A continuous biomass hydrothermal liquefaction reaction intelligent control method and system thereof

Abstract

The present disclosure relates to a continuous biomass hydrothermal liquefaction reaction intelligent control method and system, comprising: real-time monitoring of biomass feed solid content and feed flow rate by mass flow meter, dynamic adjustment of feed flow rate by feed pump frequency converter combined with pre-input material characteristic parameters, control of reaction residence time; based on real-time sampling data and feed flow rate, dynamic adjustment of reaction temperature and reaction pressure by prediction model, and adjustment of discharge valve opening to optimize reaction residence time; real-time monitoring of flow rate, regulating valve opening, separation temperature, separation pressure and liquid level of gas-liquid separation buffer tank and solid-liquid separation buffer tank, automatic adjustment of regulating valve opening according to separation pressure of gas-liquid separation buffer tank and solid-liquid separation buffer tank, and staged recovery of heat by three-stage cooler; judging whether the current key parameters exceed the warning value, if yes, triggering an emergency alarm signal and emergency process. The present disclosure improves the intelligence and safety of the continuous biomass hydrothermal liquefaction reaction process.

Description

Technical Field

[0001] This disclosure relates to the field of biomass energy conversion technology, and in particular to an intelligent control method and system for continuous biomass hydrothermal liquefaction reaction. Background Technology

[0002] The integration of artificial intelligence (AI) and industrial automation is a crucial development goal for the present and future. Its core model involves using AI to input cognition and industrial automation to implement it. However, significant challenges remain in the current integration of AI and industrial automation. Due to a lack of robust software and hardware infrastructure, many AI-provided automation solutions still face considerable implementation difficulties. In certain specific fields, thanks to relatively mature software and hardware infrastructure, it is easier to validate AI-provided solutions and establish a clear automation path, thereby significantly enhancing the intelligence level of specific scenarios.

[0003] The field of biomass energy conversion technology urgently needs the support of artificial intelligence and industrial automation. Based on upgrades in artificial intelligence, breakthroughs in automation programs and various sensors, intelligent control systems for continuous biomass hydrothermal liquefaction reactions are expected to make substantial progress. However, existing technologies still have shortcomings: batch production models lead to low efficiency and high labor costs; key parameter control is lagging, making process improvement difficult; manual operation poses risks, threatening personal and equipment safety, and conventional safety interlock response speeds are insufficient. There is a lack of corresponding process simulation systems, limited resources for training new operators, and safety risks. Summary of the Invention

[0004] To address the problems of low efficiency, high cost, lagging key parameter control, difficulty in process optimization, safety risks, and insufficient emergency response in traditional production methods, this disclosure proposes an intelligent control method for continuous biomass hydrothermal liquefaction reactions to solve these issues.

[0005] According to one aspect of this disclosure, a method for intelligent control of continuous biomass hydrothermal liquefaction reaction is provided, comprising:

[0006] S10. Real-time monitoring of biomass feed solids content and feed flow rate via mass flow meter, and dynamic adjustment of feed flow rate via feed pump frequency converter combined with pre-input material characteristic parameters to control reaction residence time;

[0007] S20. Based on real-time sampling data and feed flow rate during the reaction process, the reaction temperature and reaction pressure are dynamically adjusted through a prediction model, and the opening of the discharge valve is adjusted in conjunction to further optimize the reaction residence time. The sampling data includes reaction product composition data, reaction product quality indicators, reaction conversion efficiency parameters, and reaction system state parameters.

[0008] S30: Real-time monitoring of the flow rate, valve opening, separation temperature, separation pressure, and liquid level of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank; automatic adjustment of the valve opening based on the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank; and staged heat recovery through a three-stage cooler.

[0009] S40. Determine whether the current key parameters exceed the warning value. If they exceed the warning value, trigger an emergency alarm signal and emergency procedure. The key parameters include reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, and program running time.

[0010] Preferably, dynamically adjusting the feed flow rate based on pre-input material characteristic parameters includes:

[0011] Obtain pre-input material characteristic parameters, including feed solid content range, organic matter content, viscosity index, and elemental composition;

[0012] The feed solids content of biomass, which is monitored in real time by a mass flow meter, is compared and analyzed with the pre-input material characteristic parameters.

[0013] Based on the comparative analysis results, the dynamically adjusted feed flow rate is calculated and determined through a control algorithm.

[0014] Preferably, the reaction temperature and reaction pressure are dynamically adjusted using a predictive model, including:

[0015] The liquid level height is controlled by feeding back the liquid level signal from the level gauge to the regulating valve, and the feed flow rate is controlled by the feed pump frequency converter.

[0016] The reaction heater is controlled by thermocouple feedback signals to regulate the reaction temperature.

[0017] The reactor's discharge valve is controlled by a pressure sensor to regulate the reaction pressure.

[0018] Preferably, the opening degree of the regulating valve is automatically adjusted according to the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank, including:

[0019] The separation pressure is monitored in real time by pressure sensors installed on the gas-liquid separation buffer tank and the solid-liquid separation buffer tank.

