A carbon black production equipment control method and system based on a DCS system

Abstract

The application discloses a carbon black production equipment control method and system based on a DCS system, relates to the technical field of carbon black production control, and is used for solving the problem of increased particle size fluctuation amplitude. In the granulation control, the granulator outlet particle samples are sent to a screening machine for multi-stage screening to obtain granulation distribution data. The target particle size interval of a quality control database is called and combined with the distribution data to calculate a particle size quality score. The classification of the particle uniformity is performed according to the score. When the classification result is a coarsening state, the furnace gas pressure is collected and the rising trend is analyzed to obtain the equivalent ratio evaluation front-end power characteristics. Meanwhile, the quenching water inflow and the forward distance of the nozzle and the hot peak position are detected to analyze the rear-end inhibition characteristics. The two types of characteristics are comprehensively selected to perform process driving regulation or reaction termination regulation, real-time identification and targeted regulation of the carbon black granulation particle coarsening trend are realized, and therefore, the particle size distribution uniformity is ensured and the product quality stability is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of carbon black production control, and more particularly to a carbon black production equipment control method and system based on a DCS system. BACKGROUND

[0002] As an important chemical basic material, carbon black is widely used in rubber, plastic, ink and coating industries. Its production process usually adopts furnace process, generates carbon black particles under high temperature combustion and pyrolysis conditions, and forms products with target particle size distribution through quenching, collection and subsequent granulation processes. In the existing carbon black production process, the particle size distribution is affected by adjusting the quenching water quantity or changing the nozzle position.

[0003] The prior art has the following disadvantages:

[0004] Currently, the existing method usually obtains the particle size distribution through laboratory detection or post-analysis, which cannot identify the particle size coarsening trend in the production process in real time, lacks monitoring of the dynamic change of the particle size distribution, and when the particle size coarsening trend occurs in the production process, the particle size fluctuation range increases and the product quality stability decreases. Therefore, a carbon black production equipment control method and system based on a DCS system are proposed.

[0005] The above information disclosed in the background section is only used to strengthen the understanding of the background of the present disclosure, and therefore it can include information that does not constitute prior art known to those of ordinary skill in the art. SUMMARY

[0006] In order to overcome the above-mentioned defects of the prior art, the embodiments of the present application provide a carbon black production equipment control method and system based on a DCS system, which solves the problems proposed in the above background technology by using granulation distribution data analysis, quality score classification and front-end and back-end feature comprehensive regulation mechanism.

[0007] To achieve the above-mentioned purpose, the present application provides the following technical scheme, a carbon black production equipment control method based on a DCS system, comprising the following steps:

[0008] Step S1: In the granulation control process, the granulation particles at the outlet of the granulator are sampled to obtain a granulation particle sample, and the granulation distribution data is detected after the granulation particle sample is vibrated and sieved by a screening machine;

[0009] Step S2: The target particle size interval is called through the quality control database, the particle size quality score is judged in combination with the granulation distribution data, and the uniformity of the granulation particles is classified according to the particle size quality score;

[0010] Step S3: When the uniformity classification result of the granulation particles is coarse, set the sampling time, collect the gas pressure in the carbon black furnace and analyze the pressure rising trend, obtain the equivalence ratio in the current production process, and evaluate the power adjustment feature in combination with the pressure rising trend;

[0011] Step S4: Detect the water inflow of the quenching equipment and the forward distance of the quenching nozzle and the hot peak position of the furnace, analyze the inhibition adjustment feature according to the detection result, and select the adjustment process driving regulation or reaction termination regulation in combination with the power adjustment feature and the inhibition adjustment feature.

[0012] In a preferred embodiment, in step S1, during the granulation control process of carbon black production, a preset sampling period is set, and the granulation particles at the outlet of the granulator are randomly selected as the granulation particle samples during the preset sampling period;

[0013] The granulation particle samples are transported to a screening machine for particle size classification. The screen surface of the screening machine vibrates uniformly, so that the granulation particle samples are dispersed on the screen surface and pass through the screen meshes in turn. Granulation particle samples of different particle sizes fall into screen collection bins of different particle size intervals.

[0014] In a preferred embodiment, in step S1, after screening, the mass of the granulation particle samples in each screen collection bin is counted. The ratio of the mass of the granulation particle samples in the screen collection bin to the total mass of the granulation particle samples is taken as the particle size interval mass proportion.

[0015] Each screen collection bin corresponds to a particle size interval, and the particle size interval is defined by the screen hole sizes of the adjacent two layers of screen meshes.

[0016] In order from small to large according to the particle size interval corresponding to the screen collection bin, the particle size interval mass proportions are arranged in turn to form a particle size distribution proportion set, and the particle size distribution proportion set is taken as the granulation distribution data.

[0017] In a preferred embodiment, in step S2, the target particle size interval is called from the quality control database. The upper limit and the lower limit of the target particle size interval are denoted as the particle size upper limit threshold and the particle size lower limit threshold, respectively.

