Chemical reaction kettle control system

Abstract

The invention discloses a chemical reaction kettle control system which comprises a sensor, a controller, an actuator, a human-computer interface, a safety control unit and an automation and monitoring module. The system can monitor temperature, pressure and liquid level parameters in the reaction kettle in real time, process signals through a preset control strategy, and output control signals to the actuator so as to adjust the temperature and pressure parameters in the reaction kettle. The system further comprises a safety control unit for monitoring system safety parameters and automatically taking measures to protect equipment and personnel safety under abnormal conditions. And the automation and monitoring module integrates a monitoring and data acquisition system to realize remote monitoring and data recording. By integrating various advanced control algorithms, the system improves the control precision and the self-adaptive capability of the system, and is suitable for various chemical reaction processes.

Description

Technical Field

[0001] The invention relates to chemical equipment, in particular to a chemical reactor control system. Background Art

[0002] With the rapid development of the chemical industry, chemical reactors are the core equipment in chemical production, and the stability and accuracy of their control systems have a vital impact on product quality and production efficiency. Traditional reactor control systems mostly use simple PID control. Although the structure is simple and easy to implement, its control effect is often unsatisfactory when facing complex and changeable working conditions, and it is difficult to meet the needs of high-precision control. In addition, traditional systems lack intelligence and adaptive capabilities, and cannot effectively respond to changes in system parameters and external disturbances, resulting in decreased control accuracy and reduced production efficiency. Therefore, the development of a chemical reactor control system that integrates multiple advanced control algorithms and has adaptive and predictive capabilities is of great significance to improving the level of automation and economic benefits of chemical production. Summary of the invention

[0003] The purpose of the present invention is to provide a chemical reactor control system.

[0004] To achieve the above object, the present invention is implemented according to the following technical solutions:

[0005] The present invention includes sensors for detecting temperature, pressure and liquid level parameters, a controller, an actuator, a human-machine interface, a safety control unit and an automation and monitoring module. The controller receives sensor signals, processes the signals according to a preset control strategy, and outputs control signals to the actuator; the actuator adjusts the temperature and pressure parameters in the reactor according to the instructions of the controller; the human-machine interface displays process parameters and operation controls, allowing operators to monitor and adjust the process; the safety control unit monitors system safety parameters and automatically takes measures to protect equipment and personnel safety under abnormal circumstances; the automation and monitoring module integrates a monitoring and data acquisition system to achieve remote monitoring and data recording.

[0006] The control method of the chemical reactor control system comprises the following steps:

[0007] S1: Start the control system, including sensors, controllers, actuators and human-machine interface; set initial control parameters on the human-machine interface, including temperature set point, pressure set point, PID control parameters, including proportion, integration and differentiation;

[0008] S2: The sensor monitors the temperature, pressure and liquid level parameters in the reactor in real time; the sensor transmits the monitored data to the controller;

[0009] S3: The controller receives the signal from the sensor and converts the analog signal into a digital signal for processing by the controller;

[0010] S4: The controller calculates the deviation between the actual parameter and the set point; based on the deviation value, the controller applies the PID control algorithm to calculate the control signal;

[0011] S5: The controller outputs a control signal to the actuator; the actuator adjusts the temperature and pressure parameters in the reactor according to the control signal;

[0012] S6: The human-machine interface displays process parameters and operation controls in real time, allowing operators to monitor and adjust the process; after the actuator is adjusted, the sensor monitors the temperature and pressure parameters in the reactor again and feeds the new data back to the controller;

[0013] S7: The safety control unit monitors system safety parameters, such as over-temperature and over-pressure. When an abnormality is detected, the safety control unit automatically takes measures, including shutting off the feed and discharging the pressure, to protect the safety of equipment and personnel;

[0014] S8: The automation and monitoring module integrates the monitoring and data acquisition system to record the operating data of the reactor, realize remote monitoring and data recording, and facilitate analysis and optimization of control strategies;

[0015] S9: Regularly evaluate the performance of the control system, including stability, response speed and control accuracy. According to the performance evaluation results, adjust the PID control parameters and other control strategies to optimize the control effect.

[0016] S10: Maintenance and Recording Regularly maintain the control system, including sensor calibration, actuator inspection and software update; save all data and maintenance records during the control process for easy traceability and analysis.

[0017] Furthermore, the controller integrates PID control algorithm, fuzzy control algorithm, predictive control algorithm, adaptive control algorithm and interpolation fuzzy control algorithm.