[0020] The monitored separation pressures of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank are compared with preset pressure thresholds. Based on the comparison results, real-time feedback adjustments are made to maintain the separation pressures of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank within the set operating range.

[0021] When the separation pressure continues to rise above the safety valve burst pressure, the emergency pressure relief protection action is triggered.

[0022] Preferably, the monitored separation pressures of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank are compared with preset pressure thresholds, and real-time feedback adjustments are made based on the comparison results, including:

[0023] When the separation pressure of the gas-liquid separation buffer tank is detected to reach its preset pressure threshold, the opening of its outlet regulating valve is automatically adjusted through a proportional-integral-derivative control algorithm.

[0024] When the separation pressure of the solid-liquid separation buffer tank reaches its preset pressure threshold, the opening of its outlet regulating valve is automatically adjusted through a proportional-integral-derivative control algorithm.

[0025] Preferably, heat recovery through a three-stage cooler includes:

[0026] The high-temperature material from the reaction output is cooled from 300°C to 100-200°C by the primary cooler, and the recovered high-temperature heat is transferred to the tertiary preheater for material preheating.

[0027] The secondary cooler cools the medium-temperature material from 100-200℃ to 50-99.99℃ after the primary cooling, and the recovered medium-temperature heat is transferred to the secondary preheater for material preheating.

[0028] The low-temperature material after secondary cooling is cooled from 50-100℃ to 20-49.99℃ by a three-stage cooler, and the recovered low-temperature heat is transferred to the primary preheater for material preheating.

[0029] Preferably, the emergency alarm signal and emergency procedure include:

[0030] When the reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, or program running time parameter exceeds the primary alarm setting value, the system will automatically depressurize or disconnect the heat supply, and simultaneously issue a primary alarm signal and generate a fault analysis report.

[0031] When the reaction temperature, reaction pressure, separation temperature, or separation pressure is detected to be higher than the safety valve burst pressure, or when the key parameters exceed the emergency alarm setting value, the reaction is immediately terminated, an emergency alarm signal is triggered, and detailed fault diagnosis information is generated.

[0032] The system can be shut down directly by using the virtual emergency stop button on the control interface or the physical emergency stop button installed on site, and will automatically execute interlocking protection actions such as shutting down the feed pump, cutting off the heat supply, depressurizing, and cooling.

[0033] According to one aspect of this disclosure, a continuous biomass hydrothermal liquefaction reaction intelligent control system is provided, comprising:

[0034] The feed flow rate dynamic adjustment module monitors the feed solids content and feed flow rate of biomass in real time through a mass flow meter, and dynamically adjusts the feed flow rate by combining the feed pump frequency converter with the pre-input material characteristic parameters to control the reaction residence time.

[0035] The reaction control module dynamically adjusts the reaction temperature and pressure based on real-time sampling data and feed flow rate during the reaction process through a predictive model, and further optimizes the reaction residence time by adjusting the opening of the discharge valve in conjunction with the reaction. The sampling data includes reaction product composition data, reaction product quality indicators, reaction conversion efficiency parameters, and reaction system state parameters.

[0036] The separation control module monitors the flow rate, valve opening, separation temperature, separation pressure, and liquid level of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank in real time. It automatically adjusts the valve opening based on the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank, and recovers heat in stages through a three-stage cooler.

[0037] The alarm and emergency module determines whether the current key parameters exceed the warning value. If they exceed the warning value, it triggers an emergency alarm signal and emergency procedure. The key parameters include reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, and program running time.

[0038] According to one aspect of this disclosure, an electronic device is provided, comprising: a processor; a memory for storing processor-executable instructions; wherein the processor is configured to execute the above-described intelligent control method for continuous biomass hydrothermal liquefaction reaction.

[0039] According to one aspect of this disclosure, a computer-readable storage medium is provided that stores computer program instructions thereon, which, when executed by a processor, implement the above-described intelligent control method for continuous biomass hydrothermal liquefaction reaction.

[0040] Compared to the prior art, the beneficial effects of this disclosure are as follows:

[0041] 1) This disclosure achieves continuous production of biomass hydrothermal liquefaction reaction through automated programming and intelligent control system, significantly improving production efficiency and reducing labor costs. It employs real-time data acquisition, predictive model training, and PID control technology to dynamically and precisely adjust key parameters such as temperature, pressure, and residence time, optimizing process stability and product quality.

[0042] 2) This disclosure integrates an intelligent risk control module, which responds quickly to anomalies such as overpressure and overtemperature through multi-level early warning and emergency procedures (such as automatic pressure relief and emergency stop buttons), ensuring equipment and personal safety. It also features an innovative multi-stage waste heat recovery system, combined with pressurized and heated separation technology, to reduce energy consumption, minimize byproduct generation, and improve energy efficiency, meeting green production requirements.

[0043] 3) This disclosure provides a process simulation system for training new employees, reducing training costs and operational risks. It adopts an industrial HMI interface integrating voice control and 3D visualization technology to achieve intuitive human-computer interaction, simplify operating procedures, and improve the convenience of production management.

