A quick cooling and safe door opening control method for a carbonization furnace

Abstract

The application provides a quick cooling and safe door opening control method of a carbonization furnace, comprising the following steps: S1, monitoring a carbonization process program in real time, and when the carbonization process program completes a high-temperature reaction stage, a control system starts a high-flow circulation mode of inert gas in the furnace to perform a cooling operation; S2, monitoring a furnace temperature in real time, and when the furnace temperature reaches a preset furnace opening temperature threshold, a furnace opening operation signal is generated; S3, when the furnace opening operation signal is received, the furnace temperature and the furnace pressure are verified in safety, and when a safety verification condition is reached, a furnace opening operation is performed; and the problems of low production efficiency and high thermal shock risk of a traditional natural cooling mode are effectively solved.

Description

Technical Field

[0001] This invention relates to the field of rapid cooling and safe door opening control technology for carbonization furnaces, and particularly to a method for rapid cooling and safe door opening control of carbonization furnaces. Background Technology

[0002] Currently, in traditional PI carbonization processes, after the process is completed, the furnace body usually needs to cool naturally to near room temperature (typically <100°C) before the furnace opening operation can be performed. However, this operation method has the following significant drawbacks:

[0003] 1. Low production efficiency: The natural cooling process is lengthy, which seriously consumes valuable equipment production time and becomes a bottleneck in the entire production process.

[0004] 2. Thermal shock risk: If the furnace is opened in advance due to urgent production needs, the high temperature heat wave inside the furnace will rush out instantly, posing a serious safety threat to the operators. It may also cause irreversible thermal damage to the furnace and inner liner materials due to the violent alternation of hot and cold, shortening the equipment life.

[0005] Therefore, in order to overcome the above-mentioned technical problems, the present invention provides a method for rapid cooling and safe door opening control of a carbonization furnace. Summary of the Invention

[0006] This invention provides a rapid cooling and safe door opening control method for a carbonization furnace. By actively initiating high-flow-rate circulating cooling after the carbonization process, the waiting time is significantly reduced from 90 minutes to within 50 minutes, significantly overcoming production bottlenecks and improving equipment utilization. Furthermore, an opening signal triggering mechanism based on real-time temperature monitoring and dual safety verification conditions including temperature and pressure are established, constructing multiple safety defenses to completely avoid heat wave damage and equipment thermal damage caused by premature door opening. Simultaneously, the cooling and door opening process is optimized and accelerated while ensuring safety. Through the three-step coordinated control of program monitoring, temperature triggering, and safety verification, the problem of low production efficiency and high thermal shock risk associated with traditional natural cooling methods is effectively solved.

[0007] A method for rapid cooling and safe door opening control of a carbonization furnace, comprising:

[0008] S1: Real-time monitoring of the carbonization process, and when the high-temperature reaction stage of the carbonization process is completed, the control system starts the high-flow circulation mode of the inert gas in the furnace to perform cooling operation.

[0009] S2: Real-time monitoring of furnace temperature, and when the furnace temperature reaches the preset furnace safe opening temperature threshold, generating a furnace opening operation signal;

[0010] S3: When a furnace opening operation signal is received, the furnace temperature and pressure are verified for safety. When the safety verification conditions are met, the furnace opening operation is executed.

[0011] Preferably, a method for rapid cooling and safe door opening control of a carbonization furnace, in step S1, involves real-time monitoring of the carbonization process, including:

[0012] The execution steps of the carbonization process are obtained, and a program step pointer is constructed in the control terminal. The execution steps of the carbonization process are tracked in real time according to the program step pointer.

[0013] The system determines whether the high-temperature reaction stage has been reached based on the tracking results, and when the high-temperature reaction stage is reached, it monitors the duration of the high-temperature reaction stage in real time based on a preset timer.

[0014] When the duration reaches the preset duration threshold and the tracking results indicate that the temperature is decreasing, the high-temperature reaction phase is considered to have ended.

[0015] Preferably, in a method for rapid cooling and safe door opening control of a carbonization furnace, in step S1, the inert gas inside the furnace is nitrogen.

[0016] Preferably, a rapid cooling and safe door opening control method for a carbonization furnace includes the following steps: After the high-temperature reaction stage of the carbonization process is completed, the control system initiates a high-flow-rate circulation mode of inert gas inside the furnace for cooling operation, comprising:

[0017] When the carbonization process completes the high-temperature reaction stage, an alert command is triggered, and when the control system receives the alert command, a start command is generated.

[0018] The high-flow circulation mode of the inert gas inside the furnace is controlled according to the start-up command;

[0019] The cooling operation inside the furnace is controlled by the high-flow circulation mode of the inert gas inside the furnace.

[0020] Preferably, a method for rapid cooling and safe door opening control of a carbonization furnace, which controls the cooling operation inside the furnace based on a high-flow circulation mode of inert gas inside the furnace, includes:

[0021] Collect temperature data from multiple temperature measurement points at different time points in the furnace after the high-temperature reaction stage of the carbonization process is completed. Extract the maximum temperature value from the temperature data of multiple temperature measurement points at each time point and calculate the average temperature value of multiple temperature measurement points.

