Ferrous sulfate oxidation production automation system and control method thereof

Abstract

The invention belongs to the technical field of chemical production automation, and particularly relates to a ferrous sulfate oxidation production automation system and a control method thereof. The ferrous sulfate quantitative feeding subsystem comprises a constant mass feeding module which is used for accurately controlling the feeding amount of ferrous sulfate through a high-precision scale; the parameter setting module is used for providing a parameter input interface; the hydrogen peroxide quantitative feeding subsystem comprises a flow accumulation module which is used for obtaining a hydrogen peroxide volume parameter through instantaneous flow integration; the constant-volume feeding module is used for accurately controlling the feeding amount of hydrogen peroxide through a flow meter; the automatic stirring subsystem comprises an automatic stirring module; the automatic stirring module realizes automatic start and stop of a stirrer, so that slurry dissolution can be guaranteed to the greatest extent, and the stirrer can be protected from idling; the temperature control subsystem comprises a temperature control module which is used for accurately controlling the temperature of the reaction kettle. The temperature control device is used for solving the problems of accurate feeding and accurate temperature control in the prior art.

Description

Technical Field

[0001] The invention belongs to the technical field of chemical production automation, and in particular relates to a ferrous sulfate oxidation production automation system and a control method thereof. Background Art

[0002] Ferrous sulfate (FeSO4) is an important chemical raw material with a wide range of applications in many fields. Its oxidation reaction is a process that has attracted much attention in the chemical industry. In this process, ferrous ions (Fe 2+ ) is oxidized to iron ions (Fe 3+ ). This seemingly simple oxidation process actually has complex chemical kinetics and thermodynamic properties. The oxidation reaction of ferrous sulfate is affected by many factors, such as temperature, solution acidity (pH value), oxygen concentration, and impurities in the reaction system. Under appropriate conditions, the oxidation reaction can be carried out efficiently, and the precise control of these conditions is essential for obtaining high-quality oxidation products. Moreover, the oxidation products play an irreplaceable role in many industries. For example, in the water treatment industry, oxidized ferrous sulfate can be used as an efficient flocculant to remove suspended particles and impurities in water; in the pigment and dye industry, its oxidation products can participate in the synthesis of products with specific colors and properties; in the agricultural field, oxidized iron compounds are also important for soil improvement and plant nutrition supply.

[0003] In traditional ferrous sulfate oxidation production, manual operation and monitoring are often relied on. Operators need to manually adjust the reaction conditions, such as controlling the pH value by adding acid-base regulators, turning on or off ventilation equipment to adjust the oxygen supply, etc. However, human operation inevitably has errors and instabilities. Different operators may have different judgments on the reaction state, resulting in inaccurate control of reaction conditions. For example, when adjusting the temperature, manual operation may not be able to respond to temperature changes in a timely and accurate manner, causing large fluctuations in the reaction temperature, which will not only affect the rate of the oxidation reaction, but may also cause side reactions and reduce product quality.

[0004] The monitoring method under the traditional production method is often regular sampling and analysis, which has obvious lag. During the period from sampling to the analysis results, the reaction conditions may have changed, and the operator cannot adjust according to the real-time reaction situation. For example, during the oxidation process, if the change in the concentration of ferrous ions cannot be grasped in time, over-oxidation or under-oxidation may occur. Over-oxidation will cause the iron ion content in the product to be too high, which may affect its performance in certain applications; under-oxidation will cause the product quality to not meet the requirements and require further processing or even scrapping. Due to the limitations of manual operation and monitoring, the various links in the traditional ferrous sulfate oxidation production process are not closely connected, resulting in low production efficiency. For example, after adjusting the reaction conditions, it takes a certain amount of time to wait for the reaction to stabilize, and the manual judgment of the stabilization time may be inaccurate, which will extend the entire production cycle. Moreover, when abnormal situations occur, the speed of manual troubleshooting and problem solving is relatively slow, further affecting the continuity and efficiency of production. Summary of the invention

[0005] The invention provides a ferrous sulfate oxidation production automation system and a control method thereof, which are used to solve the problems of accurate feeding and precise temperature control in the prior art.

[0006] The present invention is achieved through the following technical solutions:

[0007] An automated system for ferrous sulfate oxidation production, the system comprising a ferrous sulfate quantitative feeding subsystem, a hydrogen peroxide quantitative feeding subsystem, an automatic stirring subsystem and a temperature control subsystem;

[0008] The ferrous sulfate quantitative feeding subsystem includes a fixed mass feeding module and a parameter setting module;

[0009] The fixed mass feeding module is used to accurately control the feeding amount of ferrous sulfate through a high-precision scale;

[0010] The parameter setting module: provides an interface for parameter input;

[0011] The hydrogen peroxide quantitative feeding subsystem includes a flow accumulation module and a fixed volume feeding module;

[0012] The flow accumulation module obtains the volume parameter of hydrogen peroxide by integrating the instantaneous flow;

[0013] The fixed volume feeding module: accurately controls the feeding amount of hydrogen peroxide through a flow meter;

[0014] The automatic stirring subsystem includes an automatic stirring module;

[0015] The automatic stirring module: realizes the automatic start and stop of the stirrer, which can not only ensure the dissolution of the slurry to the maximum extent, but also protect the stirrer from idling;

[0016] The temperature control subsystem includes a temperature control module;

[0017] The temperature control module realizes accurate control of the temperature of the reactor.

