipment, the identification module sets the initial flow and priority configuration for the new equipment, and provides reference data for subsequent flow control;

[0090] Once the new device identification is completed, the adaptive water flow control module will immediately start the flow optimization calculation, automatically adjust the working parameters of the flow regulating valve and circulating water pump, and the control unit will adjust the flow valve of the modular interface to meet the real-time flow demand of the new device, while ensuring that the flow distribution of other branches and devices in the main system is not significantly affected, realizing the efficient operation of the new device. The adaptive water flow control module allocates appropriate water flow in the overall system according to the needs of the new device, and adjusts the working frequency of the circulating water pump through frequency conversion control to maintain the stability of the total water pressure and flow of the system. In this way, the new device can run stably in the system and will not affect the normal operation of other devices;

[0091] Based on the modular adaptive expansion interface design, the system has high flexibility and scalability, meeting the user's demand for rapid access and plug-and-play of devices. Even in the case of continuous growth of the number of devices in the later period, the system can still ensure the coordinated operation of the devices and ensure the continuous optimization of water flow distribution.

[0092] Working principle, the system first uses the multi-point sensor network to collect real-time flow, water temperature and other key data of water-using equipment through the intelligent flow control module, and adjusts the circulating water pump frequency and the opening of each regulating valve based on the dynamic feedback control algorithm. The control unit combines the heat load data to prioritize the water supply of key equipment through the flow priority adjustment algorithm, ensuring the stability and heat exchange efficiency of the system under load fluctuation;

[0093] Through the machine learning model of historical data, the system estimates the future heat load trend. When a large heat load is predicted to arrive, the system will pre-adjust the parameters of the water pump and regulating valve in advance to reduce the pressure on the system caused by sudden heat load peaks, realize load pre-distribution, and optimize water flow and heat energy utilization efficiency;

[0094] 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 device and automatically include it in the flow control system. The control unit adjusts the parameters of each valve and water pump through the adaptive water flow control module to ensure the stable operation of the new device. The modular interface supports plug-and-play function, enabling the system to flexibly respond to device expansion and continuously maintain efficient and stable overall operation.

[0095] It will be apparent to those skilled in the art that the application is not limited to the details of the above-exemplified embodiments and that the present application can be implemented in other particular forms without departing from the spirit or essential characteristics of the present application. The embodiments should therefore be considered in all respects as illustrative and not restrictive, the scope of the application being indicated by the appended claims rather than by the above description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. No reference signs in the claims should be considered as limiting the scope of the claims with respect to the figures of the patent document.

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 regulation 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 for collecting water pressure, water temperature and flow data, and 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 by adjusting the rotating speed of the circulating water pump to maximize the heat exchange efficiency under different working conditions; The control unit is connected to the heat exchanger, circulating water pump, regulating valve and water-using equipment through signal lines; The control system includes an intelligent user priority allocation system, which dynamically sorts multiple water-using equipment based on the usage frequency, key process requirements and safety priority of the water-using equipment, and the control unit allocates water flow according to the sorting scheme through a flow priority regulation algorithm; In the case of limited system water flow, the water supply of high-priority water-using equipment is guaranteed, and if necessary, the flow of low-priority water-using equipment is limited or cut off to ensure the continuous operation of key process equipment; The control system is equipped with a distributed flue gas-water heat exchanger flow distribution optimization system, which includes multiple distributed heat exchanger units, each heat exchanger unit is arranged on a water-using branch, and each heat exchanger unit inlet is provided with an independent intelligent regulating valve and a heat load sensor; The control unit dynamically adjusts the water flow of each heat exchanger branch through the distribution optimization algorithm according to the real-time heat load and flow demand of each heat exchanger unit, adapts to actual heat load fluctuations, ensures efficient operation of each heat exchanger unit under different load conditions, and optimizes overall heat exchange efficiency; 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 generated waste heat in real time through time series prediction; When the control unit predicts that the heat load is about to arrive, it adjusts the water flow of the circulating water pump and the heat exchanger branch in advance to distribute the load in advance, optimize water flow distribution, reduce system pressure caused by instantaneous waste heat peak, and improve heat recovery stability and energy utilization efficiency; The control system is designed with an adaptive expansion interface, which realizes the convenient access of 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, adjusts the water flow parameters based on the adaptive water flow control module, and seamlessly integrates the new device into the flow optimization and regulation system, ensuring the plug-and-play function of the control system.

