Gasification furnace burner system with multi-channel collaborative feeding function and control method

Abstract

The invention discloses a multi-channel collaborative feeding gasifier burner system and a control method. The system comprises a waste liquid feeding system, a waste solid slurry feeding pipeline, an oven fuel gas channel, a speed increasing gas injection unit, a sensing unit and a controller. Wherein the waste liquid feeding system and the waste solid slurry feeding pipeline are arranged in parallel, and the waste liquid feeding system is provided with a positive pressure conveying device; the inlet end of the oven fuel gas channel is connected with a waste liquid feeding system, and the outlet end extends to the burner head and is used for conveying waste liquid to the burner head; the waste solid slurry feeding pipeline independently extends to the head of the burner and is used for forming a unique mixing point of waste liquid and waste solid slurry at the head of the burner; the accelerating gas injection unit comprises an accelerating gas inlet and a connecting pipeline; and dynamically adjusting the valve opening degree of the speed-increasing gas injection unit according to the speed-increasing gas flow adjusting parameter. The defects that a traditional gasifier feeding system is prone to blockage, insufficient in atomization, poor in ignition stability, low in fault treatment efficiency and the like are comprehensively overcome, the service life of equipment is prolonged, the operation and maintenance cost is reduced, and reliable technical support is provided for efficient gasification of complex multi-phase raw materials such as waste liquid and waste solid.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of industrial gasification. More particularly, the present application relates to a multi-channel coordinated feeding gasifier burner system and control method. BACKGROUND

[0002] In the industrial gasification process, the pre-mixing of waste liquid and waste solid slurry (such as coal slurry) is prone to cause pipeline blockage. The physical properties of the two types of materials are significantly different. The high viscosity characteristics of the waste liquid can wrap the solid particles in the coal slurry to form viscous clumps. The ash and fiber impurities in the coal slurry are prone to deposit due to changes in flow rate during transportation, gradually forming hard scale layers at pipe bends, valves, and other places. This blockage not only causes fluctuations in the amount of feed, but also requires shutdown and disassembly for cleaning in severe cases. A single fault can cause several hours of production interruption, significantly reducing equipment operating efficiency. The atomization effect of high-viscosity waste liquid directly affects the gasification efficiency. Traditional gasification burners are difficult to achieve uniform atomization of waste liquid with a viscosity of more than 200 mPa·s. The viscous flow is prone to form liquid filament breakage under the action of high-pressure gas flow, and the atomized particle diameter is large. Large particle droplets cannot be fully combusted in the reaction chamber, resulting in a decrease in local carbon conversion rate. Unburned carbon particles adhere to the burner head to form coking, exacerbating equipment wear and tear, further shortening the service life of the burner, and increasing operation and maintenance costs.

[0003] Therefore, it is necessary to design a technical solution that can overcome the above-mentioned defects. SUMMARY

[0004] An object of the present application is to provide a multi-channel coordinated feeding gasifier burner system and control method, which can overcome the defects of existing single-channel waste liquid delivery into the gasifier, which is prone to blockage and difficult to atomize, and achieve waste liquid co-combustion in the gasifier.

[0005] To achieve these objects and other advantages and in accordance with the purpose of the application, as embodied and broadly described herein, the present application provides a multi-channel coordinated feeding gasifier burner system, comprising a waste liquid feeding system, a waste solid slurry feeding pipeline, a furnace fuel gas channel, a velocity-increasing gas injection unit, a sensing unit, and a controller; wherein the waste liquid feeding system is physically isolated from the waste solid slurry feeding pipeline and is arranged in parallel with the waste solid slurry feeding pipeline, and the waste liquid feeding system is configured with a positive pressure conveying device; the furnace fuel gas channel is connected to the waste liquid feeding system at an inlet end and extends to a burner head at an outlet end, for conveying waste liquid to the burner head; the waste solid slurry feeding pipeline independently extends to the burner head, for forming a unique mixing point of waste liquid and waste solid slurry at the burner head; the velocity-increasing gas injection unit comprises a velocity-increasing gas inlet and a connecting pipeline, the velocity-increasing gas inlet is arranged at the waste liquid feeding system adjacent to the burner head, and the connecting pipeline is connected to inert gas or steam, for injecting velocity-increasing gas into the waste liquid flow; the sensing unit comprises a viscosity sensor, a flow rate sensor, and a temperature sensor, the viscosity sensor is arranged at the waste liquid feeding system, for monitoring the viscosity of the waste liquid, the flow rate sensor is arranged at the waste liquid feeding system, for monitoring the flow rate of the waste liquid, and the temperature sensor is arranged at the gasifier reaction chamber, for monitoring the temperature of the reaction chamber; the controller is embedded with a machine learning model trained by historical gasifier operation data, and the controller performs the following operations: starting the waste solid slurry feeding pipeline to convey waste solid slurry, switching the furnace fuel gas channel to convey waste liquid when the waste solid slurry is stably conveyed, receiving the waste liquid viscosity, waste liquid flow rate, and reaction chamber temperature data monitored by the sensing unit, outputting velocity-increasing gas flow adjustment parameters by the machine learning model, dynamically adjusting the valve opening degree of the velocity-increasing gas injection unit according to the velocity-increasing gas flow adjustment parameters, and realizing self-adaptive atomization of the waste liquid.

[0006] Further, the burner head is provided with an ignition unit, the ignition unit comprising: a central oxygen channel, in which an igniter is arranged; an outer ring oxygen channel serving as an ignition oxygen channel; and a communication valve connected between the central oxygen channel and the outer ring oxygen channel; wherein, in the ignition stage, the communication valve is opened, so that part of the ignition oxygen gas flows from the outer ring oxygen channel into the central oxygen channel, pre-mixes with the fuel gas from the furnace fuel gas channel inside the burner, and after being sprayed out, contacts the high-voltage spark generated by the igniter to realize ignition.

[0007] Furthermore, the controller is configured to execute a waste liquid feeding optimization program, including: after confirming that the waste solid slurry feed pipeline has been stably fed and the gasifier is operating normally, pressurizing the waste liquid tank to the set pressure; sequentially opening the circulation valve on the waste liquid circulation pipeline and the second shut-off valve on the outlet pipeline; after receiving the valve opening feedback signal, starting the waste liquid pump and establishing the start-up circulation flow; adjusting the outlet pressure of the waste liquid pump to be higher than the outlet pressure of the waste solid slurry pump; issuing a waste liquid feeding command, closing the waste liquid nitrogen purging valve, and opening the waste liquid programmable valve at the burner head; within a preset delay time, detecting whether the waste liquid pressure is maintained higher than the waste solid slurry pressure, and verifying that all key shut-off valves on the waste liquid pipeline are in the open state; if all the above conditions are met, the waste liquid feeding is determined to be successful; otherwise, the waste liquid system is tripped; after the waste liquid feeding is successful, the oxygen flow rate is dynamically adjusted according to the reaction chamber temperature.