[0044] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure.

[0045] Other features and aspects of this disclosure will become clear from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0046] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this disclosure and, together with the specification, serve to illustrate the technical solutions of this disclosure.

[0047] Figure 1 A flowchart of an intelligent control method for continuous biomass hydrothermal liquefaction reaction is shown.

[0048] Figure 2 This diagram shows the main interface of the intelligent feeding control system.

[0049] Figure 3 The diagram shows the structure of the intelligent control system.

[0050] Figure 4 This diagram shows the interface for setting the control parameters of the feed pump.

[0051] Figure 5 This diagram illustrates the logic flow of intelligent risk management.

[0052] Figure 6 A block diagram of a smart control system for continuous biomass hydrothermal liquefaction reaction is shown. Detailed Implementation

[0053] Various exemplary embodiments, features, and aspects of this disclosure will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0054] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0055] In this document, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Furthermore, the term "at least one" in this document means any combination of at least two of any one or more elements. For example, including at least one of A, B, and C can mean including any one or more elements selected from the set consisting of A, B, and C.

[0056] Furthermore, to better illustrate this disclosure, numerous specific details are set forth in the following detailed description. Those skilled in the art will understand that this disclosure can be practiced without certain specific details. In some instances, methods, means, components, and circuits well known to those skilled in the art have not been described in detail in order to highlight the main points of this disclosure.

[0057] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0058] This disclosure presents an intelligent control method for continuous biomass hydrothermal liquefaction reaction. Figure 1 A flowchart of a smart control method for continuous biomass hydrothermal liquefaction reaction is shown. The method includes:

[0059] S10. Real-time monitoring of biomass feed solids content and feed flow rate via mass flow meter, and dynamic adjustment of feed flow rate via feed pump frequency converter combined with pre-input material characteristic parameters to control reaction residence time;

[0060] S20. Based on real-time sampling data and feed flow rate during the reaction process, the reaction temperature and reaction pressure are dynamically adjusted through a prediction model, and the opening of the discharge valve is adjusted in conjunction to further optimize the reaction residence time. The sampling data includes reaction product composition data, reaction product quality indicators, reaction conversion efficiency parameters, and reaction system state parameters.

[0061] S30: Real-time monitoring of the flow rate, valve opening, separation temperature, separation pressure, and liquid level of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank; automatic adjustment of the valve opening based on the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank; and staged heat recovery through a three-stage cooler.

[0062] S40. Determine whether the current key parameters exceed the warning value. If they exceed the warning value, trigger an emergency alarm signal and emergency procedure. The key parameters include reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, and program running time.

[0063] This disclosure provides an intelligent control method for continuous biomass hydrothermal liquefaction reaction, including the following steps:

[0064] S10. The feed solids content and feed flow rate of biomass are monitored in real time by a mass flow meter. The feed flow rate is dynamically adjusted by the feed pump frequency converter in combination with the pre-input material characteristic parameters to control the reaction residence time.

[0065] In this embodiment, intelligent feed control uses a combination of feedback from the feed pump frequency converter and mass flow meter to monitor the feed solids content, dynamically adjust the feed flow rate, and indirectly control the reaction residence time (with a control accuracy of ±2 min in the 10-120 min range). Automated operation is implemented through Siemens PLC software programming.

[0066] The intelligent feeding control system, taking a screw feed pump system with dual hydraulic cylinders as an example, is equipped with two hydraulic cylinders, U1 and U2, which share a single hydraulic pump. Raw materials are pumped into the cylinders via the screw pump. The cylinders are pressurized and depressurized by switching between solenoid valves YV1, YV5, YV2, YV8, YV3, YV7, YV4, and YV6, thus achieving hydraulic transmission of the raw materials. Automatic and continuous material feeding is achieved through electronic control. The high-pressure tank of this feeding system has a maximum working pressure of 16 MPa; the hydraulic system pressure is 8 MPa; the maximum output flow rate of the hydraulic system is 12 L / min, corresponding to a maximum flow rate of 6 L / min during material output; the average material output flow rate reaches 100 L / H.

[0067] The system composition and functions are as follows: Hydraulic components provide power for system operation; power components include hydraulic pumps and screw pumps; cylinders serve as actuators; control components include electric valves and solenoid valves; auxiliary components include oil tanks, oil pipes, pipe fittings, filters, and pressure gauges; the control cabinet and control software serve as electrical control components. A touchscreen is used as the operating interface, which includes a main interface, parameter settings, and alarm logs. The main interface displays information on transmission pipelines, transmission components, and electrical control components. The intelligent feeding control main interface is shown below. Figure 2 As shown.