[0022] Compare the maximum temperature value at each time point with the average temperature data;

[0023] When the maximum temperature value is less than or equal to the average temperature data, the average temperature value is used as the real-time temperature value at the corresponding time point in the furnace; when the maximum temperature value is greater than the average temperature data, the maximum temperature data is used as the real-time temperature value at the corresponding time point in the furnace.

[0024] Obtain the real-time temperature value change curve over time, and obtain the slope of the curve. Then, determine the rate of temperature drop in the furnace after the high-temperature reaction stage of the carbonization process is completed based on the curve slope.

[0025] The furnace body structural parameters are obtained and a dynamic heat balance equation is constructed based on the real-time temperature value and the temperature drop rate. The real-time heat load of the furnace body is calculated based on the dynamic heat balance equation.

[0026] The system obtains the cooling rate requirement input by the user to the control terminal, dynamically determines the required inert gas flow rate value based on the real-time heat load and cooling rate requirement, and generates a dynamic valve opening control command based on the inert gas flow rate value.

[0027] The opening degree of the inert gas supply valve is controlled and adjusted according to the dynamic valve opening control command.

[0028] Preferably, a method for rapid cooling and safe door opening control of a carbonization furnace dynamically determines the required inert gas flow rate based on real-time heat load and cooling rate requirements, including:

[0029] Obtain the real-time change value of heat load, and determine the actual rate of decrease of heat load based on the real-time change value of heat load;

[0030] The expected value of the rate of decrease in heat load is determined based on the cooling rate requirement;

[0031] Compare the actual rate of decrease of heat load with the expected rate of decrease of heat load;

[0032] When the actual rate of decrease of heat load is lower than the expected rate of decrease of heat load, the system is determined to have insufficient heat dissipation capacity. At the same time, a preset positive correction amount is automatically generated, and the current inert gas flow rate is increased according to the preset positive correction amount.

[0033] When the actual rate of decrease of heat load is higher than the expected rate of decrease of heat load, it is determined that there is a risk of overcooling in the system. At the same time, a preset negative correction amount is automatically generated, and the current inert gas flow rate is reduced according to the negative correction amount.

[0034] When the actual rate of decrease of the heat load is equal to the expected rate of decrease of the heat load, the system is considered to be in a stable heat dissipation state, and the current inert gas flow rate is maintained.

[0035] Preferably, in a rapid cooling and safe door opening control method for a carbonization furnace, in step S2, the furnace temperature is monitored in real time, and when the furnace temperature reaches a preset safe furnace opening temperature threshold, a furnace opening operation signal is generated, including:

[0036] Multiple key areas inside the furnace are acquired, and multiple temperature sensors are deployed in each key area. At the same time, a distributed temperature monitoring network is constructed based on the deployment results.

[0037] The distributed temperature monitoring network monitors the real-time temperature data from multiple temperature sensors in each key area. At the same time, it calculates the average temperature value corresponding to each key area based on the real-time temperature data collected by multiple temperature sensors in each key area.

[0038] Obtain the preset weight values ​​for each key area, and calculate the weighted average temperature inside the furnace based on the preset weight values ​​and the average temperature values ​​corresponding to each key area.

[0039] The weighted average temperature inside the furnace is used as the effective opening temperature, and the target change curve of the effective opening temperature over time is continuously recorded.

[0040] The target change curve is divided into multiple sub-target curve segments according to a preset time period, and the target slope of each sub-target curve segment is calculated. At the same time, the average slope of the target slope in multiple sub-target curve segments is calculated, and the downward trend of the target change curve is predicted based on the average slope. Meanwhile, the expected effective opening temperature for future time intervals is predicted based on the current real-time effective opening temperature and the downward trend.

[0041] A furnace opening operation signal is generated when the current real-time effective opening temperature is equal to or less than the furnace safe opening temperature threshold, and the expected effective opening temperature in the predicted future time interval will not rebound to exceed the threshold.

[0042] Preferably, a method for rapid cooling and safe door opening control of a carbonization furnace involves acquiring data from multiple key areas within the furnace chamber, arranging multiple temperature sensors in each key area, and constructing a distributed temperature monitoring network based on the arrangement results. This includes:

[0043] The functional characteristics of each key area in the furnace are obtained, and the highest priority monitoring point is determined based on the functional characteristics. At the same time, the spatial distribution plane corresponding to the highest priority monitoring point is obtained, and temperature sensors are symmetrically and evenly distributed above, below or to the left and right of the highest priority monitoring point according to the preset interval.

[0044] After the deployment is completed, multiple key areas inside the furnace and the temperature sensors deployed in each key area are simulated in the computer. At the same time, the simulation is run to determine the temperature change curve of each temperature sensor in each key area.

[0045] Compare the temperature change curves of each temperature sensor;

[0046] If there are n temperature change curves in the comparison results with an overlap rate greater than a preset overlap rate threshold, then the monitoring points corresponding to the n temperature change curves will be merged. ;

[0047] The final locations of the temperature sensors are determined based on the merged results, and corresponding temperature sensors are deployed in each key area according to the final locations.

[0048] Based on the temperature sensors in each key area, sensor monitoring nodes corresponding to each key area are constructed. At the same time, a comprehensive management node is constructed to associate the sensor monitoring nodes corresponding to each key area, thereby generating a distributed temperature monitoring network.