[0018] Furthermore, the system also includes a monitoring unit, a control module and a logic processing module;

[0019] The monitoring unit is composed of a hydrogen peroxide flow meter, a ferrous sulfate scale, an oxidation reactor level meter and a thermometer, and is used to monitor the oxidation reaction value in real time;

[0020] The control module is composed of a hydrogen peroxide delivery pump, a hydrogen peroxide feed regulating valve, a steam feed regulating valve, a ferrous sulfate feed switch valve and an oxidation reactor agitator, and is used to control the oxidation reaction process;

[0021] The logic processing module is composed of a controller and an IO slave station, and is used to analyze the data collected by the monitoring unit and perform logic processing, output control results, and ultimately achieve automatic control of the entire production process.

[0022] A control method for a ferrous sulfate oxidation production automation system, the control method adopts the above-mentioned ferrous sulfate oxidation production automation system, the control method comprises:

[0023] Start the system and preset the expected feed amounts of ferrous sulfate and hydrogen peroxide, the expected temperature in the reactor and the liquid level for automatic start and stop of the agitator;

[0024] The ferrous sulfate quantitative feeding device starts working. The high-precision scale of the ferrous sulfate high-level tank obtains the real-time feeding amount of ferrous sulfate through the weight difference. After comparing it with the expected feeding amount, the linear control formula is applied to convert the valve position adjustment value of the regulating valve to ensure the accurate feeding of ferrous sulfate.

[0025] During the process of feeding ferrous sulfate, the stirrer automatic start liquid level will gradually be reached, the stirrer will automatically start, and automatically adjust the stirring speed according to the preset program to achieve uniform mixing of the reaction materials;

[0026] After the quantitative feeding of ferrous sulfate is completed, the quantitative feeding of hydrogen peroxide begins; the flow rate of the hydrogen peroxide feeding pipeline is counted by the flow meter, and the hydrogen peroxide feeding amount is obtained after integration. After comparison with the expected feeding amount, the PID control formula is applied to convert the real-time valve opening of the regulating valve to achieve accurate control of the hydrogen peroxide feeding amount;

[0027] At the same time, the thermometer will monitor the temperature inside the reactor in real time. Based on the comparison between the current temperature and the expected temperature, the opening of the steam control valve is adjusted through the PID algorithm to ensure the stability and precise control of the temperature inside the reactor.

[0028] Furthermore, the ferrous sulfate quantitative feeding subsystem in the control method realizes precise control of the ferrous sulfate dosage through real-time monitoring and feedback regulation, specifically, the difference between the expected feeding amount and the actual feeding amount is calculated by a linearization formula to linearly control the valve opening;

[0029]

[0030] Among them: Kp, Ki, Kd are proportional, integral, and differential coefficients respectively;

[0031] Represents the cumulative effect of feed deviation over time

[0032] Indicates the rate of change of feeding deviation

[0033] The above formula calculates the adjustment amount of ferrous sulfate dosage by comprehensively considering the size of the deviation, thereby achieving accurate control of the ferrous sulfate dosage.

[0034] Furthermore, the hydrogen peroxide quantitative feeding subsystem uses a flow meter and a regulating valve to calculate the volume of hydrogen peroxide pumped from the hydrogen peroxide tank by integration, and performs PID control to accurately control the feeding amount of hydrogen peroxide, specifically,

[0035] Considering the decomposition of hydrogen peroxide during the filling process, a mathematical method is used to describe the relationship between the decomposition rate and temperature, flow rate and time. It is assumed that the decomposition rate of hydrogen peroxide is proportional to a certain power form of temperature, flow rate and a certain power of time, which can be expressed as:

[0036]

[0037] Where k is a nonlinear function of temperature, expressed as k = e γT , k = e γT Substituting into the above formula, we get:

[0038]

[0039] Among them, F t is the instantaneous flow rate of hydrogen peroxide; T t is the real-time temperature; t is the filling time; α, β, and γ are model parameters, which are determined through experiments.

[0040] Furthermore, in the hydrogen peroxide quantitative feeding subsystem, the hydrogen peroxide cumulative amount measurement and the hydrogen peroxide quantitative feeding subsystem flow control method based on the hydrogen peroxide cumulative amount measurement;

[0041] The measurement of the accumulated amount of hydrogen peroxide is specifically as follows:

[0042] Where: V t represents the volume of hydrogen peroxide passing from t0 to t, and F(t) is the instantaneous flow function;

[0043] The actual calculation formula used is using the trapezoidal rule:

[0044]

[0045] Where Δt is the sampling period; F1, F2, F3...F n-1 ,F n It is the instantaneous flow value measured at each sampling point.

