A multi-parameter collaborative optimization control system for a rotary kiln incinerator

Abstract

This invention relates to the field of multi-parameter control technology for rotary kiln incinerators, and more particularly to a multi-parameter collaborative optimization control system for rotary kiln incinerators. This system includes a temperature monitoring module, a spray control module, an ash and slag monitoring module, a coking analysis module, and a control feedback module. This invention monitors the corresponding hazardous waste incineration stages in each area of ​​the rotary kiln incinerator in real time. Because the incineration area is highly molten, forming a viscous melt, the molten material adheres to the inner wall of the rotary kiln, leading to coking. As the coking thickens, it hinders material flow, easily causing damage and detachment of refractory materials. Therefore, by analyzing the ash and slag, identifying the high-risk period of wall adhesion and the causes of coking products, the invention allows for timely adjustment of various operating parameters within the rotary kiln incinerator. A damage early warning model identifies coking caused by refractory material deterioration, enabling timely shutdown to extend refractory material life and achieve effective coking control in rotary kiln incinerators.

Description

Technical Field

[0001] This invention relates to the field of multi-parameter control technology for rotary kiln incinerators, and more particularly to a multi-parameter collaborative optimization control system for rotary kiln incinerators. Background Technology

[0002] Rotary kiln incineration technology is a core method for hazardous waste disposal, offering advantages such as efficient volume reduction, thorough detoxification, and heat recovery. However, hazardous waste is complex, containing high concentrations of low-melting-point salts like Na, K, and Ca. These salts melt into a liquid state in the high-temperature zone of the kiln and flow to the kiln tail, where a sudden temperature drop causes the molten ash to adhere to the refractory material surface, forming dense coke. If the ash discharge port is heavily clogged, the furnace must be shut down for cleaning. If the adhered layer continues to thicken, it leads to thermal stress imbalance in the refractory material, causing cracks, spalling, or even collapse. Existing rotary kiln incinerator spray control only starts and stops spraying based on temperature thresholds, without considering the ash solidification rate. This makes it impossible to distinguish between low-temperature adhesion, spray failure, or refractory deterioration-related coking caused by the kiln tail temperature drop. Furthermore, emergency shutdowns rely on experience-based judgment and do not quantify the remaining refractory lifespan. Therefore, a multi-parameter collaborative optimization control system is urgently needed, integrating multiple parameters such as temperature, ash, and acoustic emission to reduce coking rate and extend refractory lifespan.

[0003] Chinese Patent Publication No. CN117739345A discloses a control system and method for gaseous pollutants in a rotary kiln incinerator. The system includes a primary air fan, a perforated duct, a rotary kiln shell, a secondary air fan, a desulfurizing agent silo, and a rotary motor. The rotary kiln shell is equipped with a perforated duct parallel to its central axis, with several air holes evenly distributed on the duct. The two ends of the perforated duct are connected to the primary air fan and the secondary air fan, respectively. The perforated duct is rotated by the rotary motor. The primary and secondary air volumes entering the rotary kiln shell generated by the primary and secondary air fans are adjustable, as is the amount of desulfurizing agent entering the rotary kiln shell. Therefore, existing rotary kiln incinerator control technologies lack the ability to dynamically optimize spray patterns and parameters by integrating temperature gradients, ash solidification rates, and wall thickness. They also fail to assess refractory material damage based on coking causes, implement graded triggering and control, and match precise intervention strategies based on coking type to suppress coking formation at its source. Summary of the Invention

[0004] To address this issue, the present invention provides a multi-parameter collaborative optimization control system for rotary kiln incinerators, which overcomes the problem of low operating efficiency in existing technologies due to the lack of identification of high-risk periods for wall adhesion and coking products by combining ash and slag analysis results, and timely adjustment of various operating parameters within the rotary kiln incinerator.

[0005] To achieve the above objectives, the present invention provides a multi-parameter collaborative optimization control system for a rotary kiln incinerator, comprising:

[0006] The temperature monitoring module is used to monitor temperature fluctuation parameters during the combustion process of the rotary kiln incinerator, analyze the degree of fluctuation, and obtain temperature fluctuation analysis results.

[0007] A spray control module, which is connected to the temperature monitoring module, is used to determine whether to start the spray mode based on the temperature fluctuation analysis results. The spray modes include foam spray and cooling water spray.