[0018] The PID control algorithm achieves precise control of the system by adjusting the three parameters of proportion, integration and differentiation; Proportional control: calculates the product of the current deviation value and the proportional gain as part of the control signal; Integral control: calculates the accumulation of the deviation value over time and uses it as part of the control signal to eliminate steady-state errors; Differential control: calculates the rate of change of the deviation value and uses it as part of the control signal to predict future trends and reduce overshoot.

[0019] The fuzzy control algorithm includes fuzzification: converting temperature deviation and change rate into fuzzy sets; rule evaluation: evaluating the current control strategy according to preset fuzzy control rules; and defuzzification: converting the fuzzy control strategy into a specific control signal.

[0020] The predictive control algorithm includes model building: building a dynamic model of the reactor; prediction: predicting temperature changes in the future based on the model; and optimization: optimizing control inputs based on the prediction results to achieve the desired temperature trajectory.

[0021] The adaptive control algorithm includes parameter identification: online identification of changes in system parameters; control parameter adjustment: automatic adjustment of PID control parameters or other control parameters based on the identification results; closed-loop control: implementation of the adjusted control strategy to achieve precise control of the reactor temperature.

[0022] The interpolation fuzzy control algorithm includes fuzzy rule establishment: establishing fuzzy rules based on temperature deviation and change rate; interpolation calculation: improving the accuracy and response speed of fuzzy control through interpolation method; control decision: making specific control decision according to interpolation result.

[0023] The beneficial effects of the present invention are:

[0024] The present invention is a chemical reactor control system. Compared with the prior art, the chemical reactor control system of the present invention realizes precise control of the temperature and pressure in the reactor by integrating PID control algorithm, fuzzy control algorithm, predictive control algorithm, adaptive control algorithm and interpolation fuzzy control algorithm. The system can automatically adapt to changes in working conditions, effectively reduce overshoot and improve response speed, and ensure the stability and safety of the chemical reaction process. In addition, through the automation and monitoring module, remote monitoring and data recording are realized, which is convenient for operators to monitor and adjust the process in real time, and improves production efficiency and product quality. The application of this system can significantly improve the control performance of chemical reactors, reduce production costs, and enhance the market competitiveness of enterprises. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a system structure block diagram of the present invention. DETAILED DESCRIPTION

[0026] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments. The illustrative embodiments and descriptions of the present invention are used to explain the present invention but are not intended to limit the present invention.

[0027] like Figure 1As shown: The present invention includes sensors for detecting temperature, pressure, and liquid level parameters, a controller, an actuator, a human-machine interface, a safety control unit, and an automation and monitoring module. The controller receives sensor signals, processes the signals according to a preset control strategy, and outputs control signals to the actuator; the actuator adjusts the temperature and pressure parameters in the reactor according to the instructions of the controller; the human-machine interface displays process parameters and operation controls, allowing operators to monitor and adjust the process; the safety control unit monitors system safety parameters and automatically takes measures to protect equipment and personnel safety under abnormal circumstances; the automation and monitoring module integrates a monitoring and data acquisition system to achieve remote monitoring and data recording.

[0028] The sensors are responsible for real-time monitoring of the temperature, pressure and liquid level parameters in the reactor and transmitting the monitored data to the controller. These sensors include temperature sensors, pressure sensors and liquid level sensors, which are used to measure the temperature, pressure and liquid level in the reactor respectively and convert them into electrical signals for output.

[0029] The controller receives signals from sensors and converts analog signals into digital signals for processing. A variety of control algorithms are integrated into the controller, including PID control algorithm, fuzzy control algorithm, predictive control algorithm, adaptive control algorithm and interpolation fuzzy control algorithm. These algorithms work together to calculate the control signal based on the deviation between the actual parameters and the set point, and output it to the actuator.

[0030] The actuator adjusts the temperature and pressure parameters in the reactor according to the instructions of the controller. Common actuators include valves and pumps, which can adjust the flow of media in the reactor to control temperature and pressure.

[0031] The human machine interface (HMI) displays process parameters and operating controls, allowing operators to monitor and adjust the process. The HMI can be a touch screen or computer interface, providing real-time data display and control parameter adjustment capabilities.

[0032] The safety control unit monitors system safety parameters, such as over-temperature and over-pressure. When abnormal conditions are detected, the safety control unit automatically takes measures, including shutting off feed and discharging pressure, to protect the safety of equipment and personnel.

[0033] The automation and monitoring module integrates the monitoring and data acquisition system to record the operating data of the reactor, realize remote monitoring and data recording, and facilitate analysis and optimization of control strategies.