[0046] Furthermore, the flow control method of the hydrogen peroxide quantitative feeding subsystem based on the measurement of the accumulated amount of hydrogen peroxide is specifically to use the PID control method for control, and the formula is as follows:

[0047]

[0048] Where: u(t) is the output signal of the PID controller, which is used to adjust the actuator; K p is the proportional coefficient, which affects the response speed and regulation accuracy of the system; K V is the error correction coefficient, which needs to be reasonably selected as a fixed value or variable according to the valve type; ΔV is the difference between the target feed amount and the actual feed amount; V sp is the expected feed amount, i.e. the required volume of hydrogen peroxide; F t is the instantaneous flow rate, which is the hydrogen peroxide flow rate at the current time t; is the cumulative compensation flow; V t is the amount of hydrogen peroxide fed at the current time t; K′ i is the integral coefficient, which approaches 0 when ΔV approaches 0; β is an adjustment parameter used to control the shape and rate of the logarithmic decreasing curve; ∈ is a protection parameter to avoid the denominator being 0; K d It is the differential coefficient, which is used to predict the changing trend of the error, make adjustments in advance, and reduce overshoot and oscillation; comprehensively consider the size of the feed amount deviation, calculate the adjustment amount of the hydrogen peroxide dosage, and thus achieve precise control of the ferrous sulfate dosage.

[0049] Furthermore, when the liquid level in the reactor reaches a preset value, the automatic stirring device starts, and automatically starts / stops the agitator according to the liquid level to achieve uniform mixing of the materials; while preventing idling from damaging the agitator, it promotes the full dissolution and oxidation of ferrous sulfate.

[0050] The temperature control subsystem uses the PID control method to control the temperature, and the formula is as follows:

[0051]

[0052] Where u(t) is the output signal of the PID controller, which is used to adjust the actuator; K p is the proportional coefficient, which affects the response speed and adjustment accuracy of the system; e(t) is the error signal, that is, the difference between the set temperature value and the actual temperature value; K i is the integral coefficient, which is used to eliminate the steady-state error of the system; is the integral of the error signal, indicating the accumulation of errors over a period of time; K d It is the differential coefficient, which is used to predict the changing trend of the error, make adjustments in advance, and reduce overshoot and oscillation; is the rate of change of the error signal, that is, the differential of the error.

[0053] A computer device comprises a memory, a processor and a computer program stored in the memory and executable on the processor, wherein when the processor executes the computer program, the above method is implemented.

[0054] A computer-readable storage medium stores a computer program, and when the computer program is executed by a processor, the method described above is implemented.

[0055] The beneficial effects of the present invention are:

[0056] The system of the present invention integrates the functions of ferrous sulfate quantitative feeding, hydrogen peroxide quantitative feeding, automatic stirring, temperature control and product processing, thereby realizing the comprehensive automation and precise control of the ferrous sulfate oxidation production process.

[0057] The present invention realizes the comprehensive automation and precise control of the ferrous sulfate oxidation production process. The system has the advantages of simple operation, precise control, high production efficiency, etc., and can be widely used in the field of chemical production, providing strong technical support for the automated production of the chemical industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] Figure 1 It is a flow chart of the control system of the present invention.

[0059] Figure 2 It is a flow chart of the method of the present invention.

[0060] Figure 3 It is a process diagram of the iron salt high-level tank of the present invention.

[0061] Figure 4 It is a process diagram of a reactor of the present invention. DETAILED DESCRIPTION

[0062] In the following description, specific details such as specific system structures, technologies, etc. are provided for the purpose of illustration rather than limitation, so as to provide a thorough understanding of the embodiments of the present application. However, it should be clear to those skilled in the art that the present application may also be implemented in other embodiments without these specific details. In other cases, detailed descriptions of well-known systems, devices, circuits, and methods are omitted to prevent unnecessary details from obstructing the description of the present application.

[0063] It should be understood that when used in this specification and the appended claims, the term "comprising" indicates the presence of described features, integers, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof.

[0064] It should also be understood that the terms used in this application specification are only for the purpose of describing specific embodiments and are not intended to limit the application. As used in this application specification and the appended claims, the singular forms "a", "an" and "the" are intended to include plural forms unless the context clearly indicates otherwise.

[0065] The following is attached to this application specification Figure 1-4 , the technical solutions in the embodiments of the present application are clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present application.

[0066] In the following description, many specific details are set forth to facilitate a full understanding of the present application, but the present application may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present application. Therefore, the present application is not limited to the specific embodiments disclosed below.