[0068] Initial State: Solenoid valves YV5, YV6, YV7, and YV8 are closed; YV1, YV2, YV3, and YV4 are closed; U1 is raised and U2 is lowered (or U2 is raised and U1 is lowered); Debugging Mode: Pressing the "Debugging Mode" function key allows manual operation of the hydraulic components on the main interface; Automatic Start: In the initial state, with the yellow indicator light constantly on, pressing the "Automatic Start" function key will execute automatic operation. During automatic operation, the signal indicator light will be constantly green; End of Operation: Pressing the "End of Operation" function key will normally end the automatic operation and return to the initial state; Emergency Stop: Pressing the "Emergency Stop" function key will stop the hydraulic system immediately; Alarm Reset: Silences and resets the status when a fault alarm occurs; Tank Parameters: Displays the current hydraulic pressure and sets the hydraulic alarm pressure; PV: Displays the current operating frequency of the hydraulic pump and screw pump; SP: Sets the operating frequency of the hydraulic pump and screw pump. The solenoid valves can be electric solenoid valves.

[0069] System operation includes debug mode, startup sequence, and shutdown sequence.

[0070] Debugging Mode: This can be understood as a manual operation mode. In debugging mode, the user can manually operate the solenoid valves, hydraulic pump, screw pump, cooling fan, etc. U1 rising process: Close YV2 and YV8 to their positions, then open YV1 and YV5, and then turn on the hydraulic pump. U1 falling process: Close the hydraulic pump, close YV1 and YV5 to their positions, then open YV2 and YV8, and then turn on the screw pump. U2 rising process: Close YV4 and YV6 to their positions, then open YV3 and YV7, and then turn on the hydraulic pump. U2 falling process: Close the hydraulic pump, close YV3 and YV7 to their positions, then open YV4 and YV6, and then turn on the screw pump.

[0071] Start-up procedure: Before starting, check the status of the manual ball valves in the feeding and transmission systems, and check the liquid level in the raw material tank. Power on: The emergency stop button should be in the unscrewed position; Initialization status check: A solid yellow indicator light indicates initialization; a flashing yellow light requires entering "Debugging Mode" and manually adjusting the transmission components to their initial state; Press the "Automatic Start" function key, and the three-color indicator light will turn solid green.

[0072] End operation sequence: Press the "End Run" function key and wait for the three-color indicator light to turn solid yellow; press the emergency stop button to cut off power. The above automated operation is implemented through Siemens PLC software programming.

[0073] Furthermore, dynamically adjusting the feed flow rate based on pre-input material characteristic parameters includes: acquiring pre-input material characteristic parameters, including the feed solids content range, organic matter content, viscosity index, and elemental composition; and inputting the data into the feed data analysis system after performing basic physical property tests on each batch of material, such as industrial analysis, elemental analysis, viscosity testing, and composition analysis. The feed solids content of biomass monitored in real time by the mass flow meter is compared and analyzed with the pre-input material characteristic parameters to obtain the optimal feed material parameters, such as solids content and organic matter range. Based on the comparison and analysis results, the dynamically adjusted feed flow rate is calculated and determined through a control algorithm.

[0074] S20. Based on real-time sampling data and feed flow rate during the reaction process, the reaction temperature and reaction pressure are dynamically adjusted through a prediction model, and the opening of the discharge valve is adjusted in conjunction to further optimize the reaction residence time. The sampling data includes reaction product composition data, reaction product quality indicators, reaction conversion efficiency parameters, and reaction system state parameters.

[0075] In this embodiment, taking the hydrothermal oil production from kitchen waste as an example, the bio-oil yield is 60% with a residence time of 60 minutes and a reaction temperature of 300°C, but the bio-oil yield is 30% with a residence time of 30 minutes and a reaction temperature of 250°C. That is, the bio-oil yield per unit hour is 60% under both reaction conditions, but the latter has lower energy consumption and lower overall cost.

[0076] A mixed sample from one reaction cycle is collected periodically using an automated sampling system. Data such as reaction yield is then tested and input into the intelligent reaction control system. The intelligent reaction control system dynamically adjusts the reaction temperature (100-350℃ range, control accuracy ±2℃), reaction pressure (1-30MPa range, control accuracy ±2MPa), and residence time (10-120min range, control accuracy ±2min) through data acquisition and predictive model training and analysis. It comprehensively evaluates the reaction and separation costs under different process conditions, as well as the composition and quality of the biomass oil, to find the optimal process route and ensure maximum economic efficiency. Specifically, the dynamic adjustment of the reaction temperature is achieved by controlling the heat supply to the preheater and reactor heater, with the reactor heater controlled via thermocouple feedback signals. The dynamic adjustment of the reaction pressure is achieved by controlling the reactor's discharge valve via pressure sensor feedback signals. The liquid level is controlled by feeding back the level signal from the level gauge to the regulating valve, and the feed flow rate is controlled by the feed pump frequency converter.

[0077] Remote temperature transmission control uses a PID controller to measure and control temperature, sending feedback signals to the heating equipment via thermocouples to control the system temperature. Remote pressure transmission control uses a PID controller to measure and control pressure, sending feedback signals to an electric regulating valve via a pressure sensor to control the system pressure. Remote flow transmission control uses a mass flow meter to send feedback signals to an electric regulating valve to control the pipeline flow rate. Remote level transmission control uses a level gauge to send feedback signals to an electric regulating valve to control the liquid level.