[0018] In the granulation distribution data, the particle size interval mass proportion of the granulation particle samples with a particle size greater than the particle size upper limit threshold is counted and accumulated to obtain the coarse particle cumulative proportion.

[0019] The particle size interval mass proportion of the granulation particle samples with a particle size between the particle size upper limit threshold and the particle size lower limit threshold is accumulated to obtain the target granulation proportion.

[0020] In a preferred embodiment, in step S2, the particle size mass score is calculated according to the coarse particle cumulative proportion and the target granulation proportion.

[0021] If the particle size quality score is greater than the preset quality score threshold, it is determined that the classification result of the granulation particle uniformity is in a non-coarsening state;

[0022] On the contrary, it is determined that the classification result of the granulation particle uniformity is in a coarsening state.

[0023] In a preferred embodiment, in step S3, when the granulation particle uniformity classification result is determined to be in a coarsening state, a fixed sampling time is set, and the static pressure value of the gas inside the carbon black furnace is obtained by the pressure sensor arranged in the carbon black furnace as the gas pressure;

[0024] The gas pressure collected in the sampling time is constructed as a pressure time sequence, and a first-order time derivative operation is performed on the pressure time sequence to obtain a pressure rising trend.

[0025] In a preferred embodiment, in step S3, the ratio of the actual oxygen supply to the carbonaceous fuel to the ratio of the oxygen supply to the carbonaceous fuel under the theoretical complete combustion condition is calculated to obtain the equivalence ratio in the current production process;

[0026] After standardizing the equivalence ratio and the pressure rising trend, a comprehensive calculation is performed in a weighted linear combination manner to obtain the power regulation feature.

[0027] In a preferred embodiment, in step S4, the flow sensor arranged on the quenching device and the water flow volume supplied by the quenching water pump to the nozzle in the water inlet pipeline within the sampling time are detected as the water inlet amount of the quenching device;

[0028] The axial distance of the quenching nozzle jet center relative to the maximum temperature position in the furnace is detected by the position sensor as the forward distance of the quenching nozzle and the hot peak position of the furnace;

[0029] The water inlet amount of the quenching device is inversely normalized to obtain the water inlet amount factor;

[0030] The forward distance of the quenching nozzle and the hot peak position of the furnace is positively normalized to obtain the forward distance factor.

[0031] In a preferred embodiment, in step S4, the water inlet amount factor and the forward distance factor are integrated into the inhibition regulation feature by using the geometric mean method;

[0032] When the power regulation feature is greater than the power regulation threshold and the inhibition regulation feature is less than or equal to the inhibition regulation threshold, the process driving regulation is performed;

[0033] When the power regulation feature is less than or equal to the power regulation threshold and the inhibition regulation feature is greater than the inhibition regulation threshold, the reaction termination regulation is performed;

[0034] When the power adjustment feature is greater than the power adjustment threshold and the inhibition adjustment feature is greater than the inhibition adjustment threshold, the process driving regulation and the reaction termination regulation are simultaneously performed;

[0035] When the power adjustment feature is less than or equal to the power adjustment threshold and the inhibition adjustment feature is less than or equal to the inhibition adjustment threshold, no regulation is performed.

[0036] A carbon black production equipment control system based on a DCS system comprises a particle size detection module, a quality classification module, a power evaluation module and an inhibition regulation module, and the functions of the modules are as follows:

[0037] The particle size detection module is used for sampling the granulation particles at the outlet of the granulator to obtain a granulation particle sample, and detecting the granulation distribution data after the granulation particle sample is vibrated and sieved by a screening machine;

[0038] The quality classification module is used for calling the target particle size interval in the quality control database, calculating the particle size quality score in combination with the granulation distribution data, and classifying the uniformity of the particle size distribution of the granulation particles according to the score result;

[0039] The power evaluation module is used for analyzing the case where the uniformity classification result is a coarsening state, collecting the gas pressure data in the carbon black hearth, analyzing the pressure rising trend, and calculating the power adjustment feature in combination with the equivalence ratio of the current production process;

[0040] The inhibition regulation module is used for detecting the water inlet amount of the quenching equipment and the forward movement distance of the quenching nozzle relative to the hot peak position of the hearth, analyzing the inhibition adjustment feature, comprehensively comparing the power adjustment feature and the inhibition adjustment feature, and selecting to perform the process driving regulation or the reaction termination regulation.

