Method for improving coal blending accuracy of blended coal by establishing digital intelligent model

Abstract

The invention provides a method for improving the coal blending accuracy of blended coal by establishing a digital intelligent model. The method comprises the following steps: connecting an original coal blending tray, an electronic automatic metering scale and a calculation controller into a computer; establishing a linkage data model of the coal blending accuracy of the single coal and the matching accuracy of the blended coal; according to the linkage data model, judging whether the difference between the percentage of different single coals accounting for the total blending amount after the coal blending amount statistics and a preset technical ratio is within 2% or not; according to a computer control PID algorithm model, comparing the maximum value and the minimum value of the difference between a plurality of single coal blending amount and the standard proportion in the total amount of the blended coal; and superposing the analog signal forming the secondary adjustment on the original analog signal, and repeatedly superposing until the matching accuracy of the blended coal is more than 96%. According to the method, the matching accuracy of single coal is adjusted, so that the matching accuracy of the mixed coal is effectively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of coal blending methods, and more particularly, to a method for improving the accuracy of blended coal by establishing a digital intelligence model. Background Art

[0002] In the coal blending coking process, multiple single coals such as gas coal, fat coal, coking coal, and lean coal are blended in a certain proportion to form blended coal for coking. Usually, according to technical requirements, the specified proportion of each single coal is fed through an automatic weighing scale to achieve the accurate feeding amount of each single coal. At present, in order to solve the problem of improving the blending accuracy, many academic papers and patents have been studied and corresponding solutions have been proposed. For example:

[0003] 1. "A method for improving the accuracy of coal blending process" applied by Zhang Xiaowu, Ma Lingjin, etc., with patent application number 202110877530.4 and application date August 1, 2021. This application proposes a method for improving the accuracy of coal blending by using an air cannon to strike. Although this application also improves the accuracy and timeliness of coal blending, it actually does not fundamentally study measures from the production process to improve the accuracy of blended coal, nor does it clarify the concept of the accuracy of blended coal ratio.

[0004] 2. "A method for improving the accuracy of coal blending in a storage and blending integrated silo" applied by Fu Lijun, Li Yabing, etc., with patent application number 202311187262.9 and application date September 14, 2023. This application improves the accuracy of coal blending by methods such as improving the accuracy of the electronic scale to control impurities in the coal material, standardizing the operation of the air cannon and feeder, and reasonably setting the startup frequency of the silo. In fact, it does not fundamentally study measures from the production process to improve the accuracy of blended coal, and also does not clarify the concept of the accuracy of blended coal ratio.

[0005] 3. "A method and system for determining the accuracy of coal blending" applied by Chen Ying, Zhang Peng, etc., with patent application 202311821519.1 and application date December 27, 2023. This application proposes a method and system for determining the accuracy of coal blending. The estimated feeding amount model obtained through neural network training can more accurately predict the actual feeding amount, thereby improving the accuracy and stability of coal blending. Although this patented technology improves the accuracy and timeliness of single coal blending and proposes the concept of the accuracy of single coal blending, it also does not clarify the concept of the accuracy of blended coal ratio. It does not improve the blending accuracy from the perspective of the accurate blending of blended coal.

[0006] In summary, the existing methods still have the characteristics of poor accuracy of blended coal ratio and serious waste. Therefore, there is an urgent need for a process method that can further improve the accuracy of blended coal ratio. Summary of the Invention

[0007] Based on the above proposal, a method for improving the accuracy of blended coal by establishing a digital intelligence model is proposed to address the technical problem that the current domestic coking coal blending process only controls the feeding accuracy of a single type of coal. This method primarily improves the accuracy of blended coal by establishing a digital intelligence model, thereby reducing coal resource waste and enterprise costs during the coking coal blending process.

[0008] The technical means adopted in the present invention are as follows:

[0009] A method for improving the accuracy of coal blending by establishing a digital intelligence model is applied to the traditional coal blending PLC automatic metering and automatic coal blending system process, including the following steps:

[0010] Step 1: Connect the original coal distribution tray, electronic automatic weighing scale and calculation controller to the computer, convert the computer data into 4-20mA analog signal and connect it to the coal distribution tray inverter. At the same time, the computer signal is automatically converted into AC380v driving voltage signal of the coal distribution tray inverter motor;

[0011] Step 2: Establish a linkage data model for the accuracy of single-type coal blending and the accuracy of the combined coal ratio; based on the linkage data model, determine whether the percentage of the total amount of coal blended by different single-type coals is within 2% of the preset technical ratio;

[0012] If the percentage of any single type of coal in the total amount of coal blended after statistics differs from the preset technical proportion by more than or equal to 2%, the coal quantity is judged to not meet the technical requirements and step 3 is executed; if the percentage of different single types of coal in the total amount of coal blended after statistics differs from the preset technical proportion by less than 2%, step 4 is executed;

[0013] Step 3: Delay the operation of the coal-blending pans whose coal quantity does not meet the technical requirements for 60 seconds, and then re-judge based on the linkage data model. If the percentage of the total coal quantity of a single type of coal blended still differs from the preset technical ratio by more than 2%, all coal-blending pans will be automatically shut down after 60 seconds. If the difference is less than 2%, proceed to step 4.