[0008] The ash and slag monitoring module is connected to the spray control module. It is used to analyze the solidification effect and wall adhesion based on the visual image of ash and slag, obtain the wall adhesion trend analysis result, and determine whether to adjust the current kiln operation status based on the wall adhesion trend analysis result.

[0009] The coking analysis module is connected to the spray control module and the ash monitoring module respectively. It is used to determine the cause of coking based on the temperature fluctuation location and spray failure type when the wall adhesion trend increases, and to select and adjust the temperature control parameters and spray parameters based on the cause of coking.

[0010] The control feedback module is connected to the temperature monitoring module, the spray control module, the ash and slag monitoring module, and the coking analysis module, respectively, and is used to determine whether to shut down the furnace in an emergency based on the coking cause and refractory damage early warning model.

[0011] Furthermore, the ash and slag monitoring module includes a solidification analysis unit and a wall adhesion analysis unit;

[0012] The curing analysis unit is used to determine the curing effect based on the comparison results between the real-time curing rate and the standard curing rate range;

[0013] The wall adhesion analysis unit is used to determine the wall adhesion thickness increment based on the actual kiln wall thickness, and to obtain the wall adhesion trend analysis result based on the comparison result between the wall adhesion thickness increment and the thickness increment threshold.

[0014] Furthermore, the curing analysis unit includes a calculation subunit and a comparison subunit;

[0015] The calculation subunit is used to calculate the real-time curing rate based on the thermodynamic curing rate, grayscale curing rate, and scattering curing rate.

[0016] The comparison subunit is used to compare the real-time curing rate with the standard curing rate range to obtain a first comparison result, a second comparison result, and a third comparison result.

[0017] Furthermore, the wall-hanging analysis unit includes a detection subunit, an incremental calculation subunit, and a wall-hanging trend analysis subunit;

[0018] The detection subunit is used to calculate the actual kiln wall thickness through distortion.

[0019] The incremental calculation subunit is used to perform differential calculations based on the actual kiln wall thickness to obtain the wall thickness increment;

[0020] The wall-mounted trend analysis subunit is used to obtain the wall-mounted trend analysis result based on the comparison result of the wall thickness increment and the thickness increment threshold.

[0021] Furthermore, the coking analysis module includes a location analysis unit and a failure type analysis unit;

[0022] The location analysis unit is used to determine the incinerator failure location based on the second comparison result and the temperature fluctuation location, including the first incineration location and the second incineration location;

[0023] The failure type analysis unit is used to determine the coking type during the incineration process based on the incineration location, including a first coking type and a second coking type.

[0024] Furthermore, the position analysis unit includes a first position analysis subunit and a second position analysis subunit;

[0025] The first position analysis subunit is used to determine the incinerator failure position as the first incineration position when the temperature fluctuation position is at the kiln tail position;

[0026] The second position analysis subunit is used to determine the incinerator failure position as the second incineration position when the temperature fluctuation position is not at the kiln tail position.

[0027] Furthermore, the coking analysis module also includes a first control unit and a second control unit;

[0028] The first control unit is used to switch the spray mode, adjust the initial air-fuel ratio, or increase the temperature of the kiln tail insulation layer according to the sudden drop gradient at the kiln tail when the failure type of the incineration operation is determined to be the first coking type.

[0029] The second control unit is used to adjust the pretreatment program or select and adjust the spray parameters when the failure type during the incineration operation is the second coking type.

[0030] Furthermore, the second control unit includes a pretreatment adjustment subunit and a spray parameter adjustment subunit;

[0031] The preprocessing adjustment subunit is used to adjust the preprocessing procedure;

[0032] The spray parameter adjustment subunit is used to adjust the spray pressure, spray frequency, or spray layout position according to the type of spray failure.

[0033] Furthermore, the control feedback module includes a signal receiving unit and an emergency response unit;

[0034] The signal receiving unit is used to receive emergency response signals;

[0035] The emergency response unit is used to obtain the remaining life index of refractory material based on the refractory material damage early warning model when it receives an emergency response signal, and to determine whether to trigger the furnace shutdown protection based on the comparison result between the remaining life index of refractory material and the early warning threshold.