2. The high efficiency annealing furnace waste heat recovery control system according to claim 1, characterized in that: The intelligent adaptive water flow regulation mechanism includes a multi-point sensor network, a dynamic feedback control algorithm and a variable frequency water pump control module; Multi-point sensor network, i.e. sensors are arranged 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, with a collection frequency of 10 times / s; Dynamic feedback control algorithm, i.e. the control unit runs a PID control algorithm based on the data collected by the multi-point sensor network, to adjust the frequency of the circulating water pump and the opening degree of the regulating valve in real time, and to perform dynamic optimization in combination with historical data and an adaptive adjustment algorithm; The variable-frequency water pump control module precisely controls the flow output by controlling the variable-frequency adjustment of the circulating water pump, avoids system water flow fluctuation, and ensures system heat exchange efficiency.

3. The high efficiency annealing furnace waste heat recovery control system according to claim 1, characterized in that: The intelligent user priority allocation system comprises a priority classification module and a flow priority adjustment algorithm; The priority classification module sorts the priorities of each water-using device by a multi-parameter algorithm, sets the priorities according to the device usage frequency, process criticality and safety requirement index, and ensures high-priority devices when the water-using demand is higher than the current total water amount of the system; The flow priority adjustment algorithm and the control unit adjust the water flow of each water-using device by a dynamic distribution algorithm, limit / stop the flow of low-priority devices according to the actual water pressure and flow conditions, and ensure stable water supply to high-priority water-using devices in the system.

4. The high efficiency annealing furnace waste heat recovery control system of claim 1, wherein: 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 adjustment module, i.e. each heat exchanger unit inlet is configured with an intelligent regulating valve, the user independently controls the water flow, and ensures efficient heat exchange in the distributed heat exchange structure; The heat load detection module, i.e. temperature sensors are arranged at the inlet and outlet of each heat exchanger unit to detect real-time temperature difference, and the control unit automatically adjusts the flow according to the detection data to ensure balanced distribution of the heat load of each heat exchanger unit; The dynamic flow optimization algorithm, i.e. the control unit optimizes the water flow distribution of different branches in real time by calculating the actual heat load of each heat exchanger unit, to ensure efficient work of each heat exchanger under different load conditions and optimize the overall system heat exchange efficiency.

5. The high efficiency annealing furnace waste heat recovery control system according to claim 1, characterized in that: The waste heat recovery data prediction and load distribution system comprises a data prediction module and a load pre-adjustment module; The data prediction module predicts future waste heat based on historical water consumption data and waste heat load data, uses time series analysis and machine learning algorithms, and obtains heat load estimation for the next 5-10 minutes in advance; When a large heat load is predicted to arrive, the load pre-adjustment module adjusts the frequency of the circulating water pump and the water flow of the heat exchanger branch in advance, avoids the impact of instantaneous heat load on system pressure, and optimizes system energy utilization efficiency.

6. The high efficiency annealing furnace waste heat recovery control system of claim 1, wherein: The adaptive and modular design of the adaptive expansion interface comprises a modular expansion interface, a new device automatic identification module and an adaptive water flow control module; The modular expansion interface, i.e. each expansion interface is configured with an independent flow regulating valve and a sensor, supports a standard plug-and-play structure design, and realizes the connection of new devices / heat exchange branches without changing the main system; The new device automatic identification module, i.e. the control unit, detects the type, flow demand and priority parameter of the access device through the new device automatic identification module, automatically configures the operation parameter, and integrates the new device into the flow regulation system. The adaptive water flow control module optimizes the flow distribution immediately after the new device automatic identification module detects the new device, adjusts the working parameter of the flow regulating valve and the circulating water pump, and ensures the efficient and stable operation of the new device in the system.

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