[0041] Technical effects and advantages of the present application:

[0042] In the granulation control process, the present application selects the granulation particles at the outlet of the granulator as the granulation particle sample to be sent into the screening machine for multi-stage screening, obtains the granulation distribution data according to the screening result, calls the target particle size interval through the quality control database, calculates the particle size quality score in combination with the granulation distribution data, classifies the uniformity of the particle size distribution of the granulation particles according to the score, collects the gas pressure data in the carbon black hearth and analyzes the pressure rising trend when the classification result is a coarsening state, obtains the equivalence ratio to evaluate the front-end power adjustment feature, detects the water inlet amount of the quenching equipment and the forward movement distance of the quenching nozzle relative to the hot peak position of the hearth, analyzes the rear-end inhibition adjustment feature, comprehensively compares the two types of features, selects to perform the process driving regulation or the reaction termination regulation, realizes the identification of the particle size coarsening trend in the carbon black granulation process, realizes the real-time identification and targeted regulation of the particle size coarsening trend in the carbon black granulation process, and thus ensures the uniformity of the particle size distribution and improves the product quality stability. BRIEF DESCRIPTION OF DRAWINGS

[0043] Figure 1 A method flow chart of a carbon black production equipment control method based on a DCS system.

[0044] Figure 2 A module schematic diagram of a carbon black production equipment control system based on a DCS system. DETAILED DESCRIPTION

[0045] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of protection of the present application.

[0046] In the granulation control process, the granulation particles at the outlet of the granulator are selected as the granulation particle samples and sent to the screening machine for multi-stage screening, the granulation distribution data are obtained according to the screening results, the target particle size interval is called from the quality control database, the particle size quality score is calculated in combination with the granulation distribution data, and the particle size distribution uniformity of the granulation particles is classified according to the score. When the classification result is coarsening state, the gas pressure data in the carbon black hearth are collected and the pressure rising trend is analyzed, the equivalent ratio is obtained to evaluate the front-end power regulation characteristics, the water inlet quantity of the quenching equipment and the forward distance of the quenching nozzle and the hearth hot peak position are detected, the rear-end inhibition regulation characteristics are analyzed, and the two types of characteristics are comprehensively selected to execute process driving regulation or reaction termination regulation, so that the identification of the particle size coarsening trend of the carbon black granulation process is realized, and the real-time identification and targeted regulation of the particle size coarsening trend of the carbon black granulation process are realized.

[0047] Embodiment 1

[0048] Please refer to Figure 1 A carbon black production equipment control method based on a DCS system, comprising the following steps:

[0049] Step S1: In the granulation control process, the granulation particles at the outlet of the granulator are sampled to obtain granulation particle samples, and the granulation distribution data are detected after the granulation particle samples are vibrated and screened by a screening machine;

[0050] Step S2: The target particle size interval is called from the quality control database, the particle size quality score is generated in combination with the granulation distribution data, and the uniformity of the granulation particles is classified according to the particle size quality score;

[0051] Step S3: When the uniformity classification result of the granulation particles is coarsening state, the sampling time is set, the gas pressure in the carbon black hearth is collected and the pressure rising trend is analyzed, the equivalent ratio in the current production process is obtained, and the power regulation characteristics are evaluated in combination with the pressure rising trend.

[0052] Step S4: detecting the water inflow of the quenching device and the forward distance of the quenching nozzle and the hot peak position of the furnace, analyzing the suppression adjustment characteristics according to the detection results, and selecting the process driving regulation or the reaction termination regulation by comprehensively considering the power adjustment characteristics and the suppression adjustment characteristics.

[0053] The specific implementation is as follows:

[0054] In step S1, during the granulation control process of carbon black production, a preset sampling period is set, and granulation particles at the outlet of the granulator are randomly selected as granulation particle samples during the preset sampling period. To ensure the representativeness of the samples, an automatic sampling device can be used to collect the granulation particles at the outlet of the granulator to obtain the granulation particle samples, and the granulation particle samples are transported to a screening machine for particle size classification.

[0055] For example, the preset sampling period refers to the time period for sampling granulation particles, which can be dynamically set according to the carbon black production batch and the equipment operating state. When the granulator is in a stable operating stage, sampling is performed every 10 minutes.

[0056] It should be explained that the automatic sampling device includes a sampling valve, a sampling pipeline, a quantitative sampling cavity, and a driving execution unit. The granulation particles at the outlet of the granulator are introduced into the quantitative sampling cavity, and a preset volume or mass is completed once to obtain the granulation samples. The screening machine is a device for multi-stage particle size classification of granulation particle samples, which includes multi-stage screens, a vibration driving device, and screen collection bins. The granulation particle samples are gradually screened by the screening machine, so that granulation particles of different particle sizes pass through the corresponding screens and fall into the corresponding screen collection bins.

[0057] The screen surface of the screening machine produces uniform vibration, so that the granulation particle samples are dispersed on the screen surface and pass through the screens one by one, and the granulation particle samples of different particle sizes fall into the screen collection bins of different particle size intervals.

[0058] After screening is completed, the mass of the granulation particle samples in each screen collection bin is counted, and the mass proportion of each screen collection bin corresponding to the particle size interval is calculated. The ratio of the mass of the granulation particle samples in the screen collection bin to the total mass of the granulation particle samples is taken as the particle size interval mass proportion.