[0036] Furthermore, the emergency response unit includes a data acquisition subunit, a calculation subunit, and an emergency early warning subunit;

[0037] The data acquisition subunit is used to acquire model input parameters, including temperature fluctuation frequency and acoustic emission event frequency;

[0038] The calculation subunit is used to output the remaining life index of refractory material based on the refractory material damage early warning model and the model input parameters;

[0039] The emergency warning subunit is used to trigger a furnace shutdown protection when the remaining refractory life index is less than the warning threshold.

[0040] Compared with the prior art, the beneficial effects of this invention are as follows: by real-time monitoring of the corresponding hazardous waste incineration stages in each area of ​​the rotary kiln incinerator, and because the incineration area is extremely prone to melting and forming a viscous melt, the molten material adheres to the inner wall of the rotary kiln, leading to coking. As the coking material thickens, it will hinder the flow of materials, easily causing damage and detachment of refractory materials. Therefore, by analyzing the ash and slag, identifying the high-risk period of wall adhesion and the causes of coking products, timely adjustment of various operating parameters in the rotary kiln incinerator can be achieved, improving the stability of furnace operation, accurately distinguishing the causes of spray failure and quickly correcting them, and identifying coking caused by refractory material deterioration through a damage early warning model, timely shutdown can be initiated to extend the service life of refractory materials, thus achieving effective coking control in the rotary kiln incinerator. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the multi-parameter collaborative optimization control system for a rotary kiln incinerator according to an embodiment of the present invention;

[0042] Figure 2 This is a schematic diagram of the ash and slag monitoring module according to an embodiment of the present invention;

[0043] Figure 3 This is a schematic diagram of the wall-mounted analysis unit according to an embodiment of the present invention;

[0044] Figure 4 This is a schematic diagram of the control feedback module in an embodiment of the present invention. Detailed Implementation

[0045] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0046] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0047] It should be noted that in the description of this invention, the terms "upper", "lower", "left", "right", "inner", "outer", etc., which indicate directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0048] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0049] Please see Figure 1 As shown, this is a schematic diagram of the multi-parameter collaborative optimization control system for a rotary kiln incinerator according to an embodiment of the present invention. The present invention provides a multi-parameter collaborative optimization control system for a rotary kiln incinerator, comprising:

[0050] The temperature monitoring module is used to monitor temperature fluctuation parameters during the combustion process of the rotary kiln incinerator, analyze the degree of fluctuation, and obtain temperature fluctuation analysis results.

[0051] A spray control module, which is connected to the temperature monitoring module, is used to determine whether to start the spray mode based on the temperature fluctuation analysis results. The spray modes include foam spray and cooling water spray.

[0052] The ash and slag monitoring module is connected to the spray control module. It is used to analyze the solidification effect and wall adhesion based on the visual image of ash and slag, obtain the wall adhesion trend analysis result, and determine whether to adjust the current kiln operation status based on the wall adhesion trend analysis result.

[0053] The coking analysis module is connected to the temperature monitoring module, the spray control module and the ash monitoring module respectively. It is used to determine the cause of coking based on the temperature fluctuation location and the type of spray failure when the wall adhesion trend increases, and to select and adjust the temperature control parameters and spray parameters based on the cause of coking.

[0054] The control feedback module is connected to the spray control module, the ash monitoring module and the coking analysis module respectively, and is used to determine whether to shut down the furnace in an emergency based on the coking cause and refractory damage early warning model.

[0055] Temperature fluctuation parameters include temperature standard deviation and kiln tail descent gradient;

[0056] In this embodiment, the combustion stages of the corresponding incinerator materials in each area of ​​the rotary kiln incinerator are monitored in real time. Since the combustion area is prone to melting and forming a viscous melt, the molten material adheres to the inner wall of the rotary kiln, which will cause coking. As the coking material thickens, it will hinder the flow of materials and easily cause damage and detachment of refractory materials. Therefore, by analyzing the ash and slag, identifying the high-risk period of wall adhesion and the causes of coking products, the operating parameters in the rotary kiln incinerator are adjusted in a timely manner to improve the stability of the furnace operation, accurately distinguish the causes of spray failure and quickly correct them, and identify coking caused by refractory material deterioration through a damage early warning model to respond to the furnace shutdown in a timely manner to extend the service life of refractory materials and achieve effective coking control in the rotary kiln incinerator.