[0049] Preferably, in a rapid cooling and safe door opening control method for a carbonization furnace, in S3, the safety verification conditions include: the furnace temperature drops to the preset furnace safe opening temperature threshold, and the furnace pressure is in a slightly positive pressure or normal pressure state.

[0050] Preferably, a rapid cooling and safe door opening control method for a carbonization furnace includes: in step S3, when the safety verification conditions are not met, an alarm command is generated, and an alarm operation is performed according to the alarm command. At the same time, the real-time temperature status and pressure status inside the furnace are fed back to the user's monitoring terminal.

[0051] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0052] By proactively initiating high-flow-rate circulating cooling after the carbonization process, the waiting time was significantly reduced from 90 minutes to within 50 minutes, breaking through production bottlenecks and improving equipment utilization. Furthermore, a triggering mechanism based on real-time temperature monitoring and dual safety verification conditions including temperature and pressure were established, constructing multiple safety defenses to completely avoid heat wave damage and equipment thermal damage caused by premature door opening. Simultaneously, the cooling and door opening process was optimized and accelerated while ensuring safety. Through the three-step coordinated control of program monitoring, temperature triggering, and safety verification, the problems of low production efficiency and high thermal shock risk associated with traditional natural cooling methods were effectively solved.

[0053] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in this application.

[0054] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0055] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0056] Figure 1 This is a flowchart of a rapid cooling and safe door opening control method for a carbonization furnace according to an embodiment of the present invention;

[0057] Figure 2 This is a flowchart of step S1 in a rapid cooling and safe door opening control method for a carbonization furnace according to an embodiment of the present invention;

[0058] Figure 3 This is a diagram showing the cooling curve of the furnace without an opening in an embodiment of the present invention;

[0059] Figure 4 This is a graph showing the temperature drop curve of the furnace opening in an embodiment of the present invention. Detailed Implementation

[0060] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0061] Example 1: This example provides a method for rapid cooling and safe door opening control of a carbonization furnace, such as... Figure 1 As shown, it includes:

[0062] S1: Real-time monitoring of the carbonization process, and when the high-temperature reaction stage of the carbonization process is completed, the control system starts the high-flow circulation mode of the inert gas in the furnace to perform cooling operation.

[0063] S2: Real-time monitoring of furnace temperature, and when the furnace temperature reaches the preset furnace safe opening temperature threshold, generating a furnace opening operation signal;

[0064] S3: When a furnace opening operation signal is received, the furnace temperature and pressure are verified for safety. When the safety verification conditions are met, the furnace opening operation is executed.

[0065] In this embodiment, the inert gas inside the furnace is nitrogen.

[0066] In this embodiment, the safety verification conditions include: the furnace temperature drops to the preset furnace safe opening temperature threshold, and the furnace pressure is in a slightly positive or normal pressure state.

[0067] In this embodiment, when the safety verification conditions are not met, an alarm command is generated, and an alarm operation is executed according to the alarm command. Simultaneously, the real-time temperature and pressure status inside the furnace are fed back to the user's monitoring terminal. The alarm operation can be one or more of light, sound, and vibration; the monitoring terminal refers to a mobile phone, computer, etc., which effectively ensures timely detection of abnormalities in the furnace opening and guarantees the safety of the furnace opening.

[0068] In this embodiment, the carbonization process is a preset PI carbonization process.

[0069] In this embodiment, the high-flow circulation mode refers to the enhanced cooling operation state that is automatically triggered by the control system after the carbonization high-temperature reaction stage, which drives the inert gas (such as nitrogen) to circulate in the furnace at a flow rate significantly higher than that of the conventional process, so as to achieve rapid heat removal.

[0070] In this embodiment, the furnace safety opening temperature threshold refers to a pre-set temperature safety boundary value. When the furnace temperature monitored in real time drops below this value, the system considers that the basic temperature conditions for opening the door have been met from the perspective of thermal shock risk, and can trigger subsequent operation signals.

[0071] In this embodiment, the safety verification conditions refer to a series of safety prerequisites that the system must confirm must be met before performing the furnace opening operation. In this embodiment, it specifically refers to the fact that the two key conditions, "the furnace temperature has indeed dropped to the safe opening temperature threshold" and "the furnace pressure is in a slightly positive or normal pressure state," must be met simultaneously.

[0072] In this embodiment, by actively initiating high-flow-rate circulating cooling after the carbonization process, the waiting time is significantly reduced from 90 minutes to within 50 minutes. A specific comparison chart (i.e., the cooling curve of the furnace without opening) is shown below. Figure 3 As shown, the furnace opening cooling curve is as follows: Figure 4 (As shown).

[0073] The working principle and beneficial effects of the above technical solution are as follows: By actively starting high-flow circulation cooling after the carbonization process, the waiting time is significantly reduced from 90 minutes to within 50 minutes, which significantly breaks through the production bottleneck and improves equipment utilization. Then, an opening signal triggering mechanism based on real-time temperature monitoring and dual safety verification conditions including temperature and pressure are set up to build multiple safety defenses, completely avoiding heat wave damage and equipment thermal damage caused by premature door opening. At the same time, the cooling and door opening process is optimized and accelerated under the premise of ensuring safety. Through the three-step coordinated control of program monitoring, temperature triggering and safety verification, the problems of low production efficiency and high thermal shock risk of traditional natural cooling methods are effectively solved.