[0034] The control method of the chemical reactor control system comprises the following steps:

[0035] S1: Start the control system, including sensors, controllers, actuators and human-machine interface; set initial control parameters on the human-machine interface, including temperature set point, pressure set point, PID control parameters, including proportion, integration and differentiation;

[0036] S2: The sensor monitors the temperature, pressure and liquid level parameters in the reactor in real time; the sensor transmits the monitored data to the controller;

[0037] S3: The controller receives the signal from the sensor and converts the analog signal into a digital signal for processing by the controller;

[0038] S4: The controller calculates the deviation between the actual parameter and the set point; based on the deviation value, the controller applies the PID control algorithm to calculate the control signal;

[0039] S5: The controller outputs a control signal to the actuator; the actuator adjusts the temperature and pressure parameters in the reactor according to the control signal;

[0040] S6: The human-machine interface displays process parameters and operation controls in real time, allowing operators to monitor and adjust the process; after the actuator is adjusted, the sensor monitors the temperature and pressure parameters in the reactor again and feeds the new data back to the controller;

[0041] S7: The safety control unit monitors system safety parameters, such as over-temperature and over-pressure. When an abnormality is detected, the safety control unit automatically takes measures, including shutting down the feed and discharging the pressure, to protect the safety of equipment and personnel;

[0042] S8: The automation and monitoring module integrates the monitoring and data acquisition system to record the operating data of the reactor, realize remote monitoring and data recording, and facilitate analysis and optimization of control strategies;

[0043] S9: Regularly evaluate the performance of the control system, including stability, response speed and control accuracy. According to the performance evaluation results, adjust the PID control parameters and other control strategies to optimize the control effect.

[0044] S10: Maintenance and Recording Regularly maintain the control system, including sensor calibration, actuator inspection and software update; save all data and maintenance records during the control process for easy traceability and analysis.

[0045] Furthermore, the controller integrates PID control algorithm, fuzzy control algorithm, predictive control algorithm, adaptive control algorithm and interpolation fuzzy control algorithm.

[0046] PID control algorithm is a classic control method, which can achieve precise control of the system by adjusting the three parameters of proportion (P), integration (I) and differentiation (D). Proportional gain is responsible for correcting the current error, integral time is responsible for eliminating the long-term accumulated error, and differentiation time predicts the future trend and improves the response speed of the system; the PID control algorithm can achieve precise control of the system by adjusting the three parameters of proportion, integration and differentiation; Proportional control: calculate the product of the current deviation value and the proportional gain as part of the control signal; Integral control: calculate the accumulation of the deviation value over time and use it as part of the control signal to eliminate the steady-state error; Differential control: calculate the rate of change of the deviation value and use it as part of the control signal to predict future trends and reduce overshoot.

[0047] Fuzzy control is a control method based on fuzzy logic. It does not require an accurate mathematical model, but handles uncertainty and fuzzy information by simulating the human decision-making process. In the temperature control of the reactor, fuzzy control can automatically adjust the control strategy according to the temperature deviation and change rate, showing good adaptability and robustness; the fuzzy control algorithm includes fuzzification: converting the temperature deviation and change rate into fuzzy sets; rule evaluation: evaluating the current control strategy according to the preset fuzzy control rules; defuzzification: converting the fuzzy control strategy into a specific control signal.

[0048] The predictive control algorithm is a model-based control algorithm that optimizes current control decisions by predicting future behavior. This algorithm is particularly suitable for systems with large lags, such as reactor temperature control; the predictive control algorithm includes model building: building a dynamic model of the reactor; prediction: predicting temperature changes in the future based on the model; optimization: optimizing the control input based on the prediction results to achieve the desired temperature trajectory.

[0049] The adaptive control algorithm can automatically adjust the control parameters according to the temperature control requirements of the reactor to improve the accuracy and stability of temperature control; the adaptive control algorithm includes parameter identification: online identification of changes in system parameters; control parameter adjustment: automatic adjustment of PID control parameters or other control parameters according to the identification results; closed-loop control: implementation of the adjusted control strategy to achieve accurate control of the reactor temperature.

[0050] The interpolation fuzzy control algorithm combines the adaptability of fuzzy control and the accuracy of interpolation calculation. Through offline calculation and online table lookup, it can obtain shorter response time and improve control performance even when there are fewer fuzzy rules. The interpolation fuzzy control algorithm includes fuzzy rule establishment: establishing fuzzy rules based on temperature deviation and change rate; interpolation calculation: improving the accuracy and response speed of fuzzy control through interpolation method; control decision: making specific control decision according to interpolation result.