[0057] See Figure 2 As shown, it is a structural schematic diagram of the ash and slag monitoring module of an embodiment of the present invention;

[0058] Specifically, the ash and slag monitoring module includes a solidification analysis unit and a wall adhesion analysis unit;

[0059] The curing analysis unit is used to determine the curing effect based on the comparison results between the real-time curing rate and the standard curing rate range;

[0060] The wall adhesion analysis unit is used to determine the wall adhesion thickness increment based on the actual kiln wall thickness, and to obtain the wall adhesion trend analysis result based on the comparison result between the wall adhesion thickness increment and the thickness increment threshold.

[0061] Specifically, the curing analysis unit includes a calculation subunit and a comparison subunit;

[0062] The calculation subunit is used to calculate the real-time curing rate based on the thermodynamic curing rate, grayscale curing rate, and scattering curing rate.

[0063] The comparison subunit is used to compare the real-time curing rate with the standard curing rate range to obtain a first comparison result, a second comparison result, and a third comparison result;

[0064] Specifically, if the real-time curing rate is less than or equal to the first standard curing rate, a first comparison result is obtained; if the real-time curing rate is between the first and second standard curing rates, a second comparison result is obtained; and if the real-time curing rate is greater than or equal to the second standard curing rate, a third comparison result is obtained.

[0065] Specifically, when the ash and slag monitoring module receives the first comparison result, it does not intervene in the current kiln operation status; when it receives the second comparison result, it determines whether to adjust the current kiln operation status based on the wall adhesion trend analysis result; when it receives the third comparison result, it sends an emergency response signal to the control feedback module.

[0066] In this embodiment, the real-time curing rate is calculated based on the thermodynamic curing rate Nt, the grayscale curing rate Ng, and the scattering curing rate Ns. The calculation formula is: Real-time curing rate = α × Nt + β × Ng + γ × Ns, where α is the weight corresponding to the thermodynamic curing rate (α = 0.5), β is the weight corresponding to the grayscale curing rate (β = 0.3), and γ is the weight corresponding to the scattering curing rate (γ = 0.2). The thermodynamic curing rate is the ratio of the area of ​​the low-temperature curing region to the total area of ​​the visual image of the ash slag. An infrared thermal imager is used to obtain the surface temperature distribution map of the ash slag to determine the area with a temperature less than or equal to 700℃ in the visual image of the ash slag as the low-temperature curing region. The grayscale curing rate is the ratio of the area of ​​the grayscale curing region to the total area of ​​the visual image of the ash slag. A high-temperature resistant CCD camera is used to acquire the visual image of the ash slag. By converting the RGB image of the ash slag visual image to a grayscale image, the area with a grayscale value ≥ 180 is taken as the grayscale curing region. The scattering curing rate = (θ - 30°) / 60°, using a laser scattering sensor installed at a 45° oblique position on the side wall of the kiln tail. The average scattering angle θ is obtained by the instrument; the solidification rate characterizes the liquid fluidity of the ash. The first standard solidification rate is set at 40%, and the second standard solidification rate is set at 70% to analyze the solidification rate of the ash. The smaller the solidification rate, the stronger the fluidity. When the real-time solidification rate is less than or equal to the first standard solidification rate, it indicates that the liquid fluidity of the ash is relatively strong. At this time, the risk of wall adhesion is very low and negligible. When the real-time solidification rate is between the first and second standard solidification rates, it indicates that more viscous melt is generated, and the risk of wall adhesion is higher. The melt may adhere to the inner wall of the rotary kiln, which will lead to coking in the rotary kiln. As the coking material thickens, it will hinder the flow of materials and easily cause damage and detachment of refractory materials. Therefore, the wall thickness is analyzed to accurately determine the coking situation. When the real-time solidification rate is greater than or equal to the second standard solidification rate, it indicates that the ash has hardened and expanded. In this case, thermal stress is likely to cause refractory spalling. Therefore, refractory damage analysis is required to ensure precise control and improve the operational stability and combustion efficiency of the rotary kiln incinerator.

[0067] See Figure 3 As shown, it is a structural schematic diagram of the wall-mounted analysis unit in an embodiment of the present invention;

[0068] Specifically, the wall-hanging analysis unit includes a detection subunit, an incremental calculation subunit, and a wall-hanging trend analysis subunit;

[0069] The detection subunit is used to calculate the actual kiln wall thickness through distortion.