[0014] Step 4: Reconstruct the computer-controlled PID algorithm model; compare the maximum and minimum values of the difference between the proportion of multiple single-type coals in the total amount of blended coal and the standard proportion according to the computer-controlled PID algorithm model; superimpose the formed simulation signal on the original simulation signal, and repeat step 4 until the accuracy of the blended coal is greater than 96%.

[0015] Furthermore, the calculation formula for the accuracy of single-type coal blending is:

[0016] Coal blending accuracy of a single type of coal (%) = actual blending amount / theoretical blending amount × 100%.

[0017] Furthermore, the calculation formula for the accuracy of the blended coal ratio is as follows:

[0018] Accuracy of blended coal ratio % = Quantity of blended coal that actually fully conforms to the ratio / Total actual input quantity.

[0019] Furthermore, the reference value for the accuracy of single coal blending is 98%. If the reference value is lower than 98%, it is determined that the accuracy of this single coal blending is unqualified, and shutdown inspection and processing are carried out.

[0020] Furthermore, the reference value for the accuracy of the blended coal ratio is 96%. If the reference value is lower than 96%, it is determined that the accuracy of this blended coal ratio is unqualified, and shutdown inspection and processing are carried out.

[0021] Furthermore, in step 4, a computer-controlled PID algorithm model is reconstructed through RS485 access.

[0022] Furthermore, in step 4, it is set to compare once every 20 s at uniform intervals. The maximum and minimum values increase or decrease by 0.5% of the set input quantity of single coal towards the standard ratio, and increase and decrease once every 20 s; the increasing and decreasing values form a 4 - 20 mA analog signal, which is superimposed on the original analog signal, and this cycle repeats, with a comparison every 20 s.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] 1. By adjusting the accuracy of single coal input, the present invention effectively improves the accuracy of the blended coal ratio, and invents a digitalized production operation program that improves the accuracy of the coal blending process and the utilization rate of coal resources.

[0025] 2. The present invention adjusts based on the original input quantity of single coal, which belongs to the digitalized and refined management and control of the accuracy of the blended coal ratio. When the accuracy of the blended coal ratio is lower than the reference number, automatic shutdown occurs, followed by manual inspection and processing to avoid loss of ratio coal resources caused by on-site problems. When the accuracy of the blended coal ratio is lower than the base number, automatic continuous adjustment and continuous operation are achieved.

[0026] 3. Based on the original automatic metering system and calculation control, the present invention adds code programming for the accuracy of the blended coal ratio, realizing feedback, adjustment, then feedback and adjustment again, saving investment.

[0027] 4. In actual industrial experiments, with the implementation of the present invention, the accuracy of coal blending ratio has been increased from the original 92% to 96%, and the utilization rate of coal resources has been increased by 4%. Calculated based on a coal transfer volume of 10,000 t / d, the amount of coal entering the blending ratio has increased by 400 t per day. Calculated at the market price of lean coal of 1,200 yuan / t, the cost reduction = 400 * 1,200 / 10,000 = 48,000 yuan per day, and the monthly cost savings is 48,000 * 30 = 1.44 million yuan.

[0028] 5. The present invention is easy to control and operate, has a high degree of digital intelligence, and has strong popularizability, and has good practicality in large-scale industrial production. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0030] Figure 1 It is a schematic diagram of the data model of the coal blending PLC system of the present invention.

[0031] Figure 2 It is a schematic diagram of the exchange method between the coal blending system model and the logic signal of the present invention.

[0032] Figure 3 It is a process flow diagram of the coal blending tray of the coal blending system of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0033] In order to enable those skilled in the art to better understand the solutions of the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0034] It should be noted that the terms "first", "second", etc. in the description, claims and drawings of the present invention are used to distinguish similar objects and do not necessarily describe a specific order or sequence. It should be understood that such data used can be interchanged under appropriate circumstances so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "comprising" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device comprising a series of steps or units need not be limited to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these processes, methods, products or devices.