[0008] Furthermore, the controller is also pre-set with waste liquid fault interlock control logic: when the waste liquid delivery flow rate is detected to be lower than the safety threshold, the trip interlock is triggered. The interlock action includes: immediately opening the nitrogen purging valve of the furnace fuel gas channel for purging, stopping the waste liquid pump at the same time, and interlocking to close all shut-off valves on the waste liquid feed pipeline; when feeding is resumed after the fault is cleared, the control logic ensures that the waste liquid first establishes pressure and flow through the circulation pipeline. Only when the waste liquid pressure is stable and exceeds the pressure of the waste solid slurry pipeline is feeding allowed to be fed to the burner head again.

[0009] Furthermore, the inlet end of the furnace drying fuel gas channel is connected to a dual-mode switching system via a three-way valve assembly. The first port of the three-way valve assembly is connected to the fuel gas source, the second port is connected to the output end of the waste liquid feeding system, and the third port is connected to the inlet pipe of the furnace drying fuel gas channel. The three-way valve assembly is equipped with a linkage control module. When the gasifier enters the furnace drying stage, the linkage control module drives the three-way valve assembly to open the flow paths of the first and third ports and cut off the second port. When the gasifier enters the normal operation stage, the linkage control module drives the three-way valve assembly to open the flow paths of the second and third ports and cut off the first port. A backflow prevention check valve is provided between the outlet end of the furnace drying fuel gas channel and the burner head to prevent the high-temperature medium in the reaction chamber from flowing back into the furnace drying fuel gas channel.

[0010] Furthermore, the outer wall of the waste solid slurry feed pipeline is covered with a steam tracing layer, into which saturated steam at 0.8-1.2 MPa is introduced to maintain the pipeline temperature ≥80℃; an inert gas backflushing interface is provided at the end of the pipeline near the burner head, which is connected to an inert gas source through a high-pressure solenoid valve, and the signal terminal of the high-pressure solenoid valve is connected to the controller; the controller is preset with anti-clogging logic, when the flow rate sensor detects that the flow rate of the waste solid slurry is below 0.6 m / s for 5 consecutive seconds, the feed valve is closed and the high-pressure solenoid valve is opened, and the pipeline is pulsed backflushed three times with nitrogen at 1.5-2.0 MPa, each lasting 0.5 seconds, and the flow rate monitoring is restarted after the backflushing is completed.

[0011] Furthermore, the speed-increasing gas inlet of the speed-increasing gas injection unit is located on the side wall of the straight pipe section at the end of the furnace fuel gas channel, and the straight pipe section at the end is located within a range of 1-3 times the pipe diameter upstream of the burner head; the axis of the speed-increasing gas inlet forms an angle of 30-60° with the axis of the straight pipe section at the end, and the speed-increasing gas nozzle is inclined towards the burner head; a Venturi flow meter and an electric regulating valve are installed in series on the connecting pipeline. The Venturi flow meter detects the actual flow rate of the speed-increasing gas in real time and feeds it back to the controller. The controller controls the opening of the electric regulating valve in a closed loop based on the deviation between the target flow rate output by the machine learning model and the measured flow rate.

[0012] Furthermore, both the viscosity sensor and the flow rate sensor are integrated into the outer wall of the end straight pipe section of the furnace fuel gas passage; the viscosity sensor is an ultrasonic viscometer, with its transmitting and receiving probes symmetrically embedded on both radial sides of the end straight pipe section, calculating the real-time viscosity by measuring the attenuation rate of ultrasonic waves in the waste liquid; the flow rate sensor is a Doppler velocity meter, with its transducer installed on the downstream end face of the end straight pipe section, calculating the flow rate by detecting the frequency shift of the reflected waves of suspended particles in the waste liquid; the temperature sensor is a sheathed thermocouple, with its probe inserted from the side wall of the gasifier reaction chamber and extending to the flame core area of ​​the burner head.

[0013] Furthermore, the input parameters of the machine learning model include the waste solid slurry flow monitoring value and the gasifier operating pressure value. The machine learning model generates the speed-up gas flow adjustment parameters through the following steps: based on real-time waste liquid viscosity, waste liquid flow rate, reaction chamber temperature, waste solid slurry flow rate, and gasifier pressure, it matches the K most similar operating scenarios in the historical operating condition database; it extracts the optimal atomized gas flow setpoint corresponding to the K scenarios and calculates the target flow benchmark value Q0 using a Gaussian weighted algorithm; based on the deviation ΔT between the current reaction chamber temperature and the set temperature, it proportionally corrects the flow value: Q tar =Q0×[1+α·ΔT], where α is the temperature compensation coefficient, 0<α≤0.05, and the controller will... tar This is converted into an opening command for the electric regulating valve.

[0014] Furthermore, the controller calculates the mass flow ratio R=Q of waste liquid to waste solid slurry in real time. l / Q s When R deviates from the set range [0.9, 1.1], proportional control is activated: if R > 1.1, press ΔP. l =-0.05·(R-1.1)·P l0 Reduce the waste liquid conveying pressure, and simultaneously adjust according to ΔP s =+0.1·(R-1.1)·P s0 Increase the conveying pressure of waste solid slurry; if R < 0.9, adjust according to ΔP. l =+0.07·(0.9-R)·Pl0 Increase the waste liquid conveying pressure, and simultaneously according to ΔP s =-0.12·(0.9-R)·P s0 Reduce the conveying pressure of waste solid slurry; where P l0 P s0 The adjusted gas flow rate Q is based on the reference pressure value. tar Synchronous correction to Q mtar =Q tar ·[1-0.2·|R-1|].

[0015] According to another aspect of the present invention, a control method is also provided, comprising: S1: starting the waste solid slurry conveying through the waste solid slurry feed pipeline; when the waste solid slurry conveying flow rate reaches 50-100 kg / s and is maintained for 10-30 seconds, switching the furnace fuel gas channel to convey waste liquid to the burner head; S2: acquiring waste liquid viscosity data of the waste liquid feeding system in real time through a viscosity sensor, acquiring waste liquid flow rate data of the waste liquid feeding system in real time through a flow rate sensor, and acquiring reaction chamber temperature data of the gasifier reaction chamber in real time through a temperature sensor; S3: converting the waste liquid viscosity data and waste liquid flow rate data into a control method. The machine learning model, which inputs the reaction chamber temperature data into the controller, outputs the acceleration gas flow rate adjustment parameters. This machine learning model is trained using historical gasifier operation data. S4: Based on the acceleration gas flow rate adjustment parameters, the valve opening of the acceleration gas injection unit is dynamically adjusted, and the acceleration gas injection unit injects inert gas or steam into the waste liquid feeding system. S5: Repeat S2 to S4 to maintain the waste liquid viscosity data within the 100-500 mPa·s adaptation range to meet the atomization requirements and maintain the reaction chamber temperature data within the 1200-1500℃ range.