[0070] The incremental calculation subunit is used to perform differential calculations based on the actual kiln wall thickness to obtain the wall thickness increment;

[0071] The wall-mounting trend analysis sub-unit is used to obtain wall-mounting trend analysis results based on the comparison between the wall-mounting thickness increment and the thickness increment threshold.

[0072] In this embodiment, the thickness increment threshold is set to 2mm. The kiln wall thickness is calculated using laser distortion based on triangulation. When a laser line is projected onto the surface of an object, the laser line will be distorted (shifted) in the camera image due to changes in the object's height. By calculating the shift of the laser line, the thickness change of the object can be deduced. A 650nm laser is emitted from a line laser onto the kiln wall surface. The reflected light is then processed by a CCD sensor to calculate the offset pixels of the laser line in the image. Combined with calibration parameters, such as the angle and distance between the camera and the laser, the actual kiln wall thickness is calculated using triangulation. Alternatively, the actual kiln wall thickness can be calculated by obtaining the mapping relationship between pixel displacement and actual thickness through calibration. Specifically, calibration yields: 1 pixel displacement = 0.1mm thickness. Therefore, if at time t0 the reference position of a point on the kiln wall is measured to be 100 pixels, and at time t1 the laser line position at that point becomes 115 pixels, then the offset d = 15 pixels. The corresponding wall thickness h = 15 × 0.1 = 1.5 mm; Based on the actual kiln wall thickness, differential calculation is performed to obtain the increment of the wall thickness. For example, within 5 minutes, the increment of the wall thickness at this point is the current thickness minus the thickness 5 minutes ago. For example, if the thickness at this point was 1.0 mm 5 minutes ago and is now 1.5 mm, then the increment of the wall thickness is 0.5 mm; The increment of the wall thickness is compared with the thickness increment threshold. When the increment of the wall thickness is greater than or equal to the thickness increment threshold, it is determined that the wall adhesion trend is increasing. In this case, as the coking material thickens, it will hinder the flow of materials, which can easily cause damage and detachment of refractory materials. It is necessary to adjust the current kiln operation status in a timely manner. Targeted control is then carried out through coking cause analysis to improve the reliability of the control; When the increment of the wall thickness is less than the thickness increment threshold, it is determined that the wall adhesion trend is not increasing. At this time, the coking situation is not enough to hinder the flow of materials, and there is no need to intervene in the current kiln operation status temporarily.

[0073] Specifically, the coking analysis module includes a location analysis unit and a failure type analysis unit;

[0074] The location analysis unit is used to determine the incinerator failure location based on the second comparison result and the temperature fluctuation location, including the first incineration location and the second incineration location;

[0075] The failure type analysis unit is used to determine the coking type during the incineration process based on the incineration location, including a first coking type and a second coking type.

[0076] Specifically, the position analysis unit includes a first position analysis subunit and a second position analysis subunit;

[0077] The first position analysis subunit is used to determine the incinerator failure position as the first incineration position when the temperature fluctuation position is at the kiln tail position.

[0078] The second position analysis subunit is used to determine the incinerator failure position as the second incineration position when the temperature fluctuation position is not at the kiln tail position.

[0079] Specifically, the failure type analysis unit includes a first coking type analysis subunit and a second coking type analysis subunit;

[0080] The first coking type analysis subunit is used to obtain the first coking type when the failure location of the incinerator is determined to be the first incineration location;

[0081] The second coking type analysis subunit is used to obtain the second coking type when the failure location of the incinerator is determined to be the second incineration location.

[0082] In this embodiment, the first coking type is low-temperature adhesive coking, and the second coking type is coking caused by spray failure. When the real-time curing rate is between the first standard curing rate and the second standard curing rate, a large amount of viscous melt is generated, which easily causes temperature fluctuations in the kiln. Therefore, the location of the incinerator failure is determined based on the location of the temperature fluctuation, and then the coking type is determined. If coking is formed at the kiln tail of the rotary kiln incinerator, the corresponding coking type is low-temperature adhesive coking. If coking is formed at a location other than the kiln tail of the rotary kiln incinerator, the corresponding coking type is temperature fluctuation caused by spray failure, which causes the generated viscous melt to adhere to the inner wall of the rotary kiln, resulting in coking in the rotary kiln. Therefore, the spray parameters need to be directionally controlled.