[0067] Implementation Method 1

[0068] like Figure 1As shown, this embodiment provides an automated system for ferrous sulfate oxidation production, and the required feeding amount, stirring automatic start liquid level, temperature and other parameters are set through the central control DCS parameter setting interface. After the setting is completed, the system monitors the values ​​in real time according to the relevant sensors and controls the feeding, temperature and stirring to achieve stable and accurate automated production; the system includes a ferrous sulfate quantitative feeding subsystem, a hydrogen peroxide quantitative feeding subsystem, an automatic stirring subsystem and a temperature control subsystem;

[0069] The ferrous sulfate quantitative feeding subsystem includes a fixed mass feeding module and a parameter setting module;

[0070] The fixed mass feeding module is used to accurately control the feeding amount of ferrous sulfate through a high-precision scale;

[0071] The parameter setting module: provides an interface for parameter input;

[0072] The hydrogen peroxide quantitative feeding subsystem includes a flow accumulation module and a fixed volume feeding module;

[0073] The flow accumulation module obtains the volume parameter of hydrogen peroxide by integrating the instantaneous flow;

[0074] The fixed volume feeding module: accurately controls the feeding amount of hydrogen peroxide through a flow meter;

[0075] The automatic stirring subsystem includes an automatic stirring module;

[0076] The automatic stirring module: realizes the automatic start and stop of the stirrer, which can not only ensure the dissolution of the slurry to the maximum extent, but also protect the stirrer from idling;

[0077] The temperature control subsystem includes a temperature control module;

[0078] The temperature control module realizes accurate control of the temperature of the reactor.

[0079] Furthermore, the system also includes a monitoring unit, a control module and a logic processing module;

[0080] The monitoring unit is composed of a hydrogen peroxide flow meter, a ferrous sulfate scale, an oxidation reactor level meter and a thermometer, and is used to monitor the oxidation reaction value in real time;

[0081] The control module is composed of a hydrogen peroxide delivery pump, a hydrogen peroxide feed regulating valve, a steam feed regulating valve, a ferrous sulfate feed switch valve and an oxidation reactor agitator, and is used to control the oxidation reaction process;

[0082] The logic processing module is composed of a controller and an IO slave station, and is used to analyze the data collected by the monitoring unit and perform logic processing, output control results, and ultimately achieve automatic control of the entire production process.

[0083] The systems exchange data and transmit instructions through the DCS control system to achieve overall collaborative work of the system.

[0084] Implementation Method 2

[0085] This embodiment provides a control method for a ferrous sulfate oxidation production automation system. The control method adopts the ferrous sulfate oxidation production automation system as described in Embodiment 1. The control method includes:

[0086] Start the ferrous sulfate oxidation production automation system, and preset the expected feed amounts of ferrous sulfate and hydrogen peroxide, the expected temperature in the reactor, and the liquid level for automatic start and stop of the agitator;

[0087] The ferrous sulfate quantitative feeding device starts working. The high-precision scale of the ferrous sulfate high-level tank obtains the real-time feeding amount of ferrous sulfate through the weight difference. After comparing it with the expected feeding amount, the linear control formula is applied to convert the valve position adjustment value of the regulating valve to ensure the accurate feeding of ferrous sulfate.

[0088] like Figure 3 As shown, the ferrous sulfate quantitative feeding device includes an iron salt high-level tank 100, a leg weighing instrument 101, a radar level gauge I 103, a ferrous sulfate solution inlet channel 104, an electric regulating valve I 105 and a ferrous sulfate solution outflow channel 106. The top of the iron salt high-level tank 100 is respectively provided with a ferrous sulfate solution inlet channel 104 and a radar level gauge I 103, the radar level gauge I 103 is arranged on one side of the ferrous sulfate solution inlet channel 104, the outside of the iron salt high-level tank 100 is provided with a leg weighing instrument 101, the bottom of the iron salt high-level tank 100 is provided with a ferrous sulfate solution outflow channel 106, and the ferrous sulfate solution inlet channel 104 is provided with an electric regulating valve I 105.

[0089] During the process of feeding ferrous sulfate, the stirrer automatic start liquid level will gradually be reached, the stirrer will automatically start, and automatically adjust the stirring speed according to the preset program to achieve uniform mixing of the reaction materials;

[0090] After the quantitative feeding of ferrous sulfate is completed, the quantitative feeding of hydrogen peroxide begins; the flow rate of the hydrogen peroxide feeding pipeline is counted by the flow meter, and the hydrogen peroxide feeding amount is obtained after integration. After comparison with the expected feeding amount, the PID control formula is applied to convert the real-time valve opening of the regulating valve to achieve accurate control of the hydrogen peroxide feeding amount;

[0091] At the same time, the thermometer will monitor the temperature inside the reactor in real time. Based on the comparison between the current temperature and the expected temperature, the opening of the steam control valve is adjusted through the PID algorithm to ensure the stability and precise control of the temperature inside the reactor.