[0016] The present invention has at least the following beneficial effects: This invention utilizes physical isolation during the transport of waste liquid and waste solid slurry, confining the mixing point to the burner head. Combined with an optimized waste liquid feeding program, it avoids issues such as pipeline gas blockage, abnormal pressure, and material cross-contamination, improving the stability of the waste liquid feeding process, reducing downtime caused by feeding anomalies, and significantly enhancing the equipment's continuous operation capability. The accelerated gas injection unit, combined with a machine learning model for dynamic adjustment, can precisely adapt atomization parameters to the characteristics of high-viscosity waste liquid, effectively improving atomization uniformity. Simultaneously, the burner head ignition unit employs a dual-channel design of central premixing and outer ring oxygen supplementation, optimizing ignition performance and preventing coking caused by incomplete combustion of fuel gas during the furnace drying stage. This, in conjunction with atomization optimization measures, further reduces the risk of coking at the burner head. The combination of real-time sensing and intelligent control systems not only stabilizes the gasifier reaction chamber temperature and improves carbon conversion rate and overall gasification efficiency, but also, through the controller's pre-set waste liquid fault interlock control logic, quickly triggers safety actions (such as pipeline purging, equipment shutdown protection, and feed cut-off) when abnormalities occur in the waste liquid supply, reducing equipment idling damage and shortening production downtime. In summary, this invention comprehensively solves the shortcomings of traditional gasifier feeding systems, such as easy clogging, insufficient atomization, poor ignition stability, and inefficient fault handling, extending equipment lifespan, reducing maintenance costs, and providing reliable technical support for the efficient gasification of complex multiphase raw materials such as waste liquid and solid waste.

[0017] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0018] Figure 1 This is a flowchart of one embodiment of this application. Detailed Implementation

[0019] The present invention will now be described in further detail so that those skilled in the art can implement it based on the description.

[0020] It should be understood that terms such as "having," "comprising," and "including" used in the embodiments of this application do not exclude the presence or addition of one or more other elements or combinations thereof. All directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of this application are only used to explain the relative positional relationship and movement of components in a specific posture. If the specific posture changes, the directional indication will also change accordingly. When an element is referred to as "fixed to" or "set on" another element, it can be directly on the other element or may have an intervening element present. When an element is referred to as "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element through an intervening element. Descriptions involving "first," "second," etc., in the embodiments of this application are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features.

[0021] It should be noted that the technical solutions of the various embodiments of this application can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this application.

[0022] This application provides a multi-channel co-feed gasifier burner system, including: a waste liquid feeding system, a waste solid slurry feeding pipeline, a furnace fuel gas channel, an accelerating gas injection unit, a sensing unit, and a controller; wherein, the waste liquid feeding system and the waste solid slurry feeding pipeline are physically isolated and connected in parallel, and the waste liquid feeding system is equipped with a positive pressure conveying device; the furnace fuel gas channel is connected to the waste liquid feeding system at its inlet end and extends to the burner head at its outlet end for conveying waste liquid to the burner head; the waste solid slurry feeding pipeline extends independently to the burner head for forming a unique mixing point between waste liquid and waste solid slurry at the burner head; the accelerating gas injection unit includes an accelerating gas inlet and a connecting pipeline, the accelerating gas inlet being located near the burner head of the waste liquid feeding system, and the connecting pipeline being connected to inert gas or steam for injecting accelerating gas into the waste liquid flow. The gas flow rate sensor unit includes a viscosity sensor, a flow rate sensor, and a temperature sensor. The viscosity sensor is installed in the waste liquid feeding system to monitor the viscosity of the waste liquid, the flow rate sensor is installed in the waste liquid feeding system to monitor the flow rate of the waste liquid, and the temperature sensor is installed in the gasifier reaction chamber to monitor the temperature of the reaction chamber. The controller is embedded with a machine learning model trained on historical gasifier operation data. The controller performs the following operations: starting the waste solid slurry feeding pipeline to transport waste solid slurry; when the waste solid slurry is transported stably, switching the furnace drying fuel gas channel to transport waste liquid; and receiving the waste liquid viscosity, waste liquid flow rate, and reaction chamber temperature data monitored by the sensor unit. The controller outputs the speed-increasing gas flow rate adjustment parameters through the machine learning model, and dynamically adjusts the valve opening of the speed-increasing gas injection unit according to the speed-increasing gas flow rate adjustment parameters to achieve adaptive atomization of the waste liquid.

[0023] For example, the system is composed of multiple functional units working together. The waste liquid feeding system can be a conveying loop consisting of a stainless steel pipe (diameter selectable 80mm) and a plunger pump (working pressure selectable 1.5MPa). The waste solid slurry feeding pipeline can be a seamless steel pipe made of wear-resistant alloy material (wall thickness selectable 8mm). Both are installed parallel to each other on the outside of the gasifier via supports, with a 30cm or 50cm gap between the pipes for physical isolation. The positive pressure conveying device configured in the waste liquid feeding system can be a screw pump or a diaphragm pump, which ensures the flow of waste liquid through continuous pressurization. The furnace drying fuel gas channel can be a high-temperature resistant alloy pipe (length selectable 1.2m), with the inlet end connected to the branch pipe of the waste liquid feeding system via a flange, and the outlet end extending to the mixing chamber of the burner head via an elbow. The entire process is sealed by welding to reduce leakage. The waste solid slurry feeding pipeline is laid independently, and the end is connected to the burner head via a dedicated interface, so that the two materials only come into contact inside the mixing chamber of the burner head. The accelerating gas injection unit's accelerating gas inlet can be a right-angle brass connector, installed on a straight pipe section of the waste liquid feeding system 30cm or 50cm from the burner head. The connecting pipe can be a pressure-resistant rubber hose (working pressure can be selected as 2.5MPa). The inert gas introduced can be nitrogen or helium, and the steam can be saturated steam at 0.8MPa or 1.0MPa, injected into the waste liquid flow through a nozzle. In the sensing unit, the viscosity sensor can be an ultrasonic viscometer, fixed to the horizontal pipe section of the waste liquid feeding system with clamps; the flow rate sensor can be an electromagnetic flowmeter, installed 20cm or 30cm downstream of the viscosity sensor; the temperature sensor can be a K-type armored thermocouple, inserted through a pre-drilled hole in the side wall of the gasifier reaction chamber, with the probe end located 50cm or 80cm from the flame zone of the burner head. The controller can be a PLC control cabinet (model S7-1200 or S7-1500 can be selected), with the internally stored machine learning model generated through training from historical operating data. During operation, the controller first starts the conveying pump of the waste solid slurry pipeline. When the flow meter shows that the flow rate is stable at 50 kg / s for 15 or 20 seconds, it sends a signal to switch the valve so that the furnace fuel gas channel can start conveying waste liquid. At the same time, it receives real-time data from the viscosity sensor (measurement range 100-1000 mPa·s), the flow velocity sensor (measurement range 0-2 m / s), and the temperature sensor (measurement range 1000-1800℃). After inputting the data into the model, the flow rate adjustment parameters are obtained. Then, the injection volume of the speed-increasing gas is adjusted through the electric regulating valve (adjustment accuracy ±1%).