[0083] Specifically, the coking analysis module further includes a first control unit and a second control unit;

[0084] The first control unit is used to switch the spray mode, adjust the initial air-fuel ratio, or increase the temperature of the kiln tail insulation layer according to the sudden drop gradient at the kiln tail when the coking type during the incineration process is determined to be the first coking type.

[0085] The second control unit is used to adjust the pretreatment program or select and adjust the spray parameters when the coking type during the incineration operation is the second coking type.

[0086] In this embodiment, for low-temperature adhesive coking, the kiln tail temperature drop gradient is detected to analyze the operational stability of the kiln tail section. The actual kiln tail temperature drop gradient is compared with the standard kiln tail temperature drop gradient. If the actual kiln tail temperature drop gradient is less than or equal to the standard kiln tail temperature drop gradient, the foam spray mode is switched to the cooling water spray mode. If the actual kiln tail temperature drop gradient is greater than the standard kiln tail temperature drop gradient, the initial air-fuel ratio is reduced to avoid excessive cold air entering the kiln tail, thus accelerating cooling. At the same time, the oxygen concentration is reduced to weaken the formation of low-melting-point oxides of alkali metals (Na, K) and heavy metals (such as Fe) in the ash. This process continues until the corrected air-fuel ratio is less than or equal to the minimum air-fuel ratio, at which point the temperature of the kiln tail insulation layer is increased to maintain the stability of the kiln tail temperature and prevent secondary coking caused by incomplete combustion.

[0087] For coking caused by spray failure, analysis of the ash composition reveals that if Na₂O > 40%, it indicates a high sodium salt content in the incinerator feedstock. Since sodium salts in the feedstock begin to melt at higher temperatures within the rotary kiln, these molten sodium salts readily adhere to other substances. When these adhered substances cool at the kiln tail, they solidify on the inner wall of the rotary kiln, forming coke. Therefore, pre-washing and desalting of the current batch of feedstock is necessary to remove water-soluble sodium salts (Na₂O). + fluoride F - and chloride salt Cl - To reduce the formation of low-melting-point eutectic matrix from the source, thereby reducing coking, if Na2O≤40%, analyze the spray failure type. Based on the spray location and ash / slag adhesion location, if the spray location is not close to the area where ash / slag easily adheres to the wall, increase the spray gun angle by 8° to adjust the spray layout. If the spray location is close to the area where ash / slag easily adheres to the wall, analyze the fluctuation rate of the wall adhesion thickness increment. Analyze whether ash / slag re-adheres based on the wall adhesion thickness increment rate. Use the ratio of the newly added wall adhesion amount per unit time to the wall adhesion thickness increment rate per unit time as the wall adhesion thickness increment rate. When the wall adhesion thickness increment rate is >0.8 mm / min, it is determined that ash / slag re-adheres in a short time, and the spray frequency needs to be increased, that is, the spray frequency is adjusted from 1 time / min to 2 times / min. When the wall adhesion thickness increment rate is ≤0.8 mm / min, continue monitoring.

[0088] Specifically, the second control unit includes a pretreatment adjustment subunit and a spray parameter adjustment subunit;

[0089] The preprocessing adjustment subunit is used to adjust the preprocessing procedure;

[0090] The spray parameter adjustment subunit is used to adjust the spray pressure, spray frequency, or spray layout position according to the type of spray failure.

[0091] In this embodiment, the initial air-fuel ratio is set to 1.4, the adjustment step size is 0.1, and the minimum air-fuel ratio is 1.1. When it is determined that the actual kiln tail temperature drop gradient is greater than the standard kiln tail temperature drop gradient, the initial air-fuel ratio is reduced to the corrected air-fuel ratio, which is the difference between the initial air-fuel ratio and the adjustment step size. The pretreatment program is adjusted to pre-wash and desalinate the raw materials of the current batch.

[0092] See Figure 4 As shown, it is a schematic diagram of the control feedback module in an embodiment of the present invention;

[0093] Specifically, the control feedback module includes a signal receiving unit and an emergency response unit;

[0094] The signal receiving unit is used to receive emergency response signals;

[0095] The emergency response unit is used to obtain the remaining life index of refractory material based on the refractory material damage early warning model when it receives an emergency response signal, and to determine whether to trigger the furnace shutdown protection based on the comparison result between the remaining life index of refractory material and the early warning threshold.