[0092] Further, such as Figure 2 As shown, the ferrous sulfate quantitative feeding subsystem in the control method uses a high-precision electronic scale and a regulating valve to perform linear control on the ferrous sulfate flowing from the high-level tank, so as to accurately control the feeding amount of the ferrous sulfate raw material. The device compares the feeding quality through a preset program and then controls the feeding speed to ensure the accurate and stable input of the ferrous sulfate raw material. Through real-time monitoring and feedback adjustment, precise control of the amount of ferrous sulfate added is achieved. Specifically, this control method not only improves the stability and reliability of the process, but also helps to optimize the treatment effect and reduce operating costs. In practical applications, parameter debugging and optimization are required according to specific process requirements and control system characteristics. The difference between the expected feed amount and the actual feed amount is calculated through a linearization formula to linearly control the valve opening;

[0093]

[0094] Among them: Kp, Ki, Kd are proportional, integral, and differential coefficients respectively, and these coefficients need to be debugged and determined according to the actual process;

[0095] Represents the cumulative effect of feed deviation over time

[0096] Indicates the rate of change of feeding deviation

[0097] The above formula calculates the adjustment amount of ferrous sulfate dosage by comprehensively considering the size of the deviation, thereby achieving accurate control of the ferrous sulfate dosage.

[0098] Furthermore, a flow meter and a regulating valve are used to calculate the volume of hydrogen peroxide pumped from the hydrogen peroxide tank by using an integral, and PID control is performed to accurately control the feeding amount of hydrogen peroxide. The device compares the feeding volume through a preset program, and then controls the feeding speed to ensure accurate and stable input of hydrogen peroxide. The hydrogen peroxide quantitative feeding subsystem uses a flow meter and a regulating valve to calculate the volume of hydrogen peroxide pumped from the hydrogen peroxide tank by using an integral, and PID control is performed to accurately control the feeding amount of hydrogen peroxide, specifically,

[0099] Considering the decomposition of hydrogen peroxide during the filling process, a mathematical method is used to describe the relationship between the decomposition rate and temperature, flow rate and time, which takes into account the nonlinear effect of temperature on the decomposition rate, as well as the power effect of flow rate and time;

[0100] Assuming that the decomposition rate of hydrogen peroxide is proportional to a certain power form of temperature, flow rate, and a certain power of time, it can be expressed as:

[0101]

[0102] Where k is a nonlinear function of temperature and can be expressed as k = eγT , here an exponential function is used to describe the effect of temperature on the decomposition rate;

[0103] k = e γT Substituting into the above formula, we get:

[0104]

[0105] Among them, F t is the instantaneous flow rate of hydrogen peroxide (unit: liter / minute); T t is the real-time temperature (unit: degrees Celsius); t is the filling time (unit: minutes); α, β, and γ are model parameters, which are determined through experiments.

[0106] Furthermore, the hydrogen peroxide quantitative feeding subsystem calculates the hydrogen peroxide feed amount by counting the flow rate of the hydrogen peroxide feed pipeline, and performs PID control on the hydrogen peroxide feeding regulating valve according to the difference between the feed amount and the expected feed amount, so as to achieve accurate feeding of hydrogen peroxide. The system monitors the flow rate of hydrogen peroxide in real time through the flow sensor, calculates its volume by integration, and compares it with the preset value. Considering the thermal decomposition properties of hydrogen peroxide, the PID controller calculates the adjustment amount of the regulating valve through the PID algorithm according to the comparison result, and automatically adjusts the valve opening, so as to accurately control the feeding amount of hydrogen peroxide and ensure its accuracy and stability.

[0107] In the hydrogen peroxide quantitative feeding subsystem, the hydrogen peroxide cumulative amount measurement and the hydrogen peroxide quantitative feeding subsystem flow control method based on the hydrogen peroxide cumulative amount measurement;

[0108] The measurement of the accumulated amount of hydrogen peroxide is specifically as follows:

[0109] Where: V t represents the volume of hydrogen peroxide passing from t0 to t, and F(t) is the instantaneous flow function;

[0110] However, in actual situations, the expression of the F(t) formula is not important. Thanks to the high scanning frequency of the controller, discrete data points of the instantaneous flow rate can be used in actual use to perform numerical integration methods to approximate the volume. The actual calculation formula used in the present invention is to use the trapezoidal rule:

[0111]

[0112] Where Δt is the sampling period; F1, F2, F3...F n-1 ,F n It is the instantaneous flow value measured at each sampling point.

[0113] In this way, integration can be used to calculate the real-time cumulative flow rate of hydrogen peroxide.

[0114] Furthermore, the flow control method of the hydrogen peroxide quantitative feeding subsystem based on the measurement of the accumulated amount of hydrogen peroxide is specifically as follows: a simplified example formula is used to illustrate the PID control method for control, and the formula is as follows:

[0115]

[0116] Where: u(t) is the output signal of the PID controller, which is used to adjust the actuator; K p is the proportional coefficient, which affects the response speed and regulation accuracy of the system; K V is the error correction coefficient, which needs to be reasonably selected as a fixed value or variable according to the valve type; ΔV is the difference between the target feed amount and the actual feed amount; V sp is the expected feed amount, i.e. the required volume of hydrogen peroxide; F t is the instantaneous flow rate, which is the hydrogen peroxide flow rate at the current time t; is the cumulative compensation flow; V t is the amount of hydrogen peroxide fed at the current time t; K′ i is the integral coefficient, which approaches 0 when ΔV approaches 0; β is an adjustment parameter used to control the shape and rate of the logarithmic decreasing curve; ∈ is a protection parameter to avoid the denominator being 0; K d It is the differential coefficient, which is used to predict the changing trend of the error, make adjustments in advance, and reduce overshoot and oscillation. Through this method, the size of the feed amount deviation is comprehensively considered to calculate the adjustment amount of hydrogen peroxide dosage, thereby achieving precise control of the ferrous sulfate dosage.