[0024] In this embodiment, the material is first fed through the waste solid slurry feed pipeline. Once the flow stabilizes, the waste liquid feed is then initiated, ensuring the two materials are fully mixed at the burner head. During operation, the sensing unit continuously monitors key parameters, and the controller dynamically adjusts the speed-increasing gas flow rate based on real-time data and a model. This design avoids premature mixing of materials during transport through physical isolation, reducing the possibility of scaling and blockage in the pipeline. The dynamic adjustment of the speed-increasing gas optimizes atomization based on changes in waste liquid characteristics, allowing the material to participate more fully in the reaction chamber. Simultaneously, the machine learning model, combined with historical data, achieves precise control, enabling the system to adapt to waste liquids of varying viscosities and flow rates. Compared to traditional systems with fixed parameter control, this significantly improves feed stability and reaction efficiency.

[0025] In another embodiment, the burner head is provided with an ignition unit, which includes: a central oxygen channel with an igniter inside; an outer ring oxygen channel serving as the ignition oxygen channel; and a connecting valve connected between the central oxygen channel and the outer ring oxygen channel. During the ignition stage, the connecting valve is opened, allowing some ignition oxygen to flow from the outer ring oxygen channel into the central oxygen channel, where it is pre-mixed with fuel gas from the furnace fuel gas channel inside the burner. The mixed gas is then ejected and comes into contact with the high-pressure spark generated by the igniter to achieve ignition.

[0026] For example, the ignition unit of the burner head works in conjunction with the furnace fuel gas passage, and the specific structure is as follows: the central oxygen passage uses an Inconel 625 high-temperature alloy tube, and a high-voltage electric spark igniter is coaxially installed inside the tube; the outer ring oxygen passage is an annular cavity of the same material (cross-sectional width 5-8mm, distributed concentrically around the central oxygen passage), and its inlet end is connected to the gasifier's main oxygen pipeline (working pressure 1.2-1.8MPa), serving as the main oxygen supply channel during the ignition stage; the connecting valve is a two-position two-way solenoid valve made of 316L stainless steel, which is connected to the middle of the central oxygen passage and the side wall of the outer ring oxygen passage through branch pipes of φ10-15mm respectively. When the gasifier enters the ignition stage (early stage of furnace drying), the controller first connects the fuel gas supply to the furnace drying fuel gas channel through the linkage control module, and then sends a signal to open the connecting valve, so that 30%-40% of the ignition oxygen in the outer ring oxygen channel flows into the central oxygen channel through the branch pipeline, and premixes with the fuel gas in the mixing chamber built into the burner head to form a combustible mixture with an air-fuel ratio of 1.2-1.5. After the mixture is ejected through the contraction nozzle of the burner head, it comes into direct contact with the high-pressure spark generated by the igniter to achieve instantaneous ignition. After successful ignition, the controller gradually closes the connecting valve according to the feedback from the temperature sensor (the reaction chamber temperature rises to 800-900℃), switches to oxygen supply from the outer ring oxygen channel alone, and connects to the subsequent furnace drying and heating process.

[0027] In this embodiment, the ignition unit employs a dual-channel design of central premixing and outer ring oxygen supply, solving the problems of flameout (excessive gas flow rate in the mixed gas) or backfire (excessively rich mixed gas) that are prone to occur in traditional single-channel ignition. Precise control of the connecting valves ensures a stable premixing ratio, while the high-pressure, high-frequency igniter ensures an ignition success rate of over 98% under low-temperature (initial reaction chamber temperature 20-50℃) and low-pressure conditions. Compared to the traditional single-point ignition structure relying solely on central oxygen, this design not only shortens the ignition time (from the traditional 30-60 seconds to 5-10 seconds) but also continuously provides combustion-supporting oxygen after ignition through the outer ring oxygen channel, preventing coking caused by incomplete combustion of fuel gas during the furnace drying stage and laying a stable temperature foundation for subsequent waste liquid feeding.

[0028] In another embodiment, the controller is configured to execute a waste liquid feeding optimization procedure, including: after confirming that the waste solid slurry feed pipeline has been stably fed and the gasifier is operating normally, pressurizing the waste liquid tank to a set pressure; sequentially opening the circulation valve on the waste liquid circulation pipeline and the second shut-off valve on the outlet pipeline; after receiving the valve opening feedback signal, starting the waste liquid pump and establishing the start-up circulation flow; adjusting the outlet pressure of the waste liquid pump to be higher than the outlet pressure of the waste solid slurry pump; issuing a waste liquid feeding command, closing the waste liquid nitrogen purging valve, and opening the waste liquid programmable valve at the burner head; within a preset delay time, detecting whether the waste liquid pressure is maintained higher than the waste solid slurry pressure, and verifying that all key shut-off valves on the waste liquid pipeline are in the open state; if all the above conditions are met, the waste liquid feeding is determined to be successful; otherwise, the waste liquid system is tripped; after the waste liquid feeding is successful, the oxygen flow rate is dynamically adjusted according to the reaction chamber temperature.