[0035] As Figures 1-3 shown, the present invention provides a method for improving the blending accuracy of blended coal by establishing a digital intelligence model, which is applied to the traditional automatic metering and automatic blending system process of coal blending PLC. The traditional PLC automatic metering and coal blending process calculates the hourly coal transfer speed by the input ratio of each single coal type according to the set single-machine coal transfer volume, and adjusts the motor speed. During the process, manual monitoring of the belt scale metering is carried out to ensure the normal operation of each single coal type according to the hourly coal transfer volume. This method mainly establishes a digital intelligence model. On the basis of the automatic metering and automatic blending system process of coal blending PLC, it further automatically fine-tunes the blending volume of each single coal type to ensure that the technical blending ratio requirements are met to the greatest extent, including the following steps:

[0036] Step 1: Connect the original coal blending tray, electronic automatic weighing scale and calculation controller to the computer, convert the computer data into 4-20mA analog signals and connect them to the frequency converter of the coal blending tray, and at the same time automatically convert the computer signals into AC380v driving voltage signals for the variable-frequency motor of the coal blending tray;

[0037] Step 2: Establish a linkage data model for the blending accuracy of each single coal type and the blending ratio accuracy of the blended coal; judge whether the percentage of the blended coal volume of each single coal type in the total blended volume after statistics and the difference from the preset technical blending ratio are within 2%;

[0038] If the difference between the percentage of the blended coal volume of any single coal type in the total blended volume after statistics and the preset technical blending ratio is greater than or equal to 2%, it is judged that the coal volume does not meet the technical requirements, and step 3 is executed; if the differences between the percentages of the blended coal volumes of different single coal types in the total blended volume after statistics and the preset technical blending ratio are all less than 2%, step 4 is executed;

[0039] Step 3: Delay the operation of the coal-blending pans whose coal quantity does not meet the technical requirements for 60 seconds, and then re-evaluate based on the linkage data model. If the percentage of the total coal quantity of a single type of coal blended still differs from the preset technical ratio by more than 2%, all coal-blending pans will be automatically shut down after 60 seconds. If the difference is less than 2%, proceed to step 4.

[0040] Step 4: Reconstruct the computer-controlled PID algorithm model; compare the maximum and minimum values of the difference between the proportion of multiple single-type coals in the total amount of blended coal and the standard proportion according to the computer-controlled PID algorithm model; superimpose the formed simulation signal on the original simulation signal, and repeat step 4 until the accuracy of the blended coal is greater than 96%.

[0041] The PLC system calls the database (ratio, ratio error, proportion, integral, differential, etc.), compares the actual operation data with the technical standard ratio data in the computer database, compares the two values with the largest error (maximum and minimum), delays the processing, and controls the speed signal of the variable frequency motor through the PLC to adjust each single type of coal, and finally realizes the automatic adjustment of the accuracy of the mixed coal ratio. Preferably, in this application, the computer control PID algorithm model is rebuilt through RS485 access.

[0042] Preferably, as a preferred embodiment of the present application, in the present application, a comparison is set every 20 seconds at a uniform interval, and the maximum and minimum values increase or decrease toward the standard ratio by 0.5% of the set amount of single coal, and increase and decrease once every 20 seconds; the increasing and decreasing values form a 4-20mA analog signal, and the formed analog signal is superimposed on the original analog signal, and the cycle is repeated, and the comparison is repeated every 20 seconds.

[0043] As a preferred embodiment, in this application, the calculation formula for the accuracy of single coal blending is:

[0044] Coal blending accuracy of a single type of coal (%) = actual blending amount / theoretical blending amount × 100%.

[0045] In this application, the benchmark value of single-type coal blending accuracy is set to 98%. If the benchmark value is lower than 98%, the single-type coal blending accuracy is judged to be unqualified and the machine is shut down for inspection.

[0046] In this application, the calculation formula for the accuracy of the coal ratio is:

[0047] The accuracy of the proportion of blended coal is % = the amount of blended coal that actually fully meets the proportion / the total amount actually blended.

[0048] In this application, the reference value for the accuracy of the blended coal ratio is set at 96%. If the reference value is lower than 96%, it is determined that the accuracy of this blended coal ratio is unqualified, and shutdown inspection and handling are carried out.

[0049] The serial numbers of the above-mentioned embodiments of the present invention are only for description and do not represent the advantages or disadvantages of the embodiments.