[0074] Example 2: Based on Example 1, this example provides a method for rapid cooling and safe door opening control of a carbonization furnace, such as... Figure 2 As shown, in S1, the carbonization process is monitored in real time, including:

[0075] S101: Obtain the execution steps of the carbonization process, construct a program step pointer in the control terminal, and track the execution steps of the carbonization process in real time according to the program step pointer;

[0076] S102: Determine whether the high-temperature reaction stage has been reached based on the tracking results, and when the high-temperature reaction stage is reached, monitor the duration of the high-temperature reaction stage in real time based on a preset timer;

[0077] S103: When the duration reaches the preset duration threshold and the tracking result indicates that the temperature is decreasing, the high-temperature reaction stage is determined to be over.

[0078] In this embodiment, the program step pointer refers to an internal variable or identifier in the control system used to indicate in real time the specific step of the carbonization process currently being executed.

[0079] In this embodiment, the preset timer refers to a timing device or software module with a specific duration set for the high-temperature reaction stage, used to monitor the elapsed time of this stage.

[0080] In this embodiment, the preset duration threshold refers to the minimum time value that is pre-set in the control system, representing the duration of the high-temperature reaction stage, and is used as a time condition for determining whether the stage has ended.

[0081] The working principle and beneficial effects of the above technical solution are as follows: by tracking the process progress in real time through the program step pointer and accurately judging the end point of the high temperature reaction stage by combining the preset timer, the automatic and accurate determination of the carbonization process program status is realized, which effectively avoids the subjective error and lag of traditional manual judgment, provides a reliable basis for the timely start of subsequent rapid cooling operation, and further improves the automation level and timing accuracy of the entire production process.

[0082] Example 3: Based on Example 1, this example provides a method for rapid cooling and safe door opening control of a carbonization furnace. After the high-temperature reaction stage of the carbonization process is completed, the control system starts a high-flow circulation mode of inert gas inside the furnace for cooling operation, including:

[0083] When the carbonization process completes the high-temperature reaction stage, an alert command is triggered, and when the control system receives the alert command, a start command is generated.

[0084] The high-flow circulation mode of the inert gas inside the furnace is controlled according to the start-up command;

[0085] The cooling operation inside the furnace is controlled by the high-flow circulation mode of the inert gas inside the furnace.

[0086] In this embodiment, the reminder instruction refers to a prompt or status change signal generated by the carbonization process program when it determines that the high-temperature reaction stage has ended.

[0087] In this embodiment, the start command refers to the action execution signal generated by the control system in response to the reminder command, which is specifically used to trigger the high-flow loop mode.

[0088] The working principle and beneficial effects of the above technical solution are as follows: by setting step-triggered reminder and start instructions, a clear logical connection is constructed between the judgment of process completion and the execution of cooling operation, which enhances the standardization and reliability of system response, avoids the risk of misoperation, and ensures the timely and accurate start of the rapid cooling process.

[0089] Example 4: Based on Example 3, this example provides a method for rapid cooling and safe door opening control of a carbonization furnace. The method controls the cooling operation inside the furnace based on a high-flow-rate circulation mode of the inert gas, including:

[0090] Collect temperature data from multiple temperature measurement points at different time points in the furnace after the high-temperature reaction stage of the carbonization process is completed. Extract the maximum temperature value from the temperature data of multiple temperature measurement points at each time point and calculate the average temperature value of multiple temperature measurement points.

[0091] Compare the maximum temperature value at each time point with the average temperature data;

[0092] When the maximum temperature value is less than or equal to the average temperature data, the average temperature value is used as the real-time temperature value at the corresponding time point in the furnace; when the maximum temperature value is greater than the average temperature data, the maximum temperature data is used as the real-time temperature value at the corresponding time point in the furnace.

[0093] Obtain the real-time temperature value change curve over time, and obtain the slope of the curve. Then, determine the rate of temperature drop in the furnace after the high-temperature reaction stage of the carbonization process is completed based on the curve slope.

[0094] The furnace body structural parameters are obtained and a dynamic heat balance equation is constructed based on the real-time temperature value and the temperature drop rate. The real-time heat load of the furnace body is calculated based on the dynamic heat balance equation.

[0095] The system obtains the cooling rate requirement input by the user to the control terminal, dynamically determines the required inert gas flow rate value based on the real-time heat load and cooling rate requirement, and generates a dynamic valve opening control command based on the inert gas flow rate value.

[0096] The opening degree of the inert gas supply valve is controlled and adjusted according to the dynamic valve opening control command.

[0097] In this embodiment, the dynamic heat balance equation refers to a mathematical relationship established based on the principle of energy conservation, comprehensively considering factors such as furnace structural parameters, real-time temperature, and temperature change rate, used to calculate the instantaneous heat load of the furnace. This dynamic heat balance equation, based on the principle of energy conservation, describes the heat balance relationship of the furnace during the cooling process. Specifically, the equation is: Power released during furnace cooling = Convective power loss + Radiation power loss, i.e. - ;in, This indicates the specific heat capacity of the furnace lining material; This represents the rate of temperature decrease. Since the rate of temperature decrease is negative, a negative sign is added before the formula. Indicates the convective heat transfer coefficient; Indicates the effective heat exchange area; This indicates the real-time temperature value inside the furnace. This represents the average temperature of the inert gas. This represents the Stefan-Boltzmann constant; Indicates the emissivity of the inner surface of the furnace body; Indicates the quality of the furnace lining; This indicates the ambient air temperature in the workshop where the carbonization furnace is located. Among these, the furnace body structural parameters (specific heat capacity of the furnace lining material) are also relevant. Furnace lining mass m, convective heat transfer coefficient Effective heat exchange area Emissivity of the inner surface of the furnace body All of these are based on equipment design drawings and material property tables that are pre-stored in the control system.