[0029] For example, the specific execution steps are as follows: 1. Pre-pressurization stage: The controller sends a command to the waste liquid tank to open the nitrogen replenishment valve and pressurize the tank to 1.8-2.2MPa (set pressure, 0.3-0.5MPa higher than the waste liquid pump inlet pressure) to prevent pump inlet cavitation; 2. Circulation flow establishment stage: Open the pneumatic butterfly valve (circulation valve) on the waste liquid circulation pipeline and the electric gate valve (second shut-off valve) on the outlet pipeline in sequence. After receiving the feedback signal that the two valves are fully open, start the variable frequency waste liquid pump and adjust the start-up circulation flow (waste liquid returns to the tank through the circulation pipeline) to 80-100 m³ / h to remove residual air in the pipeline. 3. Pressure matching stage: The controller monitors the outlet pressure of the waste liquid pump in real time through a pressure sensor (accuracy ±0.01MPa), and adjusts the pump frequency to raise the outlet pressure to 2.5-3.0MPa, ensuring that it is 0.5-0.8MPa higher than the outlet pressure of the waste solid slurry pump (2.0-2.5MPa), thus forming a stable pushing pressure difference; 4. Feeding and Verification Phase: Upon issuing the waste liquid feeding command, first close the nitrogen purge valve on the waste liquid pipeline, and after a 2-3 second delay, open the waste liquid programmable valve at the burner head. During the preset 10-20 second delay, the controller continuously monitors two key conditions: ① Whether the pressure in the waste liquid feed pipeline is maintained at 2.5-3.0 MPa (without sudden drop); ② Whether the second shut-off valve, waste liquid programmable valve, and circulation valve (maintaining 50%-60% opening to maintain partial circulation) on the waste liquid pipeline are all open. If both conditions are met, the waste liquid feeding is considered successful, and the system enters the normal adjustment phase. If either condition is not met (e.g., pressure drops below 2.3 MPa or valve feedback is abnormal), the waste liquid system trips immediately, closing the waste liquid programmable valve and reopening the nitrogen purge valve. 5. Subsequent Adjustment Stage: After successful waste liquid feeding, the controller adjusts the oxygen flow rate by 2-3 Nm³ per 10°C increment based on the reaction chamber temperature monitored by the temperature sensor (target 1200-1500°C). 3 The flow rate is adjusted according to the ratio of / h (reducing the flow rate when the temperature is too high and increasing the flow rate when the temperature is too low) to dynamically adapt to the gasification reaction requirements and avoid excessive temperature fluctuations.

[0030] In this embodiment, the waste liquid feeding optimization program solves the problems of pipeline air blockage, sudden pressure drop, and material cross-contamination that are prone to occur in traditional manual feeding through a step-by-step logic of pre-pressurization, circulation flow establishment, pressure matching, and multi-condition verification. Establishing the start-up circulation flow rate can eliminate air bubbles in the pipeline in advance, avoiding flow fluctuations during feeding (controlling fluctuation amplitude ≤5%); the pressure difference design between waste liquid and waste solid slurry prevents waste solid slurry from flowing back into the waste liquid pipeline, reducing the risk of blockage. Compared with the traditional feeding method without verification, this program increases the feeding success rate from 85% to over 98%, and by adjusting the oxygen flow rate through temperature linkage, it keeps the carbon conversion rate fluctuation within 2%, significantly improving the stability and economy of the gasification process.

[0031] In another embodiment, the controller is also pre-configured with waste liquid fault interlock control logic: when the waste liquid delivery flow rate is detected to be lower than the safety threshold, a trip interlock is triggered. The interlock action includes: immediately opening the nitrogen purging valve of the furnace fuel gas channel for purging, stopping the waste liquid pump at the same time, and interlocking to close all shut-off valves on the waste liquid feed pipeline; when feeding resumes after the fault is cleared, the control logic ensures that the waste liquid first establishes pressure and flow through the circulation pipeline, and only allows feeding to the burner head again after the waste liquid pressure stabilizes and exceeds the pressure of the waste solid slurry pipeline.

[0032] For example, the controller's preset waste liquid fault interlock control logic uses the flow safety threshold as the trigger condition, and the specific design is as follows: 1. Trigger condition setting: The safety threshold for waste liquid conveying flow rate is set to 30-40 kg / s (determined based on 60% of the gasifier's design load). The flow rate is monitored in real time by an electromagnetic flow meter on the waste liquid pipeline (measurement range 0-150 kg / s, accuracy ±0.5%). When the flow meter detects that the flow rate is below the safety threshold for 3-5 consecutive seconds, it is determined to be an abnormal waste liquid supply and the trip interlock is immediately triggered. 2. Trip Sequence: After the interlock is triggered, the controller executes three key actions according to the preset sequence: ① First, the nitrogen purging valve on the branch pipeline of the furnace fuel gas channel is opened to purge the waste liquid feed pipeline with nitrogen at 1.5-2.0MPa to remove the residual high-viscosity waste liquid in the pipeline (to prevent solidification and blockage); ② After a delay of 0.5-1 seconds, a stop signal is sent to the waste liquid pump, causing the pump to stop running urgently within 2-3 seconds to avoid damage from idling; ③ Simultaneously, a shut-off command is sent to all shut-off valves on the waste liquid feed pipeline (including the second shut-off valve at the outlet end and the waste liquid programmable valve at the burner head) to cut off the waste liquid supply and prevent local overheating caused by insufficient material in the reaction chamber; 3. Fault Recovery Control: After the fault is resolved (e.g., pipeline blockage is cleared, waste liquid raw material replenishment is completed, or pump failure is repaired), when resuming feeding, the control logic forcibly executes the circulation pressure building process: ① First, open the waste liquid circulation valve and nitrogen replenishment valve, start the waste liquid pump, and adjust the circulation flow rate to 60-80 m³ / h. 3 / h; ② Monitor the outlet pressure of the waste liquid pump in real time through the pressure sensor until the pressure stabilizes at 2.5-3.0MPa and lasts for 5-8 seconds, and at the same time confirm that the pressure is higher than the outlet pressure of the waste solid slurry pump by more than 0.5MPa; ③ After the above conditions are met, the controller is allowed to issue the instruction to open the waste liquid programmable valve and feed the material to the burner head again. It is forbidden to skip the circulation pressure building step directly.

[0033] In this embodiment, the waste liquid fault interlock control logic solves the pain points of residual waste liquid blockage and insufficient feed pressure recovery in traditional fault handling by designing a rapid cut-off + active purging + forced recovery process. Nitrogen purging can remove residual waste liquid in the pipeline within 30-60 seconds, avoiding the risk of blockage during subsequent startup; the timing control of emergency pump stop and valve closure (purging before valve closure) prevents negative pressure from forming in the pipeline, which could lead to air intake and ensure system safety. Compared with the traditional fault handling method that relies solely on manual shutdown, this logic shortens the fault response time from 30-60 seconds to less than 5 seconds, and increases the feed success rate after fault recovery to over 95%, significantly reducing the risk of equipment damage and production interruption time, and is especially suitable for continuous gasification scenarios of high-viscosity waste liquid. In another embodiment, the inlet end of the furnace drying fuel gas channel is connected to a dual-mode switching system via a three-way valve assembly. The first port of the three-way valve assembly is connected to the fuel gas source, the second port is connected to the output end of the waste liquid feeding system, and the third port is connected to the inlet pipe of the furnace drying fuel gas channel. The three-way valve assembly is equipped with a linkage control module. When the gasifier enters the furnace drying stage, the linkage control module drives the three-way valve assembly to open the flow paths of the first and third ports and cut off the second port. When the gasifier enters the normal operation stage, the linkage control module drives the three-way valve assembly to open the flow paths of the second and third ports and cut off the first port. A backflow prevention check valve is provided between the outlet end of the furnace drying fuel gas channel and the burner head to prevent the high-temperature medium in the reaction chamber from flowing back into the furnace drying fuel gas channel.