[0051] The technical solution of the present invention is not limited to the above-mentioned specific embodiments. All technical variations made according to the technical solution of the present invention fall within the protection scope of the present invention.

Claims

1. A chemical reactor control system, characterized in that: It includes sensors for detecting temperature, pressure and liquid level parameters, a controller, an actuator, a human-machine interface, a safety control unit and an automation and monitoring module. The controller receives sensor signals, processes the signals according to a preset control strategy, and outputs control signals to the actuator; the actuator adjusts the temperature and pressure parameters in the reactor according to the instructions of the controller; the human-machine interface displays process parameters and operation controls, allowing operators to monitor and adjust the process; the safety control unit monitors system safety parameters and automatically takes measures to protect equipment and personnel safety under abnormal circumstances; the automation and monitoring module integrates a monitoring and data acquisition system to achieve remote monitoring and data recording.

2. The chemical reactor control system according to claim 1, characterized in that: The control method of the chemical reactor control system comprises the following steps: S1: Start the control system, including sensors, controllers, actuators and human-machine interface; set initial control parameters on the human-machine interface, including temperature set point, pressure set point, PID control parameters, including proportion, integration and differentiation; S2: The sensor monitors the temperature, pressure and liquid level parameters in the reactor in real time; the sensor transmits the monitored data to the controller; S3: The controller receives the signal from the sensor and converts the analog signal into a digital signal for processing by the controller; S4: The controller calculates the deviation between the actual parameter and the set point; based on the deviation value, the controller applies the PID control algorithm to calculate the control signal; S5: The controller outputs a control signal to the actuator; the actuator adjusts the temperature and pressure parameters in the reactor according to the control signal; S6: The human-machine interface displays process parameters and operation controls in real time, allowing operators to monitor and adjust the process; after the actuator is adjusted, the sensor monitors the temperature and pressure parameters in the reactor again and feeds the new data back to the controller; S7: The safety control unit monitors system safety parameters, such as over-temperature and over-pressure. When an abnormality is detected, the safety control unit automatically takes measures, including shutting down the feed and discharging the pressure, to protect the safety of equipment and personnel; S8: The automation and monitoring module integrates the monitoring and data acquisition system to record the operating data of the reactor, realize remote monitoring and data recording, and facilitate analysis and optimization of control strategies; S9: Regularly evaluate the performance of the control system, including stability, response speed and control accuracy. According to the performance evaluation results, adjust the PID control parameters and other control strategies to optimize the control effect. S10: Maintenance and Recording Regularly maintain the control system, including sensor calibration, actuator inspection and software update; save all data and maintenance records during the control process for easy traceability and analysis.

3. The chemical reactor control system according to claim 2, characterized in that: The controller integrates PID control algorithm, fuzzy control algorithm, predictive control algorithm, adaptive control algorithm and interpolation fuzzy control algorithm.

4. The chemical reactor control system according to claim 3, characterized in that: The PID control algorithm achieves precise control of the system by adjusting the three parameters of proportion, integration and differentiation; Proportional control: calculates the product of the current deviation value and the proportional gain as part of the control signal; Integral control: calculates the accumulation of the deviation value over time and uses it as part of the control signal to eliminate steady-state errors; Differential control: calculates the rate of change of the deviation value and uses it as part of the control signal to predict future trends and reduce overshoot.

5. The chemical reactor control system according to claim 3, characterized in that: The fuzzy control algorithm includes fuzzification: converting temperature deviation and change rate into fuzzy sets; rule evaluation: evaluating the current control strategy according to preset fuzzy control rules; and defuzzification: converting the fuzzy control strategy into a specific control signal.

6. The chemical reactor control system according to claim 3, characterized in that: The predictive control algorithm includes model building: building a dynamic model of the reactor; Prediction: Predict temperature changes over a period of time in the future based on the model; Optimization: Based on the prediction results, optimize the control input to achieve the desired temperature trajectory.

7. The chemical reactor control system according to claim 3, characterized in that: The adaptive control algorithm includes parameter identification: online identification of changes in system parameters; control parameter adjustment: automatic adjustment of PID control parameters or other control parameters based on the identification results; closed-loop control: implementation of the adjusted control strategy to achieve precise control of the reactor temperature.

8. The chemical reactor control system according to claim 3, characterized in that: The interpolation fuzzy control algorithm includes fuzzy rule establishment: establishing fuzzy rules based on temperature deviation and change rate; interpolation calculation: improving the accuracy and response speed of fuzzy control through interpolation method; control decision: making specific control decision according to interpolation result.

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