[0078] The pressure, temperature, and flow rate are all controlled using PID control. The primary preheater and tertiary cooler, the secondary preheater and secondary cooler, and the tertiary preheater and primary cooler are all integrated into one unit to improve heat exchange efficiency.

[0079] S30: Real-time monitoring of the flow rate, valve opening, separation temperature, separation pressure, and liquid level of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank. Automatically adjusts the valve opening based on the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank, and recovers heat in stages through a three-stage cooler to achieve gas-solid-liquid three-phase separation with temperature and pressure, which does not affect the continuous process of the reaction and can recover waste heat to the maximum extent.

[0080] In this embodiment, taking the gas-solid-liquid three-phase separation with temperature and pressure as an example, the outlet temperature of the biomass hydrothermal liquefaction reaction is 300℃ and the pressure is 15MPa. The gas-solid-liquid three-phase separation with temperature and pressure does not affect the continuous process of the reaction and can recover waste heat to the maximum extent. In addition, the slow cooling after the biomass reaction can reduce biochar by-products, but this relies on certain technical means for risk management. Intelligent separation control, through Mitsubishi PLC programming, is connected to mass flow meters, valve opening adjustment valves, temperature sensors, and pressure sensors to monitor the overall flow, valve opening, temperature, and pressure of the gas-liquid separation and solid-liquid separation units in real time, facilitating the regulation of the separation process and the recovery of corresponding heat.

[0081] The automatic adjustment of the regulating valve opening based on the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank includes: real-time monitoring of the separation pressure using pressure sensors installed on the gas-liquid separation buffer tank and the solid-liquid separation buffer tank; comparing the monitored separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank with a preset pressure threshold, and making real-time feedback adjustments based on the comparison results to maintain the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank within the set operating range; and triggering an emergency pressure relief protection action when the separation pressure continues to rise above the burst pressure of the safety valve.

[0082] Furthermore, the monitored separation pressures of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank are compared with preset pressure thresholds, and real-time feedback adjustments are made based on the comparison results. This includes: when the separation pressure of the gas-liquid separation buffer tank reaches its preset pressure threshold, the opening of its outlet regulating valve is automatically adjusted using a proportional-integral-derivative control algorithm; when the separation pressure of the solid-liquid separation buffer tank reaches its preset pressure threshold, the opening of its outlet regulating valve is automatically adjusted using a proportional-integral-derivative control algorithm.

[0083] The structure diagram of the intelligent control system is as follows: Figure 3 As shown, the heat recovery through the three-stage cooler specifically includes: First, before the reaction discharge, the material is cooled in the first stage of the heat circulation loop to recover some heat for the third-stage preheating before the reaction. The high-temperature material from the reaction discharge is cooled from 300℃ to 100-200℃ in the first-stage cooler and enters the gas-liquid separation buffer tank for gas-liquid separation. The recovered high-temperature heat is then transferred to the third-stage preheater for material preheating.

[0084] At this point, the discharge pressure remains at 15 MPa and continues to rise with continuous discharge. Through automated programming, when the pressure in the gas-liquid separation buffer tank reaches 15.1 MPa (adjustable), the regulating valve at the bottom of the gas-liquid separation buffer tank automatically opens to separate the liquid-solid phase products. The opening of the regulating valve is controlled in real time based on the discharge flow rate of the liquid-solid phase products to ensure stable discharge of the liquid-solid phase products. When the pressure in the gas-liquid separation buffer tank is less than 15 MPa (adjustable), the regulating valve at the bottom of the gas-liquid separation buffer tank automatically closes. Simultaneously, through the secondary cooling of the heat circulation loop, some heat is recovered for secondary preheating before the reaction. The intermediate-temperature material after primary cooling is cooled from 100-200℃ to 50-99.99℃ (e.g., from 100℃ to 99.9℃, or from 200℃ to 50℃, the cooling range is controllable and adjustable) by the secondary cooler, and enters the solid-liquid separation buffer tank for solid-liquid separation. The recovered intermediate-temperature heat is transferred to the secondary preheater for material preheating.

[0085] At this point, the pressure in the solid-liquid separation buffer tank remains at 5-10 MPa and continues to rise with continuous separation. Through automated programming, when the pressure in the solid-liquid separation buffer tank reaches 5.1 MPa (adjustable), the regulating valve at the bottom of the tank automatically opens, allowing the liquid phase product to be separated by the filtration equipment under pressure. The valve opening is controlled in real time based on the liquid phase product discharge flow rate to ensure stable liquid phase product discharge. When the pressure in the gas-liquid separation buffer tank is less than 5 MPa (adjustable), the regulating valve at the bottom of the tank automatically closes. Simultaneously, a portion of the heat is recovered through a three-stage cooling system in the heat circulation loop for primary preheating before the reaction. The three-stage cooler cools the low-temperature material after the secondary cooling from 50-100℃ to 20-49.99℃ (e.g., from 100℃ to 20℃, or from 50℃ to 49.99℃, the temperature drop is controllable and adjustable), reducing the pressure to normal atmospheric pressure. The recovered low-temperature heat is then transferred to the primary preheater for material preheating.