[0034] For example, a three-way valve assembly (material can be cast steel or stainless steel) is installed at the inlet end of the furnace fuel gas channel. This valve assembly includes three interfaces: the first interface is connected to the fuel gas source (which can be a natural gas pipeline or a liquefied gas storage tank) via a pipeline; the second interface is connected to the output branch pipe of the waste liquid feeding system via a flange; and the third interface is connected to the inlet pipeline of the furnace fuel gas channel (diameter can be 50mm or 65mm) via welding. The linkage control module configured in the three-way valve assembly can be a relay control board or an intelligent valve positioner, which is connected to the main control system of the gasifier via a signal line. When the gasifier starts and enters the furnace drying stage, the main control system sends a signal to the linkage control module, which drives the valve core inside the three-way valve assembly to rotate, so that the flow path between the first interface and the third interface is fully open. At this time, the fuel gas (pressure can be 0.3MPa or 0.5MPa) is delivered to the burner head through the channel; at the same time, the valve core cuts off the connection between the second interface and the third interface to prevent waste liquid from entering the channel. When the furnace drying process is complete and enters normal operation, the main control system sends a switching signal, and the linkage control module drives the valve core to rotate in the reverse direction, closing the flow paths of the first and third interfaces and opening the second and third interfaces, allowing the waste liquid output from the waste liquid feeding system (temperature selectable at 60℃ or 80℃) to flow through the channel to the burner head. A backflow prevention check valve (nominal pressure selectable at 1.6MPa or 2.5MPa) is installed between the outlet end of the furnace fuel gas channel and the burner head via a threaded connection. The valve disc inside this valve opens when the medium flows in the forward direction. When a high-temperature medium (temperature can reach above 1200℃) in the reaction chamber attempts to flow in the reverse direction, the valve disc automatically closes the valve seat under pressure, preventing high-temperature gas or molten material from entering the channel.

[0035] In this embodiment, the system first enters the furnace baking stage upon startup. The linkage control module controls the three-way valve group to switch to the fuel gas channel, preheating the furnace body through fuel combustion. After the furnace baking is completed, the module automatically switches the three-way valve group to the waste liquid channel, initiating the normal gasification reaction. The anti-backflow check valve continuously functions throughout the operation, preventing the backflow of the high-temperature medium in the reaction chamber. This dual-mode switching design allows the furnace baking and normal operation stages to share the same channel, simplifying the equipment structure and reducing pipeline layout space. The automatic switching function of the linkage control module avoids delays and errors caused by manual operation, ensuring smooth stage transitions. The anti-backflow check valve effectively protects the channel and valve group from high-temperature damage, improving both equipment integration and operational safety compared to traditional systems with separately installed furnace baking pipelines.

[0036] In another embodiment, the outer wall of the waste solid slurry feed pipeline is covered with a steam tracing layer, through which saturated steam at 0.8-1.2 MPa is introduced to maintain the pipeline temperature ≥80°C. An inert gas backflushing port is provided at the end of the pipeline near the burner head. This port is connected to an inert gas source through a high-pressure solenoid valve, and the signal terminal of the high-pressure solenoid valve is connected to the controller. The controller is preset with anti-clogging logic. When the flow rate sensor detects that the flow rate of the waste solid slurry is below 0.6 m / s for 5 consecutive seconds, the feed valve is closed and the high-pressure solenoid valve is opened. The pipeline is pulsed backflushed three times with nitrogen at 1.5-2.0 MPa, each lasting 0.5 seconds. After the backflushing is completed, the flow rate monitoring is restarted.

[0037] For example, the outer wall of the waste slurry feed pipeline is covered with a steam tracing layer fixed by insulation nails. The tracing layer can be a sleeve made of seamless steel pipe (diameter can be selected as 20mm or 25mm). An annular space is formed between the sleeve and the outer wall of the pipeline. The saturated steam pressure introduced into the interior can be selected as 0.8MPa or 1.2MPa. The temperature inside the pipeline is maintained above 80℃ or 90℃ through heat transfer from the steam, preventing the slurry from solidifying due to excessively low temperature. At the end of the pipeline, 15cm or 20cm from the burner head, an inert gas backflush port (diameter can be selected as 1 / 2 inch or 3 / 4 inch) is welded to the side wall. This port is connected to the outlet of a high-pressure solenoid valve (working pressure can be selected as 3MPa or 4MPa) via a high-pressure hose. The inlet of the solenoid valve is connected to an inert gas source (can be a nitrogen cylinder group or nitrogen storage tank). The signal control terminal of the high-pressure solenoid valve is connected to the digital output port of the controller via a wire to receive the switch control signal. The controller has a pre-programmed anti-clogging control logic program. When the flow rate sensor detects that the flow rate of the waste solid slurry in the pipeline is below 0.6 m / s for 5 consecutive seconds, the controller first outputs a signal to close the feed valve at the front end of the pipeline (which can be a pneumatic ball valve or an electric gate valve) to cut off the slurry supply. Then, it opens the high-pressure solenoid valve to inject nitrogen from the air source into the pipeline through the backflushing interface at a pressure of 1.5 MPa or 2.0 MPa for pulse backflushing. The backflushing process is performed in 3 stages, each lasting 0.5 seconds, with a 1-second interval between two backflushing stages. After the backflushing is completed, the controller closes the high-pressure solenoid valve, reopens the feed valve, and controls the flow rate sensor to start monitoring the flow rate in the pipeline again.

[0038] In this embodiment, saturated steam is continuously supplied to the steam-heated layer during operation to maintain the pipeline temperature within the set range, ensuring that the waste solid slurry remains in a flowable state. When the pipeline experiences excessively low flow rate, potentially leading to blockage, the controller automatically triggers anti-blockage logic, using nitrogen pulse backflushing to remove accumulated material from the pipeline. Steam heating effectively prevents the slurry from cooling and solidifying during transport, reducing the risk of blockage at its source; while the backflushing mechanism addresses blockages in their early stages, preventing them from worsening. Compared to traditional methods relying on manual inspection and cleaning, this automatic anti-blockage design reduces downtime for maintenance, improves the system's continuous operation capability, and reduces the intensity of manual operations, resulting in a more stable and reliable pipeline operation.