[0098] In this embodiment, the real-time heat load refers to the amount of heat that needs to be removed from the furnace per unit time during the cooling process. It is an instantaneous power value that changes dynamically with the furnace temperature and cooling rate.

[0099] In this embodiment, the inert gas flow rate value refers to the set value of the volume or mass flow rate of the inert gas that needs to be introduced into the furnace, calculated based on the real-time heat load, in order to achieve a specific cooling rate target.

[0100] In this embodiment, the dynamic valve opening control command refers to a real-time control signal generated based on the inert gas flow rate value calculated in real time, used to adjust the opening degree of the gas supply valve.

[0101] The working principle and beneficial effects of the above technical solution are as follows: By using a multi-temperature measurement point data fusion strategy, a representative real-time temperature is dynamically selected based on the comparison between the maximum and average temperature values. This effectively avoids interference from local high-temperature points on the overall operating condition judgment, significantly improving the accuracy and reliability of temperature monitoring. By establishing temperature change curves and slope analysis, the system can accurately capture the actual temperature drop rate inside the furnace, providing key dynamic parameters for subsequent control. Based on the dynamic heat balance equation of the furnace body structural parameters, the real-time temperature and cooling rate are transformed into precise real-time heat load quantification indicators, thereby achieving a scientific assessment of the furnace body's thermal state. On this basis, the real-time heat load is combined with the user-set cooling rate requirements, and the optimal inert gas flow rate is dynamically calculated through advanced control algorithms, generating precise valve opening control commands. Ultimately, precise closed-loop control of the cooling process is achieved. This not only ensures cooling efficiency and effectively shortens the production cycle, but also avoids excessive consumption of inert gas through precise on-demand flow adjustment. Simultaneously, it effectively prevents equipment thermal stress damage caused by excessively rapid cooling, achieving significant comprehensive benefits in ensuring safety, improving efficiency, and reducing energy consumption.

[0102] Example 5: Based on Example 4, this example provides a method for rapid cooling and safe door opening control of a carbonization furnace. The required inert gas flow rate is dynamically determined based on real-time heat load and cooling rate requirements, including:

[0103] Obtain the real-time change value of heat load, and determine the actual rate of decrease of heat load based on the real-time change value of heat load;

[0104] The expected value of the rate of decrease in heat load is determined based on the cooling rate requirement;

[0105] Compare the actual rate of decrease of heat load with the expected rate of decrease of heat load;

[0106] When the actual rate of decrease of heat load is lower than the expected rate of decrease of heat load, the system is determined to have insufficient heat dissipation capacity. At the same time, a preset positive correction amount is automatically generated, and the current inert gas flow rate is increased according to the preset positive correction amount.

[0107] When the actual rate of decrease of heat load is higher than the expected rate of decrease of heat load, it is determined that there is a risk of overcooling in the system. At the same time, a preset negative correction amount is automatically generated, and the current inert gas flow rate is reduced according to the negative correction amount.

[0108] When the actual rate of decrease of the heat load is equal to the expected rate of decrease of the heat load, the system is considered to be in a stable heat dissipation state, and the current inert gas flow rate is maintained.

[0109] In this embodiment, the actual rate of decrease of heat load refers to the amount of real-time reduction of heat load per unit time, reflecting the actual working efficiency of the current cooling system.

[0110] In this embodiment, the expected value of the heat load reduction rate refers to the idealized heat load reduction rate calculated theoretically based on the preset target cooling rate and system characteristics, which serves as the benchmark target for regulation.

[0111] In this embodiment, the preset positive correction amount refers to the incremental adjustment parameter generated according to a predetermined rule to appropriately increase the inert gas flow rate when the system has insufficient heat dissipation; the preset negative correction amount refers to the reduction adjustment parameter generated according to a predetermined rule to appropriately reduce the inert gas flow rate when the system has a risk of overcooling. Both the preset positive correction amount and the preset negative correction amount are determined through previous process adjustments. For example, the positive correction amount is set to 5% of the current flow rate.

[0112] The working principle and beneficial effects of the above technical solution are as follows: By establishing a comparison mechanism between the actual rate of decrease in heat load and the expected value, intelligent closed-loop control of the cooling process is achieved. When the actual rate is lower than expected, the system can automatically increase the cooling intensity to prevent cooling stagnation; when the actual rate is higher than expected, the cooling intensity is intelligently reduced, effectively avoiding the risk of overcooling and gas waste. This method dynamically matches the inert gas flow rate with the real-time thermal state, significantly improving the economy and safety of the process while ensuring cooling efficiency, achieving the best balance between high efficiency and energy saving.

[0113] Example 6: Based on Example 1, this example provides a rapid cooling and safe door opening control method for a carbonization furnace. In S2, the furnace temperature is monitored in real time, and when the furnace temperature reaches a preset furnace safe opening temperature threshold, a furnace opening operation signal is generated, including:

[0114] Multiple key areas inside the furnace are acquired, and multiple temperature sensors are deployed in each key area. At the same time, a distributed temperature monitoring network is constructed based on the deployment results.