[0059] Each screen collection bin corresponds to a particle size interval, which is defined by the mesh size of the adjacent two layers of screens. The mesh size of each layer of screens is the particle size demarcation point. For example, if the mesh size of a screen is 45 μm, the layer of screen is used to separate particles with a particle size greater than 45 μm. A particle sample that falls below the upper layer mesh size and cannot pass through the lower layer finer mesh is collected in the screen collection bin. For example, when the upper layer mesh size is 150 μm and the lower layer mesh size is 106 μm, the screen collection bin corresponds to a particle size interval of [106 μm, 150 μm].

[0060] The particle size distribution proportion set is formed by arranging the mass proportions of each particle size interval in order from small to large according to the particle size intervals corresponding to the screen collection bins. The particle size distribution proportion set is used as the granulation distribution data to reflect the distribution of the granulation particle sample in each particle size interval.

[0061] This step reflects the particle size distribution of the granulation particles in the current carbon black production process by collecting the granulation particle sample and performing multi-stage particle size classification on the sample through the vibrating screen flow. The mass proportions of each particle size interval are calculated and combined to form the granulation distribution data, which provides a reliable data basis for subsequent quality scoring and uniformity classification.

[0062] In step S2, the target particle size interval is retrieved from the quality control database. The upper limit and lower limit of the target particle size interval are denoted as the particle size upper limit threshold and the particle size lower limit threshold, respectively.

[0063] It should be explained that the quality control database refers to a database for storing process benchmarks and historical statistical data related to particle size control in the carbon black production process. In this embodiment, the database is used to provide the target particle size interval corresponding to the current carbon black production process. The target particle size interval refers to the particle size interval used to limit the granulation particle size distribution to the standard range.

[0064] In the granulation distribution data, the mass proportion of the particle size interval with a particle size greater than the particle size upper limit threshold is calculated and accumulated to obtain the coarse particle cumulative proportion.

[0065] The particle size of the granulation particle sample between the particle size upper limit threshold and the particle size lower limit threshold is accumulated to obtain the target granulation proportion.

[0066] The particle size quality score is calculated based on the coarse particle cumulative proportion and the target granulation proportion: wherein, is the target granulation proportion, is the coarse particle cumulative proportion, is the particle size quality score.

[0067] The greater the value of the cumulative coarse particle proportion, the higher the proportion of granulation particles falling above the upper threshold of the target particle size interval, the more obvious the particle size distribution of the current granulation particle sample deviates to the coarse particle end, the more serious the deviation from the target particle size interval, and the smaller the particle size quality score.

[0068] The preset quality score threshold is compared with the particle size quality score to evaluate the uniformity of the granulation particles:

[0069] If the particle size quality score is greater than the preset quality score threshold, the classification result of the uniformity of the granulation particles is determined to be in a non-coarsening state.

[0070] If the particle size quality score is less than or equal to the preset quality score threshold, the classification result of the uniformity of the granulation particles is determined to be in a coarsening state.

[0071] It should be explained that the preset quality score threshold refers to a reference value for determining whether the particle size distribution of the granulation particles is in a coarsening state, which is pre-set by the quality control database or historical statistical data, for example, the median minus one median absolute deviation of the particle size quality score of the qualified batch is taken as the preset quality score threshold.

[0072] After obtaining the granulation distribution data, the target particle size interval in the quality control database is retrieved, the particle size quality score is calculated, and the score result is compared with the preset quality score threshold to determine the coarsening state of the granulation particles, quantify the deviation degree of the particle size distribution from the target particle size interval, and improve the monitoring accuracy and response speed of the carbon black granulation process.

[0073] In step S3, when the classification result of the uniformity of the granulation particles is determined to be in a coarsening state, a fixed sampling time is set, and the static pressure value of the gas in the carbon black furnace is obtained by the pressure sensor arranged in the carbon black furnace as the gas pressure, reflecting the gas generation rate and flow intensity in the reaction process in the furnace;

[0074] It should be noted that the fixed sampling time refers to the time interval set when collecting the output signal of the pressure sensor in the carbon black production process, and is divided into multiple periodic sampling times, which is set to satisfy the Nyquist sampling law, that is, the sampling frequency should be greater than twice the highest change frequency of the pressure signal, so as to ensure that the sampling data can be used for subsequent time derivative operation and pressure rising trend analysis; the pressure sensor is a detection element installed in the carbon black production furnace or its connected pipeline, which is used to output the static pressure value of the gas in the furnace.

[0075] The gas pressure collected in the sampling time is constructed as a pressure time sequence, and a first-order time derivative operation is performed on the pressure time sequence to obtain the pressure rising trend:

[0076] ;

[0077] wherein, is a pressure rise tendency, is a gas pressure at a sampling time , and is a first derivative of the gas pressure with respect to time.