[0039] In another embodiment, the accelerating gas injection unit has its accelerating gas inlet located on the side wall of the straight pipe section at the end of the furnace fuel gas passage. The straight pipe section is located 1-3 times the pipe diameter upstream of the burner head. The axis of the accelerating gas inlet forms an angle of 30-60° with the axis of the straight pipe section, and the accelerating gas nozzle is inclined towards the burner head. A Venturi flow meter and an electric regulating valve are connected in series on the connecting pipeline. The Venturi flow meter detects the actual flow rate of the accelerating gas in real time and feeds it back to the controller. The controller controls the opening of the electric regulating valve in a closed loop based on the deviation between the target flow rate output by the machine learning model and the measured flow rate.

[0040] For example, the core components of the accelerating gas injection unit are installed in a specific location to optimize atomization. The accelerating gas inlet can be a stainless steel nozzle interface, located on the side wall of a straight pipe section at the end of the furnace fuel gas passage. This straight pipe section is upstream of the burner head and its length is 1 or 3 times the passage diameter (e.g., 50 mm or 150 mm for a 50 mm diameter pipe). The angle between the inlet axis and the straight pipe section axis can be selected as 30° or 60°, with the nozzle direction inclined towards the burner head, allowing the injected gas to form a swirling flow along the waste liquid flow direction. The connecting pipeline uses seamless steel pipe (diameter can be selected as 25 mm or 32 mm), with a Venturi flow meter (measuring range 0-50 m) connected in series on the pipeline. 3 The gas flow meter ( / h) and an electric regulating valve (20mm or 25mm diameter selectable) are used. The Venturi flow meter is installed upstream of the regulating valve via a flange, detecting the gas flow in real time and transmitting a 4-20mA current signal to the controller. The electric regulating valve is connected to the controller via a signal line, receiving opening control commands. Once the controller obtains the target flow rate, it calculates the deviation from the measured flow rate and outputs a regulating signal using a PID algorithm, controlling the valve opening to increase from the current 30% to 40% to eliminate the deviation.

[0041] In this embodiment, a speed-increasing gas is injected into the waste liquid flow through an angled inlet, utilizing the angle design to enhance the shearing effect of the airflow on the waste liquid. A Venturi flow meter continuously monitors the actual flow rate, and the controller ensures that the flow rate accurately matches the target value through closed-loop control. This structure allows the speed-increasing gas to participate in the atomization process more efficiently, and the angled design reduces airflow resistance and improves energy utilization. Real-time closed-loop control avoids the impact of flow fluctuations on the atomization effect. Compared with the traditional open-loop regulation method, the gas flow control accuracy is higher, and the waste liquid atomized particles are more uniform, which helps to fully convert the materials in the reaction chamber.

[0042] In another embodiment, both the viscosity sensor and the flow rate sensor are integrated into the outer wall of the end straight pipe section of the furnace fuel gas passage; the viscosity sensor is an ultrasonic viscometer, with its transmitting and receiving probes symmetrically embedded on both radial sides of the end straight pipe section, calculating the real-time viscosity by measuring the attenuation rate of ultrasonic waves in the waste liquid; the flow rate sensor is a Doppler velocity meter, with its transducer installed on the downstream end face of the end straight pipe section, calculating the flow rate by detecting the frequency shift of reflected waves from suspended particles in the waste liquid; the temperature sensor is a sheathed thermocouple, with its probe inserted from the side wall of the gasifier reaction chamber and extending to the flame core area of ​​the burner head.

[0043] For example, the core sensors of the sensing unit are integrated to improve detection accuracy. The viscosity sensor and flow velocity sensor are fixed to the outer wall of the straight pipe section at the end of the furnace fuel gas passage, near the burner head, via a dedicated bracket. The viscosity sensor is an ultrasonic viscometer, with its transmitting and receiving probes symmetrically mounted radially on both sides of the straight pipe section via threads. The probes are tightly fitted to the outer wall of the pipe. The transmitting probe emits 1MHz or 2MHz ultrasonic waves that penetrate the pipe wall and waste liquid. The receiving probe detects the attenuation of the sound waves, and the controller calculates the real-time viscosity value (in mPa·s) based on the correlation between the attenuation rate and viscosity. The flow velocity sensor is a Doppler velocity meter, with its transducer mounted via a flange at the center of the downstream end face of the straight pipe section. It emits 500kHz sound waves into the waste liquid and receives the sound waves reflected by suspended particles. The flow velocity is calculated using the frequency shift difference (e.g., 500kHz transmission frequency, 500.5kHz reflection frequency). The temperature sensor is a K-type armored thermocouple (the diameter can be selected as 3mm or 5mm). It is inserted from the reserved sleeve on the side wall of the gasifier reaction chamber, and the detection end extends to 10cm or 20cm away from the flame core area of ​​the burner head, directly contacting the high-temperature flame area to obtain temperature data.

[0044] In this embodiment, all sensors synchronously collect data during operation: an ultrasonic viscometer monitors the viscosity of the waste liquid in real time, a Doppler flow meter tracks the flow velocity, and a thermocouple provides feedback on the core temperature of the reaction chamber. The integrated installation of the sensors shortens the signal transmission distance and reduces detection delay; the symmetrically arranged ultrasonic probes ensure a stable sound wave propagation path, improving viscosity measurement accuracy; and the end-face mounting method of the Doppler transducer avoids interference with the fluid. These designs allow the controller to more accurately perceive the material state and reaction environment, providing a reliable basis for subsequent adjustments. Compared to a distributed sensor layout, data consistency is better, and the control response is more timely.

[0045] In another embodiment, the input parameters of the machine learning model further include the waste solid slurry flow monitoring value and the gasifier operating pressure value; the machine learning model generates the speed-up gas flow adjustment parameters through the following steps: based on the real-time waste liquid viscosity, waste liquid flow rate, reaction chamber temperature, waste solid slurry flow rate and gasifier pressure, it matches the most similar K groups of operating scenarios in the historical operating condition database; it extracts the optimal atomized gas flow set value corresponding to the K groups of scenarios, and calculates the target flow benchmark value Q0 through a Gaussian weighted algorithm; according to the deviation ΔT between the current reaction chamber temperature and the set temperature, it proportionally corrects the flow value: Qtar=Q0×[1+α·ΔT], where α is the temperature compensation coefficient, 0<α≤0.05, and the controller converts Qtar into an opening command for the electric regulating valve.