[0117] Furthermore, when the liquid level in the reactor reaches a preset value, the automatic stirring device is started, wherein the automatic stirring device is a prior art, which automatically starts / stops the agitator according to the liquid level to achieve uniform mixing of the materials, prevents idling and damages the agitator, and promotes the full dissolution and oxidation of ferrous sulfate.

[0118] like Figure 4 As shown, the reactor 200 is provided with blades 201 of an automatic stirring device, which are driven by a stirring motor 202. A temperature transmitter 203 is inserted into the lower part of the reactor 200. A liquid channel 204 of a ferrous sulfate solution and a liquid channel 205 of a hydrogen peroxide solution as well as a radar level indicator II 206 are provided above the reactor 200. A steam inlet 207 is provided at the upper part of the reactor 200, and a steam condensate outlet 208 is provided at the bottom of the reactor 200.

[0119] An electric regulating valve II 209 is provided on the liquid channel 204 of the ferrous sulfate solution, an electromagnetic flowmeter 211 and an electric regulating valve III 210 are provided on the liquid channel 205 of the hydrogen peroxide solution; and an electric regulating valve IV 212 is provided on the steam inlet 207 .

[0120] The temperature control subsystem uses a thermometer and a regulating valve to control the temperature. The system monitors the temperature in the reactor in real time through a temperature sensor, and applies PID control after comparing it with the preset temperature value. The PID controller calculates the adjustment amount through the PID algorithm based on the comparison result, and automatically adjusts the opening of the steam regulating valve, thereby controlling the steam supply to ensure the accuracy and stability of the reaction temperature of the reactor. The control formula is consistent with the hydrogen peroxide PID formula.

[0121] The following uses a simplified example formula to illustrate the PID control method for temperature control. The formula is as follows:

[0122]

[0123] Where u(t) is the output signal of the PID controller, which is used to adjust the actuator; K p is the proportional coefficient, which affects the response speed and adjustment accuracy of the system; e(t) is the error signal, that is, the difference between the set temperature value and the actual temperature value; K i is the integral coefficient, which is used to eliminate the steady-state error of the system; is the integral of the error signal, indicating the accumulation of errors over a period of time; K d It is the differential coefficient, which is used to predict the changing trend of the error, make adjustments in advance, and reduce overshoot and oscillation; is the rate of change of the error signal, that is, the differential of the error.

[0124] Through this method, the size of the feed amount deviation is comprehensively considered to achieve precise control of the reactor temperature.

[0125] Implementation Method 3

[0126] An embodiment of the present invention provides an electronic device, which includes a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the memory is used to store software programs and modules, and the processor executes various functional applications and data processing by running the software programs and modules stored in the memory. The memory and the processor are connected via a bus. Specifically, the processor implements any step in the first embodiment above by running the computer program stored in the memory.

[0127] It should be understood that in the embodiments of the present invention, the processor may be a central processing unit (CPU), and the processor may also be other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field-programmable gate arrays (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor may be a microprocessor or the processor may also be any conventional processor, etc.

[0128] The memory may include a read-only memory, a flash memory, and a random access memory, and provides instructions and data to the processor. A part or all of the memory may also include a nonvolatile random access memory.

[0129] As can be seen from the above, the electronic device provided in the embodiment of the present invention can realize the control mode of the ferrous sulfate oxidation production automation system as described in the first embodiment by running a computer program, thereby realizing the comprehensive automation and precise control of the ferrous sulfate oxidation production process. The system has the advantages of simple operation, precise control, high production efficiency, etc., and can be widely used in the field of chemical production, providing strong technical support for the automated production of the chemical industry.

[0130] It should be understood that if the above-mentioned integrated module / unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on such an understanding, the present invention implements all or part of the processes in the above-mentioned implementation method, and can also be completed by instructing the relevant hardware through a computer program. The above-mentioned computer program can be stored in a computer-readable storage medium, and the computer program can implement the steps of the above-mentioned various method implementations when executed by the processor. Among them, the above-mentioned computer program includes computer program code, and the above-mentioned computer program code can be in source code form, object code form, executable file or some intermediate form. The above-mentioned computer-readable medium may include: any entity or device capable of carrying the above-mentioned computer program code, recording medium, U disk, mobile hard disk, disk, optical disk, computer memory, read-only memory (ROM), random access memory (RAM), electric carrier signal, telecommunication signal and software distribution medium. It should be noted that the content contained in the above-mentioned computer-readable storage medium can be appropriately increased or decreased according to the requirements of legislation and patent practice in the jurisdiction.