[0050] In the above-mentioned embodiments of the present invention, the descriptions of each embodiment have their own emphases. For the parts not detailed in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0051] In the several embodiments provided by this application, it should be understood that the disclosed technical content can be implemented in other ways. Among them, the device embodiments described above are only illustrative. For example, the division of units can be a logical function division. In actual implementation, there can be other division methods. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the displayed or discussed couplings or direct couplings or communication connections to each other can be through some interfaces. The indirect couplings or communication connections of units or modules can be in electrical or other forms.

[0052] The units described as separate components may or may not be physically separated. The components displayed as units may or may not be physical units, that is, they can be located in one place or distributed to multiple units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0053] In addition, the functional units in each embodiment of the present invention can be integrated into one processing unit, or each unit can exist physically alone, or two or more units can be integrated into one unit. The above-mentioned integrated units can be implemented in the form of hardware or in the form of software functional units.

[0054] When the integrated 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 this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of this technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes: various media that can store program codes, such as USB flash drives, read-only memories (ROMs), random access memories (RAMs), mobile hard disks, magnetic disks, or optical discs.

[0055] Finally, it should be noted that: the above 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 foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A method for improving the accuracy of blended coal in a blended coal preparation process by establishing a digital intelligence model, which is applied to the traditional PLC automatic metering and automatic coal blending system technology for coal blending, and is characterized in that, The following steps are involved: Step 1: Connect the original coal distribution tray, electronic automatic weighing scale and calculation controller to the computer, convert the computer data into 4-20mA analog signal and connect it to the coal distribution tray inverter. At the same time, the computer signal is automatically converted into AC380v driving voltage signal of the coal distribution tray inverter motor; Step 2: Establish a linkage data model for the accuracy of single-type coal blending and the accuracy of the combined coal ratio; based on the linkage data model, determine whether the percentage of the total amount of coal blended by different single-type coals after statistics and the difference between the preset technical ratio is less than 2%; If the percentage of any single type of coal in the total amount of coal blended after statistics differs from the preset technical proportion by more than or equal to 2%, the coal quantity is judged to not meet the technical requirements and step 3 is executed; if the percentage of different single types of coal in the total amount of coal blended after statistics differs from the preset technical proportion by less than 2%, step 4 is executed; Step 3: Delay the operation of the coal-blending pans whose coal quantity does not meet the technical requirements for 60 seconds, and then re-judge based on the linkage data model. If the percentage of the total coal quantity of a single type of coal blended still differs from the preset technical ratio by more than 2%, all coal-blending pans will be automatically shut down after 60 seconds. If the difference is less than 2%, proceed to step 4. Step 4: Reconstruct the computer-controlled PID algorithm model; compare the maximum and minimum values of the difference between the proportion of multiple single-type coals in the total amount of blended coal and the standard proportion according to the computer-controlled PID algorithm model; superimpose the formed simulation signal on the original simulation signal, and repeat step 4 until the accuracy of the blended coal is greater than 96%.

2. A method for improving the blending accuracy of blended coal by establishing a digital intelligence model according to claim 1, characterized in that The calculation formula for the accuracy of single coal blending is: Coal blending accuracy of a single type of coal (%) = actual blending amount / theoretical blending amount × 100%.

3. A method for improving the blending accuracy of blended coal by establishing a digital intelligence model according to claim 1, characterized in that, The calculation formula for the accuracy of the blending coal ratio is: The accuracy of the proportion of blended coal is % = the amount of blended coal that actually fully meets the proportion / the total amount actually blended.

4. A method for improving the blending accuracy of blended coal by establishing a digital intelligence model according to claim 1, characterized in that, The reference value of the single-type coal blending accuracy is 98%. If the reference value is lower than 98%, the single-type coal blending accuracy is judged to be unqualified and the machine is shut down for inspection.

5. A method for improving the blending accuracy of blended coal by establishing a digital intelligence model according to claim 1, characterized in that, The reference value of the accuracy of the blended coal ratio is 96%. If the reference value is lower than 96%, the accuracy of the blended coal ratio is judged to be unqualified and the unit is shut down for inspection.

6. The method for improving the blending accuracy of blended coal by establishing a digital intelligence model according to claim 1, wherein In step 4, the computer-controlled PID algorithm model is rebuilt through RS485 access.

7. A method for improving the accuracy of blended coal in a coking coal blend by establishing a digital intelligence model, characterized in that, In step 4, a comparison is performed every 20 seconds at a uniform interval, and the maximum and minimum values are increased or decreased toward the standard ratio by 0.5% of the set amount of single coal, and are increased and decreased once every 20 seconds; the increasing and decreasing values form a 4-20mA analog signal, and the formed analog signal is superimposed on the original analog signal, and the cycle is repeated, with comparison performed every 20 seconds.

Images