[0115] The distributed temperature monitoring network monitors the real-time temperature data from multiple temperature sensors in each key area. At the same time, it calculates the average temperature value corresponding to each key area based on the real-time temperature data collected by multiple temperature sensors in each key area.

[0116] Obtain the preset weight values ​​for each key area, and calculate the weighted average temperature inside the furnace based on the preset weight values ​​and the average temperature values ​​corresponding to each key area.

[0117] The weighted average temperature inside the furnace is used as the effective opening temperature, and the target change curve of the effective opening temperature over time is continuously recorded.

[0118] The target change curve is divided into multiple sub-target curve segments according to a preset time period, and the target slope of each sub-target curve segment is calculated. At the same time, the average slope of the target slope in multiple sub-target curve segments is calculated, and the downward trend of the target change curve is predicted based on the average slope. Meanwhile, the expected effective opening temperature for future time intervals is predicted based on the current real-time effective opening temperature and the downward trend.

[0119] A furnace opening operation signal is generated when the current real-time effective opening temperature is equal to or less than the furnace safe opening temperature threshold, and the expected effective opening temperature in the predicted future time interval will not rebound to exceed the threshold.

[0120] In this embodiment, the distributed temperature monitoring network refers to a system that can comprehensively perceive the spatial temperature distribution by arranging temperature sensors in multiple key areas within the furnace.

[0121] In this embodiment, the weighted average temperature refers to the comprehensive temperature value obtained by assigning different weights to the temperature data of different key areas according to their importance when calculating the overall average temperature of the furnace.

[0122] In this embodiment, the effective opening temperature refers specifically to the comprehensive temperature index obtained after weighted average calculation, which is used to determine the safety of opening the door.

[0123] In this embodiment, the target change curve refers to the data trajectory formed by the change of the effective opening temperature over time.

[0124] In this embodiment, the sub-target curve segment refers to the local curve segment obtained by dividing the target change curve according to a preset time interval.

[0125] In this embodiment, the target slope refers to the rate of temperature change reflected by the sub-target curve segment within that time period.

[0126] In this embodiment, the average slope refers to the arithmetic mean of the target slopes of multiple consecutive sub-target curve segments, which is used to characterize the overall cooling trend.

[0127] In this embodiment, the downward trend prediction refers to the prediction of the temperature trend in the near future based on historical temperature data and its slope.

[0128] In this embodiment, the expected effective opening temperature refers to the effective opening temperature value at a specific future time point predicted based on the current cooling trend.

[0129] In this embodiment, the preset weight values ​​are set by engineers based on the importance of the region in thermal balance. For example, the weight of the central region of the furnace is 0.6, and the weight of the edge region is 0.4.

[0130] The working principle and beneficial effects of the above technical solution are as follows: By constructing a distributed temperature monitoring network and calculating the weighted average temperature of key areas, the random errors and local high-temperature interference that may exist in single-point temperature measurement are effectively avoided, significantly improving the overall and representative nature of the furnace temperature status assessment; by continuously recording the temperature change curve and performing segmented slope analysis, the dynamic characteristics of the cooling trend can be accurately captured, and the future temperature can be scientifically predicted based on historical data; the intelligent decision-making mechanism that combines the current real-time temperature with the predicted trend effectively prevents accidental door opening when the temperature briefly reaches the target but there is a risk of rebound, greatly improving the safety and reliability of door opening decisions; at the same time, under the premise of ensuring safety, a stable and continuously reaching cooling state can be identified earlier, providing a scientific basis for timely early door opening and further shortening the production cycle, achieving simultaneous optimization of safety and production efficiency.

[0131] Example 7: Based on Example 6, this example provides a method for rapid cooling and safe door opening control of a carbonization furnace. It acquires data from multiple key areas within the furnace chamber and deploys multiple temperature sensors in each key area. Simultaneously, a distributed temperature monitoring network is constructed based on the deployment results, including:

[0132] The functional characteristics of each key area in the furnace are obtained, and the highest priority monitoring point is determined based on the functional characteristics. At the same time, the spatial distribution plane corresponding to the highest priority monitoring point is obtained, and temperature sensors are symmetrically and evenly distributed above, below or to the left and right of the highest priority monitoring point according to the preset interval.

[0133] After the deployment is completed, multiple key areas inside the furnace and the temperature sensors deployed in each key area are simulated in the computer. At the same time, the simulation is run to determine the temperature change curve of each temperature sensor in each key area.

[0134] Compare the temperature change curves of each temperature sensor;

[0135] If there are n temperature change curves in the comparison results with an overlap rate greater than a preset overlap rate threshold, then the monitoring points corresponding to the n temperature change curves will be merged. ;

[0136] The final locations of the temperature sensors are determined based on the merged results, and corresponding temperature sensors are deployed in each key area according to the final locations.

[0137] Based on the temperature sensors in each key area, sensor monitoring nodes corresponding to each key area are constructed. At the same time, a comprehensive management node is constructed to associate the sensor monitoring nodes corresponding to each key area, thereby generating a distributed temperature monitoring network.