[0131] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest range consistent with the principles and novel features disclosed herein.

[0132] Those skilled in the art can clearly understand that for the convenience and simplicity of description, only the division of the above-mentioned functional units and modules is used as an example for illustration. In actual applications, the above-mentioned function allocation can be completed by different functional units and modules as needed, that is, the internal structure of the above-mentioned device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the implementation method can be integrated into a processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The above-mentioned integrated unit can be implemented in the form of hardware or in the form of software functional units. In addition, the specific names of the functional units and modules are only for the convenience of distinguishing each other, and are not used to limit the scope of protection of the present invention. The specific working process of the units and modules in the above-mentioned system can refer to the corresponding process in the aforementioned method implementation method, which will not be repeated here.

[0133] It should be noted that the methods and detailed examples provided in the above embodiments can be combined with the devices and equipment provided in the embodiments, and references can be made to each other, and no further details will be given.

[0134] Those skilled in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of the present invention.

[0135] In the embodiments provided by the present invention, it should be understood that the disclosed device / terminal equipment and method can be implemented in other ways. For example, the device / equipment implementation described above is only illustrative, for example, the division of the above modules or units is only a logical function division, and in actual implementation, there may be other division methods, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed.

[0136] The above-mentioned embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them. Although the present invention has been described in detail with reference to the above-mentioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above-mentioned embodiments, or replace some of the technical features therein by equivalents. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention, and should all be included in the protection scope of the present invention.

[0137] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. An automated system for ferrous sulfate oxidation production, characterized in that: The system includes a ferrous sulfate quantitative feeding subsystem, a hydrogen peroxide quantitative feeding subsystem, an automatic stirring subsystem and a temperature control subsystem; The ferrous sulfate quantitative feeding subsystem includes a fixed mass feeding module and a parameter setting module; The fixed mass feeding module is used to accurately control the feeding amount of ferrous sulfate through a high-precision scale; The parameter setting module: provides an interface for parameter input; The hydrogen peroxide quantitative feeding subsystem includes a flow accumulation module and a fixed volume feeding module; The flow accumulation module obtains the volume parameter of hydrogen peroxide by integrating the instantaneous flow; The fixed volume feeding module: accurately controls the feeding amount of hydrogen peroxide through a flow meter; The automatic stirring subsystem includes an automatic stirring module; The automatic stirring module: realizes the automatic start and stop of the stirrer, which can not only ensure the dissolution of the slurry to the maximum extent, but also protect the stirrer from idling; The temperature control subsystem includes a temperature control module; The temperature control module realizes accurate control of the temperature of the reactor.

2. According to claim 1, a ferrous sulfate oxidation production automation system is characterized in that: The system also includes a monitoring unit, a control module and a logic processing module; The monitoring unit is composed of a hydrogen peroxide flow meter, a ferrous sulfate scale, an oxidation reactor level meter and a thermometer, and is used to monitor the oxidation reaction value in real time; The control module is composed of a hydrogen peroxide delivery pump, a hydrogen peroxide feed regulating valve, a steam feed regulating valve, a ferrous sulfate feed switch valve and an oxidation reactor agitator, and is used to control the oxidation reaction process; The logic processing module is composed of a controller and an IO slave station, and is used to analyze the data collected by the monitoring unit and perform logic processing, output control results, and ultimately achieve automatic control of the entire production process.

3. A control method for a ferrous sulfate oxidation production automation system, characterized in that: The control method adopts the ferrous sulfate oxidation production automation system as described in any one of claims 1-2, and the control method includes: Start the system and preset the expected feed amounts of ferrous sulfate and hydrogen peroxide, the expected temperature in the reactor and the liquid level for automatic start and stop of the agitator; The ferrous sulfate quantitative feeding device starts working. The high-precision scale of the ferrous sulfate high-level tank obtains the real-time feeding amount of ferrous sulfate through the weight difference. After comparing it with the expected feeding amount, the linear control formula is applied to convert the valve position adjustment value of the regulating valve to ensure the accurate feeding of ferrous sulfate. During the process of feeding ferrous sulfate, the stirrer automatic start liquid level will gradually be reached, the stirrer will automatically start, and automatically adjust the stirring speed according to the preset program to achieve uniform mixing of the reaction materials; After the quantitative feeding of ferrous sulfate is completed, the quantitative feeding of hydrogen peroxide begins; the flow rate of the hydrogen peroxide feeding pipeline is counted by the flow meter, and the hydrogen peroxide feeding amount is obtained after integration. After comparison with the expected feeding amount, the PID control formula is applied to convert the real-time valve opening of the regulating valve to achieve accurate control of the hydrogen peroxide feeding amount; At the same time, the thermometer will monitor the temperature inside the reactor in real time. Based on the comparison between the current temperature and the expected temperature, the opening of the steam control valve is adjusted through the PID algorithm to ensure the stability and precise control of the temperature inside the reactor.