[0096] Specifically, the emergency response unit includes a data acquisition subunit, a calculation subunit, and an emergency early warning subunit;

[0097] The data acquisition subunit is used to acquire model input parameters, including temperature fluctuation frequency and acoustic emission event frequency;

[0098] The calculation subunit is used to output the remaining life index of refractory material based on the refractory material damage early warning model and the model input parameters;

[0099] The emergency warning subunit is used to trigger a furnace shutdown protection when the remaining refractory life index is less than the warning threshold.

[0100] Specifically, the refractory damage early warning model is as follows: ;

[0101] Where R is the remaining life index of refractory material, σ is the temperature fluctuation frequency in Hertz, ƒ is the acoustic emission event frequency in Hertz, δ is the radial deformation of the kiln body in millimeters, and K is the initial life coefficient, which is set between 0.8 and 1, preferably K=1. When the measured σ, ƒ, and δ are substituted into the model calculation, σ, ƒ, and δ need to be normalized. Substituting the normalized variables into the refractory material damage early warning model, a new expression is obtained: , As the reference fluctuation frequency, The reference deformation is expressed in millimeters. As the baseline number, =1 Hz, =1 time, =1 millimeter.

[0102] In this embodiment, temperature fluctuations during the combustion process in the rotary kiln incinerator are monitored, and the temperature standard deviation is used as the temperature fluctuation frequency, measured in times per minute. Acoustic emission sensors are installed outside the kiln shell to monitor stress waves generated by internal cracking and spalling of the refractory material. The frequency of acoustic emission events is obtained through acoustic emission monitoring, which operates 24 hours a day. This is because refractory material damage is a cumulative process, and sudden spalling can occur at any stage of operation during the rotary kiln incinerator's operation. The acoustic emission event frequency is the number of elastic wave signals detected per minute from internal cracks or spalling of the refractory material. The initial life coefficient is 1, and it decays with operating time, with the K value decreasing by 0.02 every 1000 hours. This represents the cumulative amount of acoustic emission events within a time interval T, reflecting the cumulative effect of refractory material damage. The time interval T can be 24 hours. A higher ƒ value indicates more severe microcrack propagation within the refractory material. The higher the value, the more severe the overall deterioration of the refractory material. The warning threshold is set to 0.2. When the remaining life index of the refractory material is determined to be less than the warning threshold, the furnace shutdown protection is triggered. When the remaining life index of the refractory material is determined to be greater than or equal to the warning threshold, the remaining life index of the refractory material is compared with the warning level threshold. The warning level threshold includes a first warning level threshold and a second warning level threshold. The first warning level threshold is set to 0.3, and the second warning level threshold is set to 0.6. When the remaining life index of the refractory material is greater than or equal to the warning threshold and less than or equal to the first warning level threshold, it is determined that the rotary kiln incinerator may be damaged, and on-site inspection and maintenance are required. When the remaining life index of the refractory material is determined to be between the first and second warning level thresholds, the load needs to be reduced to reduce temperature fluctuations. When the remaining life index of the refractory material is determined to be greater than or equal to the second warning level threshold, it indicates that the current operating status has not affected the quality of the refractory material, and operation can be maintained.

[0103] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

[0104] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A rotary kiln incinerator multi-parameter collaborative optimization control system, characterized in that, The method comprises the following steps: a temperature monitoring module is used to monitor temperature fluctuation parameters in the incineration process of the rotary kiln incinerator and analyze the fluctuation degree to obtain temperature fluctuation analysis results; a spraying control module connected with the temperature monitoring module is used to determine whether to start a spraying mode based on the temperature fluctuation analysis results, the spraying mode including foam spraying and cooling water spraying; a ash monitoring module connected with the spraying control module is used to analyze solidification effect and wall hanging situation based on ash visual images to obtain wall hanging trend analysis results, and determine whether to adjust the current kiln running state based on the wall hanging trend analysis results; the ash monitoring module includes a solidification analysis unit and a wall hanging analysis unit; the solidification analysis unit is used to determine the solidification effect according to a comparison result of a real-time solidification rate and a standard solidification rate range; the wall hanging analysis unit is used to determine a wall hanging thickness increment according to an actual kiln wall thickness, and obtain wall hanging trend analysis results according to a comparison result of the wall hanging thickness increment and a thickness increment threshold value; a coking analysis module connected with the temperature monitoring module, the spraying control module and the ash monitoring module respectively is used to determine coking causes according to temperature fluctuation positions and spraying failure types when the wall hanging trend increases, and select adjustment temperature control parameters and spraying parameters based on the coking causes; the coking analysis module includes a position analysis unit and a failure type analysis unit; the position analysis unit is used to determine incinerator failure positions including first incineration positions and second incineration positions based on a second comparison result and temperature fluctuation positions; the failure type analysis unit is used to determine coking types of the incineration operation process including first coking types and second coking types based on the incineration positions; a control feedback module connected with the spraying control module, the ash monitoring module and the coking analysis module respectively is used to determine whether to perform emergency shutdown based on the coking causes and a refractory damage early warning model.