[0078] The pressure rise tendency is used to characterize the rate of change of the furnace gas pressure, reflecting the strength of the reaction drive inside the furnace. The greater the pressure rise tendency, the faster the furnace gas pressure increases with time, and the more material supply and energy conditions the downstream generated prilling particles obtain in the growth process, thereby increasing the prilling particle size and intensifying the coarsening trend. Conversely, the smaller the pressure rise tendency or even approaching zero, the more gentle the change in the furnace gas pressure, the weaker the reaction drive, and the lower the impact on the coarsening of the particle size.

[0079] The actual oxygen supply to carbon fuel ratio in the current production process in the carbon black furnace is measured in real time by a gas flow meter and a component analyzer, the ratio of the actual oxygen supply to carbon fuel ratio to the oxygen supply to carbon fuel ratio under the theoretical complete combustion condition is calculated, and the equivalence ratio in the current production process is obtained;

[0080] wherein, the oxygen supply to carbon fuel ratio under the theoretical complete combustion condition is a theoretical ratio calculated based on the complete combustion stoichiometric ratio;

[0081] The equivalence ratio reflects the deviation between the oxygen-fuel ratio under the current reaction condition and the theoretical combustion condition. If the equivalence ratio is greater than 1, it indicates that the reaction system is in an oxygen excess supply state, the oxidation reaction drive is enhanced, the combustion rate is accelerated, the particle growth dynamics of the carbon black product is stronger, and thus the average particle size of the prilling material increases, and the coarsening trend is more significant. If the equivalence ratio is less than 1, it indicates that the reaction system is in a fuel excess state, the oxygen supply is insufficient, and the prilling coarsening trend is weakened.

[0082] It should be noted that the gas flow meter is a detection device installed in the gas inlet pipeline or fuel gas supply pipeline of the carbon black production system, which functions to measure the gas volume flow or mass flow through the pipeline in real time; the component analyzer is a detection device arranged on the gas sampling pipeline in the carbon black production process, which functions to quantitatively analyze the gas components entering the furnace, and is used to provide actual ratio data of oxygen and carbon fuel, which is combined with the measurement results of the gas flow meter to calculate the equivalence ratio.

[0083] After standardizing the equivalence ratio and the pressure rise tendency, the dynamic adjustment feature is calculated by weighted linear combination, and the calculation formula is as follows:

[0084] ;

[0085] wherein, As a dynamic regulation characteristic, This is the standardized value of the equivalence ratio. This is the value standardized by the upward trend of pressure. and These are the preset weighting coefficients.

[0086] The larger the dynamic regulation characteristic, the stronger the reaction driving force under the combined effect of oxygen supply status and pressure change rate, and the more significant the coarsening trend of granulated particles; the smaller the dynamic regulation characteristic, the less the reaction driving force, and the weaker the effect on the coarsening of granulated particles.

[0087] It should be noted that standardization refers to the process of mapping raw data of different physical quantities or different dimensions to a uniform dimension, uniform numerical range or uniform statistical distribution through specific mathematical transformations. Standardization methods include, but are not limited to, standard linear transformation based on interval scaling, Z-Score standardization based on statistics, or normalization method based on nonlinear mapping functions. The application methods of standardization will not be elaborated here. The weighting coefficient is used to characterize the relative contribution of the equivalence ratio and the pressure rise trend to the reaction driving characteristics in the comprehensive calculation of dynamic regulation characteristics. The equivalence ratio and pressure rise trend are collected under different working conditions, and the changes in the coarsening trend of granulated particles are recorded. The sensitivity to the coarsening trend is determined by analysis of variance, and the sensitivity is used as the corresponding weighting coefficient.

[0088] In step S4, the water inlet flow rate of the quenching equipment and the forward displacement distance between the quenching nozzle and the furnace heat peak position are detected.

[0089] It should be noted that a quenching device is a process unit located at the rear end of a carbon black production furnace. Its function is to rapidly cool down and terminate the reaction inside the furnace by spraying water or other cooling media onto the high-temperature reaction gas.

[0090] The flow rate of the quenching equipment is determined by the flow sensor installed on the quenching equipment and the volume of water supplied by the quenching pump to the nozzle in the inlet pipe during the sampling time.

[0091] The axial distance between the spray center of the quench nozzle and the position of the maximum temperature in the furnace is detected by the position sensor, and it is used as the forward displacement distance between the quench nozzle and the position of the heat peak in the furnace.

[0092] It should be noted that a flow sensor is a detection element installed in the inlet water pipe of a quenching device to detect the volume of water flowing through the pipe in real time; a position sensor is a detection element installed on the moving mechanism of the quenching nozzle to measure the axial distance of the nozzle spray center relative to the position of the furnace heat peak.