[0086] The pressure, temperature, and flow rate are all controlled using PID control. The primary preheater and tertiary cooler, the secondary preheater and secondary cooler, and the tertiary preheater and primary cooler are all integrated into one unit to improve heat exchange efficiency.

[0087] S40. Determine whether the current key parameters exceed the warning value. If they exceed the warning value, trigger an emergency alarm signal and emergency procedure. The key parameters include reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, and program running time.

[0088] In this embodiment, intelligent risk control focuses on preventing system overpressure, overtemperature, over-level, or critical program time delays caused by equipment failures, as well as the secondary risks they bring. By setting warning values ​​for key parameters and program execution time, the system can self-check the location of faults, trigger emergency procedures, and issue alarm signals and fault analysis.

[0089] Taking the automatic emergency stop of the feed pump (overpressure or timeout feedback) as an example, the feed pump control parameter setting interface is mainly designed to prevent the system from failing to set alarms due to damage to the proximity switches of cylinders U1 and U2. It is accessed through the "Parameter Setting" function key on the main interface. A schematic diagram of the feed pump control parameter setting interface is shown below. Figure 4 As shown. U1 cylinder extension time: the time it takes for U1 cylinder to extend from the lower proximity switch to the upper proximity switch; U1 cylinder retraction time: the time it takes for U1 cylinder to retract from the upper proximity switch to the lower proximity switch; U2 cylinder extension time: the time it takes for U2 cylinder to extend from the lower proximity switch to the upper proximity switch; U2 cylinder retraction time: the time it takes for U2 cylinder to retract from the upper proximity switch to the lower proximity switch.

[0090] In addition to the aforementioned real-time automated temperature and pressure control methods, the stability of the reaction and separation system is maintained. The intelligent risk management logic diagram is as follows: Figure 5 As shown, when the reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, or program running time exceeds the primary alarm setting, the system automatically depressurizes or disconnects the heat supply, simultaneously issuing a primary alarm signal and generating a fault analysis report. If the emergency procedure eliminates the overpressure, overtemperature, or over-level issues, or if the critical program running time returns to normal, the reaction and separation will proceed automatically. If the abnormal state cannot be eliminated, the reaction and separation will continue to terminate, awaiting troubleshooting and maintenance.

[0091] When the reaction temperature, reaction pressure, separation temperature, or separation pressure is detected to be higher than the safety valve burst pressure, or when key parameters exceed the emergency alarm setting value, the reaction is immediately terminated, an emergency alarm signal is triggered, and detailed fault diagnosis information is generated, awaiting investigation and repair. Specifically, the safety diaphragm burst pressure setting value is higher than the emergency alarm setting value, and the emergency alarm setting value is higher than the primary alarm setting value.

[0092] The system can be shut down directly via a virtual emergency stop button on the control interface or a physical emergency stop button installed on-site, automatically executing interlocking protection actions such as shutting down the feed pump, cutting off the heat supply, depressurizing, and cooling. In this embodiment, an emergency operation button is provided: pressing the "Emergency Stop" button on the control interface shuts down the feed pump, activates automatic depressurization, and disconnects the heat supply; pressing the physical "Emergency Stop" button shuts down the system, cools it, and depressurizes it.

[0093] Intelligent process simulation allows users to manually input or change material parameters and reaction conditions to simulate real-time feeding, reaction, and separation processes. It displays the real-time operating status of each module and potential reaction risks. When a risk occurs, it can provide relevant solutions and emergency measures, making it useful for new employee training and daily safety education.

[0094] Intelligent human-machine interaction, using an industrial HMI interface to integrate a voice control module, can display the real-time status of the 3D visualized reactor and separator.

[0095] This embodiment proposes an intelligent control method for continuous biomass hydrothermal liquefaction, improving the intelligence, automation, stability, and safety of the continuous biomass hydrothermal liquefaction process. Through reaction process data acquisition and predictive model training and analysis, the method dynamically adjusts the reaction temperature, reaction pressure, and residence time to find the optimal process route and ensure optimal economic efficiency. Intelligent separation control enables three-phase separation of gas, solid, and liquid phases under varying temperatures and pressures. Real-time monitoring of flow rates, valve openings, temperatures, and pressures in gas-liquid and solid-liquid separation facilitates the regulation of the separation process and the recovery of corresponding heat. Intelligent risk control focuses on preventing system overpressure, overtemperature, over-level, or critical process delays caused by equipment failures and their resulting secondary risks.

[0096] As another aspect of the embodiments of this disclosure, a continuous biomass hydrothermal liquefaction reaction intelligent control system 100 is also provided, such as... Figure 6 As shown, it includes:

[0097] The feed flow rate dynamic adjustment module 1 monitors the feed solid content and feed flow rate of biomass in real time through a mass flow meter, and dynamically adjusts the feed flow rate by combining the feed pump frequency converter with the pre-input material characteristic parameters to control the reaction residence time.