[0138] In this embodiment, the highest priority monitoring point refers to the location that is most important for safety or process and therefore must be monitored for temperature, based on the functional characteristics of the critical area within the furnace.

[0139] In this embodiment, the spatial distribution plane refers to a two-dimensional planar area in the three-dimensional furnace space, defined for a highest priority monitoring point, used to plan the symmetrical layout of sensors.

[0140] In this embodiment, the temperature change curve overlap rate refers to the degree of similarity between the curves showing the changes in readings of two or more temperature sensors over time during simulation or actual operation.

[0141] In this embodiment, the preset overlap rate threshold refers to the minimum similarity of temperature change curves preset to determine whether multiple monitoring points can be merged. The preset overlap rate threshold is preset based on the uniformity of the temperature field within the furnace, the temperature gradient requirements of key areas, and a comprehensive consideration of system safety and economy; its value ranges from 85% to 95%. Through computer simulation and preliminary experimental data, correlation analysis is performed on the temperature change curves of the deployed multiple temperature monitoring points. When the overlap rate of the curves of several monitoring points is consistently higher than this threshold, it indicates that the temperature dynamic characteristics they reflect are highly consistent, and they can be merged to reduce the number of sensors while ensuring the accuracy of monitoring the overall temperature state of the furnace. Based on this, as an optional embodiment, the preset overlap rate threshold is set to 90%.

[0142] In this embodiment, the sensor monitoring node refers to a basic monitoring unit consisting of one or more temperature sensors arranged in the same key area, capable of independently acquiring and performing preliminary data processing.

[0143] In this embodiment, the integrated management node refers to the central unit responsible for aggregating, processing, and coordinating data from all sensor monitoring nodes, and for unified management of the entire distributed temperature monitoring network.

[0144] In this embodiment, the simulation is performed using computational fluid dynamics (CFD) software; the comparison of temperature change curves is achieved by calculating the Pearson correlation coefficient between each curve, and when the correlation coefficient is greater than the preset overlap rate threshold, the curves are determined to overlap.

[0145] The working principle and beneficial effects of the above technical solution are as follows: By combining functional feature identification with spatial structure analysis, a symmetrical and uniform deployment strategy is adopted in the plane of the highest priority monitoring points in the key area, ensuring the comprehensiveness and representativeness of basic monitoring coverage; by simulating and analyzing the overlap rate of temperature change curves of each sensor through computer simulation, it is possible to scientifically identify and merge temperature measurement points with highly repetitive monitoring data, thereby effectively optimizing the number of sensors while ensuring the integrity of temperature field information, avoiding the increased cost and system complexity caused by redundant deployment; finally, based on the merging results, the final deployment location of the sensors is determined, and a distributed temperature monitoring network is constructed in which sensor monitoring nodes in each area and integrated management nodes work together, realizing efficient, economical and reliable monitoring of the temperature field in the furnace space, providing a solid data foundation for subsequent temperature assessment and control decisions.

[0146] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for rapid cooling and safe door opening control of a carbonization furnace, characterized by, include: S1: Real-time monitoring of the carbonization process, and when the high-temperature reaction stage of the carbonization process ends, the control system starts the high-flow circulation mode of the inert gas in the furnace to perform cooling operation. S2: Real-time monitoring of furnace temperature, and when the furnace temperature reaches the preset furnace safe opening temperature threshold, generating a furnace opening operation signal; S3: When a furnace opening operation signal is received, the furnace temperature and furnace pressure are verified for safety, and the furnace opening operation is executed when the safety verification conditions are met. In S1, the carbonization process is monitored in real time, including: The execution steps of the carbonization process are obtained, and a program step pointer is constructed in the control terminal. The execution steps of the carbonization process are tracked in real time according to the program step pointer. The system determines whether the high-temperature reaction stage has been reached based on the tracking results, and when the high-temperature reaction stage is reached, it monitors the duration of the high-temperature reaction stage in real time based on a preset timer. When the duration reaches the preset duration threshold and the tracking results indicate that the temperature is decreasing, the high-temperature reaction phase is considered to have ended. After the high-temperature reaction stage of the carbonization process is completed, the control system activates a high-flow-rate circulation mode of inert gas inside the furnace for cooling operations, including: When the carbonization process completes the high-temperature reaction stage, an alert command is triggered, and when the control system receives the alert command, a start command is generated. The high-flow circulation mode of the inert gas inside the furnace is controlled according to the start-up command; The cooling operation inside the furnace is controlled by the high-flow circulation mode of the inert gas inside the furnace. In S2, the furnace temperature is monitored in real time, and when the furnace temperature reaches the preset safe furnace opening temperature threshold, a furnace opening operation signal is generated, including: Multiple key areas inside the furnace are acquired, and multiple temperature sensors are deployed in each key area. At the same time, a distributed temperature monitoring network is constructed based on the deployment results. The distributed temperature monitoring network monitors the real-time temperature data from multiple temperature sensors in each key area. At the same time, it calculates the average temperature value corresponding to each key area based on the real-time temperature data collected by multiple temperature sensors in each key area. Obtain the preset weight values ​​for each key area, and calculate the weighted average temperature inside the furnace based on the preset weight values ​​and the average temperature values ​​corresponding to each key area. The weighted average temperature inside the furnace is used as the effective opening temperature, and the target change curve of the effective opening temperature over time is continuously recorded. The target change curve is divided into multiple sub-target curve segments according to a preset time period, and the target slope of each sub-target curve segment is calculated. At the same time, the average slope of the target slope in multiple sub-target curve segments is calculated, and the downward trend of the target change curve is predicted based on the average slope. Meanwhile, the expected effective opening temperature for future time intervals is predicted based on the current real-time effective opening temperature and the downward trend. A furnace opening operation signal is generated when the current real-time effective opening temperature is equal to or less than the furnace safe opening temperature threshold, and the expected effective opening temperature in the predicted future time interval will not rebound to exceed the threshold.