[0093] After obtaining the water inlet quantity of the quenching device and the forward distance of the quenching nozzle and the hot peak position of the furnace, the water inlet quantity of the quenching device is inversely normalized to obtain a water inlet quantity factor, and the forward distance of the quenching nozzle and the hot peak position of the furnace is normalized to obtain a forward distance factor, and the calculation formula is as follows:

[0094]

[0095] is the water inlet quantity factor, is the forward distance factor, is the water inlet quantity of the quenching device, is the forward distance of the quenching nozzle and the hot peak position of the furnace, and are the maximum and minimum water inlet quantities of the quenching device within the process allowable range, and are the maximum and minimum forward distances within the adjustable range of the quenching nozzle position.

[0096] It should be noted that the maximum and minimum water inlet quantities and the maximum and minimum forward distances are derived from the process allowable operating range set by the quenching device manufacturer; during the normalization process, the water inlet quantity of the quenching device is inversely normalized to ensure consistency in numerical value and physical meaning, i.e., the greater the water inlet quantity, the smaller the water inlet quantity factor, and the stronger the inhibition effect; the smaller the water inlet quantity, the greater the water inlet quantity factor, and the weaker the inhibition effect.

[0097] The water inlet quantity factor and the forward distance factor are combined into an inhibition adjustment characteristic using the geometric mean method, and the specific calculation formula is as follows:

[0098]

[0099] is the inhibition adjustment characteristic, is the water inlet quantity factor, is the forward distance factor.

[0100] It should be noted that the geometric mean method is a mathematical processing method used to combine two or more parameters with different dimensions or numerical ranges to obtain a single characteristic value.

[0101] The smaller the water inlet quantity of the quenching device, the further the quenching nozzle is located, the lower the spray pressure, and the greater the inhibition adjustment characteristic, indicating that the inhibition effect of the quenching device on the furnace reaction is weaker, i.e., the reaction termination is delayed and the particle size of the granulation particles is coarse; the greater the water inlet quantity of the quenching device, the closer the quenching nozzle is located, the higher the spray pressure, and the smaller the inhibition adjustment characteristic, indicating that the inhibition effect is sufficient and the constraint on the particle coarsening trend is more significant.

[0102] ​​​​The power regulation feature and the suppression regulation feature are compared with the power regulation threshold and the suppression regulation threshold respectively to determine the selection of the control strategy:

[0103] When the power regulation feature is greater than the power regulation threshold and the suppression regulation feature is less than or equal to the suppression regulation threshold, it is determined that the front-end reaction driving force is too strong and the rear-end suppression effect is normal, and a process driving regulation is performed to reduce the reaction driving force in the furnace by adjusting the fuel supply amount, oxygen flow or other front-end process parameters, thereby slowing down the coarsening trend of the granulated particles;

[0104] When the power regulation feature is less than or equal to the power regulation threshold and the suppression regulation feature is greater than the suppression regulation threshold, it is determined that the rear-end reaction suppression is insufficient and the front-end driving force is normal, and a reaction termination regulation is performed to strengthen the quenching effect by increasing the amount of quenching water, moving the nozzle position forward or increasing the spray pressure, so that the reaction is terminated in time and the particles are prevented from continuing to coarsen;

[0105] When the power regulation feature is greater than the power regulation threshold and the suppression regulation feature is greater than the suppression regulation threshold, it indicates that the front-end driving force is too strong and the rear-end suppression effect is insufficient, and therefore the process driving regulation and the reaction termination regulation are simultaneously performed to coordinate the adjustment of the front-end reaction intensity and the rear-end quenching suppression effect, so as to realize the dynamic optimization of the particle size of the carbon black granulated particles;

[0106] When the power regulation feature is less than or equal to the power regulation threshold and the suppression regulation feature is less than or equal to the suppression regulation threshold, it indicates that the front-end reaction driving force is in a normal range, and at the same time the rear-end suppression effect is sufficient and effective, and the reaction process is running in a stable interval, and the coarsening trend of the particles is not significant, so no active regulation needs to be performed, and only the current process parameters are maintained unchanged to avoid unnecessary fluctuations caused by excessive intervention.

[0107] It should be noted that the power regulation threshold and the suppression regulation threshold are respectively used to determine whether the front-end driving force and the rear-end suppression effect are in a normal range, the power regulation threshold is obtained by statistical analysis of the mean and standard deviation of the furnace gas equivalence ratio and the pressure rise rate under typical operating conditions of the carbon black production device, and an appropriate upper limit value is set in combination with the process requirements of the product particle size distribution; the suppression regulation threshold is determined by the normalized geometric mean result of the boundary conditions of the beginning of the coarsening of the granulated particles in combination with the factory set parameters of the quenching equipment, including the maximum allowed water inlet and the maximum forward distance of the nozzle.