[0098] The reaction control module 2 dynamically adjusts the reaction temperature and pressure based on real-time sampling data and feed flow rate during the reaction process through a predictive model, and further optimizes the reaction residence time by adjusting the opening of the discharge valve in conjunction with the sampling data. The sampling data includes reaction product composition data, reaction product quality indicators, reaction conversion efficiency parameters, and reaction system state parameters.

[0099] The separation control module 3 monitors the flow rate, valve opening, separation temperature, separation pressure, and liquid level of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank in real time. It automatically adjusts the valve opening according to the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank, and recovers heat in stages through a three-stage cooler.

[0100] Alarm and emergency module 4 determines whether the current key parameters exceed the warning value. If they exceed the warning value, it triggers an emergency alarm signal and emergency procedure. The key parameters include reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, and program running time.

[0101] Without causing contradictions, the above-described modules in the system of the present disclosure embodiments can implement any of the above-described methods.

[0102] Based on the description of the above embodiments, it can be seen that the embodiments of this disclosure can achieve the following technical effects:

[0103] 1) This disclosure achieves continuous production of biomass hydrothermal liquefaction reaction through automated programming and intelligent control system, significantly improving production efficiency and reducing labor costs. It employs real-time data acquisition, predictive model training, and PID control technology to dynamically and precisely adjust key parameters such as temperature, pressure, and residence time, optimizing process stability and product quality.

[0104] 2) This disclosure integrates an intelligent risk control module, which responds quickly to anomalies such as overpressure and overtemperature through multi-level early warning and emergency procedures (such as automatic pressure relief and emergency stop buttons), ensuring equipment and personal safety. It also features an innovative multi-stage waste heat recovery system, combined with pressurized and heated separation technology, to reduce energy consumption, minimize byproduct generation, and improve energy efficiency, meeting green production requirements.

[0105] 3) This disclosure provides a process simulation system for training new employees, reducing training costs and operational risks. It adopts an industrial HMI interface integrating voice control and 3D visualization technology to achieve intuitive human-computer interaction, simplify operating procedures, and improve the convenience of production management.

[0106] This disclosure also proposes an electronic device, including: a processor; and a memory for storing processor-executable instructions; wherein the processor is configured for the aforementioned intelligent control method for continuous biomass hydrothermal liquefaction reaction. The electronic device can be provided as a terminal, a server, or other form of device.

[0107] This disclosure also proposes a computer-readable storage medium storing computer program instructions, which, when executed by a processor, implement the aforementioned intelligent control method for continuous biomass hydrothermal liquefaction reaction. The computer-readable storage medium can be a non-volatile computer-readable storage medium.

[0108] Those skilled in the art will understand that, in the above-described intelligent control method and system for continuous biomass hydrothermal liquefaction reaction in specific embodiments, the order in which each step is written does not imply a strict execution order and does not constitute any limitation on the implementation process. The specific execution order of each step should be determined by its function and possible internal logic.

[0109] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of an instruction containing one or more executable instructions for implementing a specified logical function. In some alternative implementations, the functions marked in the blocks may occur in a different order than those shown in the drawings. For example, two consecutive blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, may be implemented using a dedicated hardware-based system that performs the specified function or action, or using a combination of dedicated hardware and computer instructions.

[0110] The various embodiments of this disclosure have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical applications, or technical improvements to the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A method for intelligent control of continuous biomass hydrothermal liquefaction reaction, characterized in that, Includes the following steps: S10. Real-time monitoring of biomass feed solids content and feed flow rate via mass flow meter, and dynamic adjustment of feed flow rate via feed pump frequency converter combined with pre-input material characteristic parameters to control reaction residence time; Dynamically adjusting the feed flow rate based on pre-input material characteristic parameters includes: Obtain pre-input material characteristic parameters, including feed solid content range, organic matter content, viscosity index, and elemental composition; The feed solids content of biomass, which is monitored in real time by a mass flow meter, is compared and analyzed with the pre-input material characteristic parameters. Based on the comparative analysis results, the dynamically adjusted feed flow rate is calculated and determined through a control algorithm. S20. Based on real-time sampling data and feed flow rate during the reaction process, the reaction temperature and pressure are dynamically adjusted through a predictive model, and the discharge valve opening is adjusted accordingly to further optimize the reaction residence time, resulting in lower energy consumption and lower overall cost. The sampling data includes reaction product composition data, reaction product quality indicators, reaction conversion efficiency parameters, and reaction system state parameters. The dynamic adjustment of reaction temperature and pressure through the predictive model includes: The liquid level height is controlled by feeding back the liquid level signal from the level gauge to the regulating valve, and the feed flow rate is controlled by the feed pump frequency converter. The reaction heater is controlled by thermocouple feedback signals to regulate the reaction temperature. The reactor's discharge valve is controlled by a pressure sensor to regulate the reaction pressure. S30: Real-time monitoring of the flow rate, valve opening, separation temperature, separation pressure, and liquid level of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank; automatic adjustment of the valve opening based on the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank; and staged heat recovery through a three-stage cooler. The opening degree of the regulating valve is automatically adjusted according to the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank, including: The separation pressure is monitored in real time by pressure sensors installed on the gas-liquid separation buffer tank and the solid-liquid separation buffer tank. The monitored separation pressures of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank are compared with preset pressure thresholds. Based on the comparison results, real-time feedback adjustments are made to maintain the separation pressures of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank within the set operating range. When the separation pressure continues to rise above the safety valve burst pressure, the emergency pressure relief protection action is triggered. S40. Determine whether the current key parameters exceed the warning value. If they exceed the warning value, trigger an emergency alarm signal and emergency procedure. The key parameters include reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, and program running time.