4. The control method of a ferrous sulfate oxidation production automation system according to claim 3, characterized in that: The ferrous sulfate quantitative feeding subsystem in the control method realizes accurate control of the ferrous sulfate dosage through real-time monitoring and feedback regulation. Specifically, the difference between the expected feeding amount and the actual feeding amount is calculated by a linearization formula to linearly control the valve opening; Among them: Kp, Ki, Kd are proportional, integral, and differential coefficients respectively; The above formula calculates the adjustment amount of ferrous sulfate dosage by comprehensively considering the size of the deviation, thereby achieving accurate control of the ferrous sulfate dosage.

5. The control method of a ferrous sulfate oxidation production automation system according to claim 3, characterized in that: The hydrogen peroxide quantitative feeding subsystem uses a flow meter and a regulating valve to calculate the volume of hydrogen peroxide pumped from the hydrogen peroxide tank by integration, and performs PID control to accurately control the feeding amount of hydrogen peroxide, specifically, Considering the decomposition of hydrogen peroxide during the filling process, a mathematical method is used to describe the relationship between the decomposition rate and temperature, flow rate and time. It is assumed that the decomposition rate of hydrogen peroxide is proportional to a certain power form of temperature, flow rate and a certain power of time, which can be expressed as: Where k is a nonlinear function of temperature, Substituting into the above formula, we get: Among them, F t is the instantaneous flow rate of hydrogen peroxide; T t is the real-time temperature; t is the filling time; α, β, and γ are model parameters, which are determined through experiments.

6. According to claim 5, a ferrous sulfate oxidation production automation system is characterized in that: In the hydrogen peroxide quantitative feeding subsystem, the hydrogen peroxide cumulative amount measurement and the hydrogen peroxide quantitative feeding subsystem flow control method based on the hydrogen peroxide cumulative amount measurement; The measurement of the accumulated amount of hydrogen peroxide is specifically as follows: Where: V t represents the volume of hydrogen peroxide passing from t0 to t, and F(t) is the instantaneous flow function; The actual calculation formula used is using the trapezoidal rule: Where Δt is the sampling period; F1, F2, F3...F n-1 ,F n It is the instantaneous flow value measured at each sampling point.

7. The control method of a ferrous sulfate oxidation production automation system according to claim 6, characterized in that: The flow control method of the hydrogen peroxide quantitative feeding subsystem based on the measurement of the accumulated amount of hydrogen peroxide is specifically to use the PID control method for control, and the formula is as follows: Where: u(t) is the output signal of the PID controller, which is used to adjust the actuator; K p is the proportional coefficient, which affects the response speed and regulation accuracy of the system; K V is the error correction coefficient, which needs to be reasonably selected as a fixed value or variable according to the valve type; ΔV is the difference between the target feed amount and the actual feed amount; V sp is the expected feed amount, i.e. the required volume of hydrogen peroxide; F t is the instantaneous flow rate, which is the hydrogen peroxide flow rate at the current time t; is the cumulative compensation flow; V t is the amount of hydrogen peroxide fed at the current time t; K′ i is the integral coefficient, which approaches 0 when ΔV approaches 0; β is an adjustment parameter used to control the shape and rate of the logarithmic decreasing curve; ∈ is a protection parameter to avoid the denominator being 0; K d It is the differential coefficient, which is used to predict the changing trend of the error, make adjustments in advance, and reduce overshoot and oscillation; comprehensively consider the size of the feed amount deviation, calculate the adjustment amount of the hydrogen peroxide dosage, and thus achieve precise control of the ferrous sulfate dosage.

8. The control method of a ferrous sulfate oxidation production automation system according to claim 7, characterized in that: When the liquid level in the reactor reaches the preset value, the automatic stirring device starts, and automatically starts / stops the agitator according to the liquid level to achieve uniform mixing of the materials; while preventing idling damage to the agitator, it promotes the full dissolution and oxidation of ferrous sulfate; The temperature control subsystem uses the PID control method to control the temperature, and the formula is as follows: Where u(t) is the output signal of the PID controller, which is used to adjust the actuator; K p is the proportional coefficient, which affects the response speed and adjustment accuracy of the system; e(t) is the error signal, that is, the difference between the set temperature value and the actual temperature value; K i is the integral coefficient, which is used to eliminate the steady-state error of the system; is the integral of the error signal, indicating the accumulation of errors over a period of time; K d It is the differential coefficient, which is used to predict the changing trend of the error, make adjustments in advance, and reduce overshoot and oscillation; is the rate of change of the error signal, that is, the differential of the error.

9. A computer device, characterized in that: The method comprises a memory, a processor and a computer program stored in the memory and executable on the processor, wherein when the processor executes the computer program, the method according to any one of claims 3 to 8 is implemented.

10. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a computer program, and when the computer program is executed by a processor, the method according to any one of claims 3 to 8 is implemented.

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