[0108] Example 2, a carbon black production equipment control system based on a DCS system, as shown in Figure 2 for implementing a carbon black production equipment control method based on a DCS system, including a particle size detection module, a quality classification module, a power evaluation module and a suppression regulation module, and the functions of each module are as follows:

[0109] The particle size detection module is used to sample the granulation particles at the outlet of the granulator to obtain a granulation particle sample, and detect the granulation distribution data after the granulation particle sample is vibrated and sieved by a screening machine;

[0110] The quality classification module is used to call the target particle size interval in the quality control database, calculate the particle size quality score in combination with the granulation distribution data, and classify the uniformity of the particle size distribution of the granulation particles according to the score result;

[0111] The power evaluation module is used to analyze the case where the uniformity classification result is the coarsening state, collect the gas pressure data in the carbon black hearth, analyze the pressure rising trend, and calculate the power adjustment feature in combination with the equivalence ratio of the current production process.

[0112] The inhibition regulation module is used to detect the water inlet amount of the quenching equipment and the forward distance of the quenching nozzle relative to the hot peak position of the hearth, analyze the inhibition adjustment feature, and comprehensively compare the power adjustment feature to select the process driving regulation or the reaction termination regulation to be executed.

[0113] The above formulas are all dimensionless values, and the formulas are obtained by software simulation of a large amount of data to obtain a formula closest to the actual situation, and the preset parameters in the formula are set by a person skilled in the art according to the actual situation.

[0114] Finally, it should be noted that in this document, relational terms such as first and second and the like can only be used to distinguish one entity or action from another entity or action, without necessarily requiring or implying any such actual relationship or order between such entities or actions.

[0115] Moreover, the terms "comprising", "including", or any other variant thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements recited, but can also include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without more limitations, an element defined by the phrase "comprising a" does not exclude the existence of additional identical elements in the process, method, article, or apparatus that includes the element.

[0116] In this document, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. It will be further understood that the terms "comprises," "comprising," "includes," and "including," or the like, when used in this specification, specify the presence of stated features, integers, steps, operations, components, parts, or the like, but do not preclude the presence or addition of one or more other features, integers, steps, operations, components, parts, or the like.

[0117] Various embodiments described in this specification are described with reference to particular implementations. Embodiments can be practiced with other systems, components, materials, acts, operations, and steps than those described and / or shown in this specification, and not solely with the particular implementations described in this specification. The terms "comprise," "comprising," "include," "including," and "includes" as well as "has," "having," and "have" or the like are used synonymously to denote or describe the presence of stated features, integers, steps, operations, components, parts, or the like, but do not preclude the presence or addition of one or more other features, integers, steps, operations, components, parts, or the like.

[0118] The above description of disclosed embodiments is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. While specific embodiments of, and examples for, the application are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the application, as those skilled in the relevant art will recognize. The teachings of the application provided herein can be applied to other embodiments and examples, without departing from the spirit and scope of the application. Accordingly, the application is not to be considered as limited to the foregoing embodiments and examples, and the application is defined by the following claims and their equivalents.

Claims

1. A control method for carbon black production equipment based on a DCS system, characterized in that: Includes the following steps: Step S1: During the granulation control process, the granulated particles at the outlet of the granulator are sampled to obtain granulated particle samples. The granulated particle samples are then vibrated and sieved by a screening machine to detect the granulation distribution data. Step S2: Retrieve the target particle size range from the quality control database, combine it with the granulation distribution data to generate a particle size quality score, and classify the uniformity of the granulated particles based on the particle size quality score. Step S3: When the uniformity classification result of the granulated particles is coarse, set the sampling time, collect the gas pressure in the carbon black furnace and analyze the pressure rise trend, obtain the equivalence ratio in the current production process, and evaluate the power regulation characteristics in combination with the pressure rise trend. Step S4: Detect the water inlet flow rate of the quenching equipment and the forward movement distance between the quenching nozzle and the furnace heat peak position. Analyze the inhibition and regulation characteristics based on the detection results, and select the adjustment process drive regulation or reaction termination regulation by combining the dynamic regulation characteristics and the inhibition and regulation characteristics. In step S4, the volume of water supplied by the quench water pump to the nozzle in the inlet water pipeline during the sampling time is measured by a flow sensor arranged on the quench equipment and taken as the inlet water volume of the quench equipment. The axial distance between the spray center of the quench nozzle and the position of the maximum temperature in the furnace is detected by the position sensor, and it is used as the forward displacement distance between the quench nozzle and the position of the heat peak in the furnace. The inflow rate of the quenching equipment is reverse normalized to obtain the inflow rate factor. The forward displacement factor is obtained by positively normalizing the forward displacement distance between the quench nozzle and the furnace hot peak position; In step S4, the influent flow factor and the forward movement distance factor are combined into a suppression and regulation characteristic using the geometric mean method; When the dynamic regulation characteristic is greater than the dynamic regulation threshold and the inhibition regulation characteristic is less than or equal to the inhibition regulation threshold, the execution process drives the regulation. When the dynamic regulation characteristic is less than or equal to the dynamic regulation threshold and the inhibition regulation characteristic is greater than the inhibition regulation threshold, the response termination regulation is executed. When the dynamic regulation characteristic is greater than the dynamic regulation threshold and the inhibition regulation characteristic is greater than the inhibition regulation threshold, process-driven regulation and response termination regulation are executed simultaneously. When the dynamic regulation characteristic is less than or equal to the dynamic regulation threshold and the inhibition regulation characteristic is less than or equal to the inhibition regulation threshold, no regulation is performed.