2. The method according to claim 1, characterized in that, The monitored separation pressures of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank are compared with preset pressure thresholds, and real-time feedback adjustments are made based on the comparison results, including: When the separation pressure of the gas-liquid separation buffer tank is detected to reach its preset pressure threshold, the opening of its outlet regulating valve is automatically adjusted through a proportional-integral-derivative control algorithm. When the separation pressure of the solid-liquid separation buffer tank reaches its preset pressure threshold, the opening of its outlet regulating valve is automatically adjusted through a proportional-integral-derivative control algorithm.

3. The method according to claim 1, characterized in that, The emergency alarm signal and emergency procedures include: When the reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, or program running time parameter exceeds the primary alarm setting value, the system will automatically depressurize or disconnect the heat supply, and simultaneously issue a primary alarm signal and generate a fault analysis report. When the reaction temperature, reaction pressure, separation temperature, or separation pressure is detected to be higher than the safety valve burst pressure, or when the key parameters exceed the emergency alarm setting value, the reaction is immediately terminated, an emergency alarm signal is triggered, and detailed fault diagnosis information is generated. The system can be shut down directly by using the virtual emergency stop button on the control interface or the physical emergency stop button installed on site, and will automatically execute interlocking protection actions such as shutting down the feed pump, cutting off the heat supply, depressurizing, and cooling.

4. A continuous biomass hydrothermal liquefaction reaction intelligent control system, characterized in that, include: The feed flow rate dynamic adjustment module monitors the feed solids content and feed flow rate of biomass in real time through a mass flow meter, and dynamically adjusts the feed flow rate by combining the feed pump frequency converter with the pre-input material characteristic parameters to control the reaction residence time. Dynamically adjusting the feed flow rate based on pre-input material characteristic parameters includes: Obtain pre-input material characteristic parameters, including feed solid content range, organic matter content, viscosity index, and elemental composition; The feed solids content of biomass, which is monitored in real time by a mass flow meter, is compared and analyzed with the pre-input material characteristic parameters. Based on the comparative analysis results, the dynamically adjusted feed flow rate is calculated and determined through a control algorithm. The reaction control module, based on real-time sampling data and feed flow rate during the reaction process, dynamically adjusts the reaction temperature and pressure using a predictive model, and further optimizes the reaction residence time by adjusting the discharge valve opening to achieve lower energy consumption and lower overall cost. The sampling data includes reaction product composition data, reaction product quality indicators, reaction conversion efficiency parameters, and reaction system state parameters. The dynamic adjustment of reaction temperature and pressure using the predictive model includes: The liquid level height is controlled by feeding back the liquid level signal from the level gauge to the regulating valve, and the feed flow rate is controlled by the feed pump frequency converter. The reaction heater is controlled by thermocouple feedback signals to regulate the reaction temperature. The reactor's discharge valve is controlled by a pressure sensor to regulate the reaction pressure. The separation control module monitors the flow rate, valve opening, separation temperature, separation pressure, and liquid level of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank in real time. It automatically adjusts the valve opening based on the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank, and recovers heat in stages through a three-stage cooler. The opening degree of the regulating valve is automatically adjusted according to the separation pressure of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank, including: The separation pressure is monitored in real time by pressure sensors installed on the gas-liquid separation buffer tank and the solid-liquid separation buffer tank. The monitored separation pressures of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank are compared with preset pressure thresholds. Based on the comparison results, real-time feedback adjustments are made to maintain the separation pressures of the gas-liquid separation buffer tank and the solid-liquid separation buffer tank within the set operating range. When the separation pressure continues to rise above the safety valve burst pressure, the emergency pressure relief protection action is triggered. The alarm and emergency module determines whether the current key parameters exceed the warning value. If they exceed the warning value, it triggers an emergency alarm signal and emergency procedure. The key parameters include reaction temperature, reaction pressure, separation temperature, separation pressure, liquid level, and program running time.

5. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the intelligent control method for continuous biomass hydrothermal liquefaction reaction as described in any one of claims 1 to 3.

6. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the program is executed by the processor, it implements the intelligent control method for continuous biomass hydrothermal liquefaction reaction as described in any one of claims 1 to 3.

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