2. The rapid cooling and safe door opening control method of a carbonization furnace according to claim 1, characterized by, In S1, the inert gas inside the furnace is nitrogen.

3. The method of claim 1, wherein the method further comprises: The cooling operation inside the furnace is controlled according to the high-flow circulation mode of the inert gas inside the furnace, including: Collect temperature data from multiple temperature measurement points at different time points in the furnace after the high-temperature reaction stage of the carbonization process is completed. Extract the maximum temperature value from the temperature data of multiple temperature measurement points at each time point and calculate the average temperature value of multiple temperature measurement points. Compare the maximum temperature value with the average temperature value at each time point; When the maximum temperature value is less than or equal to the average temperature value, the average temperature value is used as the real-time temperature value at the corresponding time point in the furnace; when the maximum temperature value is greater than the average temperature value, the maximum temperature value is used as the real-time temperature value at the corresponding time point in the furnace. Obtain the real-time temperature value change curve over time, and obtain the slope of the curve. Based on the slope of the curve, determine the rate of temperature drop in the furnace after the high-temperature reaction stage of the carbonization process is completed. The furnace body structural parameters are obtained and a dynamic heat balance equation is constructed based on the real-time temperature value and the temperature drop rate. The real-time heat load of the furnace body is calculated based on the dynamic heat balance equation. The system obtains the cooling rate requirement input by the user to the control terminal, dynamically determines the required inert gas flow rate value based on the real-time heat load and cooling rate requirement, and generates a dynamic valve opening control command based on the inert gas flow rate value. The opening degree of the inert gas supply valve is controlled and adjusted according to the dynamic valve opening control command.

4. The rapid cooling and safe door opening control method of a carbonization furnace according to claim 3, characterized by, The required inert gas flow rate is dynamically determined based on real-time heat load and cooling rate requirements, including: Obtain the real-time change value of heat load, and determine the actual rate of decrease of heat load based on the real-time change value of heat load; The expected value of the rate of decrease in heat load is determined based on the cooling rate requirement; Compare the actual rate of decrease of heat load with the expected rate of decrease of heat load; When the actual rate of decrease of heat load is lower than the expected rate of decrease of heat load, the system is determined to have insufficient heat dissipation capacity. At the same time, a preset positive correction amount is automatically generated, and the current inert gas flow rate is increased according to the preset positive correction amount. When the actual rate of decrease of heat load is higher than the expected rate of decrease of heat load, it is determined that there is a risk of overcooling in the system. At the same time, a preset negative correction amount is automatically generated, and the current inert gas flow rate is reduced according to the preset negative correction amount. When the actual rate of decrease of the heat load is equal to the expected rate of decrease of the heat load, the system is considered to be in a stable heat dissipation state, and the current inert gas flow rate is maintained.

5. The rapid cooling and safe door opening control method of a carbonization furnace according to claim 1, characterized by, Multiple key areas within the furnace are acquired, and multiple temperature sensors are deployed in each key area. Simultaneously, a distributed temperature monitoring network is constructed based on the deployment results, including: The functional characteristics of each key area in the furnace are obtained, and the highest priority monitoring point is determined based on the functional characteristics. At the same time, the spatial distribution plane corresponding to the highest priority monitoring point is obtained, and temperature sensors are symmetrically and evenly distributed above, below or to the left and right of the highest priority monitoring point according to the preset interval. After the deployment is completed, multiple key areas inside the furnace and the temperature sensors deployed in each key area are simulated in the computer. At the same time, the simulation is run to determine the temperature change curve of each temperature sensor in each key area. Compare the temperature change curves of each temperature sensor; When there are n temperature change curves in the comparison result with a coincidence rate greater than a preset coincidence rate threshold, the n temperature change curves are merged, wherein, ; The final locations of the temperature sensors are determined based on the merged results, and corresponding temperature sensors are deployed in each key area according to the final locations. Based on the temperature sensors in each key area, sensor monitoring nodes corresponding to each key area are constructed. At the same time, a comprehensive management node is constructed to associate the sensor monitoring nodes corresponding to each key area, thereby generating a distributed temperature monitoring network.

6. The rapid cooling and safe door opening control method of a carbonization furnace according to claim 1, characterized by, In S3, the safety verification conditions include: the furnace temperature drops to the preset furnace safe opening temperature threshold, and the furnace pressure is in a slightly positive or normal pressure state.

7. The rapid cooling and safe door opening control method of a carbonization furnace according to claim 1, characterized by, include: In S3, when the safety verification conditions are not met, an alarm command is generated and an alarm operation is performed according to the alarm command. At the same time, the real-time temperature and pressure status inside the furnace are fed back to the user's monitoring terminal.

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