2. The method for controlling carbon black production equipment based on a DCS system according to claim 1, characterized in that: In step S1, during the granulation control process of carbon black production, a sampling period is preset, and granulated particles at the outlet of the granulator are randomly selected as granulated particle samples during the preset sampling period. The granulated particle samples are transported to a sieving machine for particle size classification. The sieve surface of the sieving machine vibrates uniformly, causing the granulated particle samples to disperse on the sieve surface and pass through the sieve in sequence. Granulated particle samples of different sizes fall into the sieve collection bins of different particle size ranges.

3. The method for controlling carbon black production equipment based on a DCS system according to claim 2, characterized in that: In step S1, after sieving, the mass of the granulated particle samples in each sieve collection chamber is counted, and the ratio of the mass of the granulated particle samples in the sieve collection chamber to the total mass of the granulated particle samples is taken as the mass ratio of the particle size range. Each screen collection chamber corresponds to a particle size range, which is defined by the sieve aperture size of the two adjacent screen layers. According to the particle size range corresponding to the screen collection bin, the mass percentage of each particle size range is arranged in ascending order to form a particle size distribution percentage set, which is used as the granulation distribution data.

4. The method for controlling carbon black production equipment based on a DCS system according to claim 3, characterized in that: In step S2, the target particle size range is retrieved from the quality control database. The upper and lower limits of the target particle size range are recorded as the upper limit threshold and the lower limit threshold, respectively. In the granulation distribution data, the mass percentage of the particle size range with a particle size greater than the upper limit threshold of the particle size is statistically analyzed, and these percentages are accumulated to obtain the cumulative percentage of coarse particles. The target granulation ratio is obtained by summing the mass percentages of granulated particle samples between the upper and lower particle size thresholds.

5. The method for controlling carbon black production equipment based on a DCS system according to claim 4, characterized in that: In step S2, the particle size quality score is calculated based on the cumulative proportion of coarse particles and the target granulation proportion; If the particle size quality score is greater than the preset quality score threshold, the classification result of the granulation particle uniformity is determined to be a non-coarsened state. Conversely, the classification result for the uniformity of granulated particles is a coarsened state.

6. The method for controlling carbon black production equipment based on a DCS system according to claim 1, characterized in that: In step S3, when the granulation particle uniformity classification result is determined to be in a coarsened state, a fixed sampling time is set, and the static pressure value of the gas inside the carbon black furnace is obtained by a pressure sensor arranged in the carbon black furnace as the gas pressure. The gas pressure collected during the sampling period is constructed into a pressure time series. The first time derivative of the pressure time series is calculated to obtain the pressure upward trend.

7. The method for controlling carbon black production equipment based on a DCS system according to claim 6, characterized in that: In step S3, the ratio of actual oxygen supply to carbonaceous fuel is calculated to the ratio of oxygen supply to carbonaceous fuel under theoretical complete combustion conditions, so as to obtain the equivalence ratio in the current production process. After standardizing the equivalence ratio and the upward trend of pressure, the dynamic regulation characteristics are obtained by comprehensive calculation using a weighted linear combination method.

8. A control system for carbon black production equipment based on a DCS system, used to implement the control method for carbon black production equipment based on a DCS system as described in any one of claims 1-7, characterized in that: It includes a particle size detection module, a quality classification module, a kinetic assessment module, and an inhibition control module. The functions of each module are as follows: The particle size detection module is used to sample the granulated particles at the outlet of the granulator to obtain granulated particle samples. After the granulated particle samples are vibrated and sieved by a screening machine, the granulation distribution data is detected. The quality classification module is used to call the target particle size range in the quality control database, calculate the particle size quality score by combining it with the granulation distribution data, and classify the uniformity of the particle size distribution based on the score results. The power assessment module is used to analyze cases where the uniformity classification result is coarsened. It collects gas pressure data in the carbon black furnace, analyzes the pressure rise trend, and calculates the power regulation characteristics in combination with the equivalence ratio of the current production process. The suppression and control module is used to detect the water inlet flow of the quenching equipment and the forward movement distance of the quenching nozzle relative to the furnace heat peak position, analyze the suppression and control characteristics, compare them with the dynamic control characteristics, and select to execute process-driven control or reaction termination control.

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