2. The rotary kiln incinerator multi-parameter collaborative optimization control system according to claim 1, characterized in that, The solidification analysis unit includes a calculation subunit and a comparison subunit; the calculation subunit is used to calculate a real-time solidification rate according to a thermodynamic solidification rate, a grayscale solidification rate and a scattering solidification rate; the comparison subunit is used to compare the real-time solidification rate with a standard solidification rate range to obtain a first comparison result, a second comparison result and a third comparison result.

3. The rotary kiln incinerator multi-parameter collaborative optimization control system according to claim 1, characterized in that, The wall hanging analysis unit includes a detection subunit, an increment calculation subunit and a wall hanging trend analysis subunit; the detection subunit is used to calculate an actual kiln wall thickness through distortion; the increment calculation subunit is used to calculate a wall hanging thickness increment based on the actual kiln wall thickness through difference calculation; the wall hanging trend analysis subunit is used to obtain wall hanging trend analysis results based on a comparison result of the wall hanging thickness increment and a thickness increment threshold value.

4. The rotary kiln incinerator multi-parameter collaborative optimization control system according to claim 1, characterized in that, The position analysis unit includes a first position analysis subunit and a second position analysis subunit; the first position analysis subunit is used to determine that the incinerator failure position is the first incineration position when the temperature fluctuation position is at a kiln tail position; the second position analysis subunit is used to determine that the incinerator failure position is the second incineration position when the temperature fluctuation position is at a non-kiln tail position.

5. The rotary kiln incinerator multi-parameter collaborative optimization control system according to claim 4, characterized in that, The coking analysis module further includes a first control unit and a second control unit. The first regulation unit is configured to switch a spraying mode or adjust an initial air-fuel ratio or increase a kiln tail heat preservation layer temperature according to a kiln tail sudden drop gradient when determining that the failure type of the incineration operation process is a first coking type; The second regulation unit is configured to adjust a pretreatment program or select and adjust a spraying parameter when the failure type of the incineration operation process is a second coking type.

6. The rotary kiln incinerator multi-parameter collaborative optimization control system according to claim 5, characterized in that, The second regulation unit comprises a pretreatment adjustment subunit and a spraying parameter adjustment subunit. The pretreatment adjustment subunit is configured to adjust the pretreatment program. The spraying parameter adjustment subunit is configured to adjust a spraying pressure or a spraying frequency or a spraying layout position according to the spraying failure type.

7. The rotary kiln incinerator multi-parameter collaborative optimization control system according to claim 1, characterized in that, The regulation feedback module comprises a signal receiving unit and an emergency response unit. The signal receiving unit is configured to receive an emergency response signal. The emergency response unit is configured to obtain a refractory remaining life index based on a refractory damage early warning model when the emergency response signal is received, and determine whether to trigger a shutdown protection based on a comparison result of the refractory remaining life index and a warning threshold.

8. The rotary kiln incinerator multi-parameter collaborative optimization control system according to claim 7, characterized in that, The emergency response unit comprises a data acquisition subunit, a calculation subunit and an emergency warning subunit. The data acquisition subunit is configured to acquire model input parameters, including a temperature fluctuation frequency and an acoustic emission event frequency. The calculation subunit is configured to output the refractory remaining life index according to the refractory damage early warning model and the model input parameters. The emergency warning subunit is configured to trigger the shutdown protection when the refractory remaining life index is less than the warning threshold.

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