[0046] For example, the machine learning model achieves precise adjustment through multi-parameter fusion. In addition to basic parameters, the model's input parameters include the waste solid slurry flow rate (detected by an electromagnetic flowmeter, unit: kg / s) and the gasifier operating pressure (detected by a pressure transmitter, unit: MPa). During model execution, it first extracts the 5 or 8 operating scenarios (K-values) most similar to the current parameter combination from a historical database (stores operating data from the past 6 months). Similarity is calculated using Euclidean distance (e.g., the distance between the current viscosity of 200 mPa·s and the historical viscosity of 210 mPa·s is 10). The optimal atomized gas flow rate corresponding to these scenarios (e.g., 15 m³ / s, respectively) is then extracted. 3 / h, 16m 3 / h, 15.5m 3 / h), and calculate the baseline value Q0 (e.g., 15.6m) using a Gaussian weighted algorithm (where the weights increase with increasing similarity). 3 / h). When the reaction chamber is set to 1300℃ and the current measured temperature is 1280℃, ΔT is -20℃. Taking α=0.03, then Qtar=15.6×[1+0.03×(-20)]=15.6×0.4=6.24m³ / h (actual calculations need to be adjusted according to the actual deviation direction). The controller converts Qtar into the corresponding opening command (e.g., 6.24m) based on the valve flow characteristic curve. 3 / h corresponds to 25% opening).

[0047] In this embodiment, the model continuously receives multi-dimensional operating parameters and generates adjustment commands through historical data matching and algorithmic calculation. Multi-parameter input allows the model to comprehensively perceive the system state, K-nearest neighbor matching ensures the reliability of the reference scenario, and Gaussian weighting highlights the impact of high-quality data. A temperature compensation mechanism enables flow regulation to quickly respond to changes in reaction chamber temperature, avoiding localized overheating or insufficient reaction. Compared to adjustment methods relying on only a single parameter, this multi-parameter fusion intelligent model outputs adjustment parameters that better match actual needs, and the system has a stronger ability to adapt to changes in operating conditions.

[0048] In another embodiment, the controller calculates the mass flow ratio R=Q of waste liquid to waste solid slurry in real time. l / Q s When R deviates from the set range [0.9, 1.1], proportional control is activated: if R > 1.1, press ΔP. l =-0.05·(R-1.1)·P l0 Reduce the waste liquid conveying pressure, and simultaneously adjust according to ΔP s =+0.1·(R-1.1)·P s0 Increase the conveying pressure of waste solid slurry; if R < 0.9, adjust according to ΔP. l =+0.07·(0.9-R)·P l0 Increase the waste liquid conveying pressure, and simultaneously according to ΔP s =-0.12·(0.9-R)·P s0 Reduce the conveying pressure of waste solid slurry; where P l0 P s0 The adjusted gas flow rate Q is based on the reference pressure value. tar Synchronous correction to Q mtar =Q tar ·[1-0.2·|R-1|].

[0049] For example, the controller achieves dynamic balance of material proportions by calculating the flow ratio in real time. The controller reads the waste liquid mass flow rate Ql (kg / h) and the waste solid slurry mass flow rate Qs (kg / h) every 0.5 seconds, and calculates the ratio R = Ql / Qs (e.g., R = 1.1 when Ql = 1100 kg / h and Qs = 1000 kg / h). The set range is [0.9, 1.1]. When R = 1.2 (exceeding the upper limit), adjustment is initiated: P l0 If it is 2.0 MPa, then ΔP l =-0.05×(1.2-1.1)×2.0=-0.01MPa, the waste liquid pressure drops from 2.0MPa to 1.99MPa; P s0 If the pressure is 1.5 MPa, then ΔP s=+0.1×(1.2-1.1)×1.5=+0.015MPa, the slurry pressure increases from 1.5MPa to 1.515MPa. If R=0.8 (below the lower limit), ΔPl=+0.07×(0.9-0.8)×2.0=+0.014MPa, ΔPs=-0.12×(0.9-0.8)×1.5=-0.018MPa. The original Qtar was 20m. 3 At / h, Qmtar = 20 × [1 - 0.2 × |0.8 - 1|] = 20 × 0.96 = 19.2m 3 / h. During the adjustment process, the controller continuously monitors the R value until it returns to the set range.

[0050] In this embodiment, the runtime controller tracks the material ratio in real time. When it deviates from the ideal range, it simultaneously adjusts the pressure of both material streams and corrects the flow rate of the increasing gas. The proportional adjustment formula ensures that the pressure change is proportional to the degree of deviation, avoiding over-adjustment. The coordinated adjustment of waste liquid and slurry can quickly restore the ratio balance and reduce reaction fluctuations caused by material ratio imbalance. The synchronous correction of the increasing gas flow rate adapts to the new material state and maintains stable atomization effect. Compared with the single-stream adjustment method, this coordinated control allows the material ratio to return to stability more quickly, and the system's anti-interference capability is significantly improved.

[0051] In another embodiment, a new dataset is extracted from the gasifier DCS system every 24 hours, including real-time values ​​of waste liquid viscosity, waste liquid flow rate, waste solid slurry flow rate, gasifier operating pressure, effective gas volume fraction of syngas, and carbon conversion rate. The new dataset is split into a training subset and a validation subset in a 7:3 ratio. The historical model is loaded and the input layer weights to the hidden layer weights are frozen. Only the output layer weights are unfrozen for backpropagation training. The loss function uses the weighted squared error of the effective gas volume fraction prediction error and the carbon conversion rate prediction error. When the waste liquid viscosity fluctuates by ≥30% for 2 consecutive hours, step flow points are generated with a step size of 2% within ±10% of the current flow rate of the accelerating gas. The carbon conversion rate and effective gas fraction of each point are collected. The objective function is constructed by the sum of the carbon conversion rate and the effective gas fraction. The flow point that maximizes the objective function is selected as the temporary optimal value and added to the training set.

[0052] For example, the model maintains stable performance through regular updates and adaptive optimization. At a fixed time each day (e.g., 3 AM), the controller automatically extracts the past 24 hours of operational data from the DCS system. Each data point includes parameters such as viscosity (e.g., 200-500 mPa·s), flow rate (e.g., 0.8-1.5 m / s), slurry flow rate (e.g., 800-1200 kg / h), pressure (e.g., 3.0-3.5 MPa), effective gas fraction (e.g., 85%-95%), and carbon conversion rate (e.g., 90%-98%). The dataset is split into a training set (7000 data points) and a validation set (3000 data points) in a 7:3 ratio. When updating the model, a previously trained neural network model is loaded, the weight parameters from the input layer to the third hidden layer are frozen, only the weights of the output layer are unfrozen, and backpropagation training is performed using the training set (50 iterations). The loss function is (effective gas error) / (effective gas error). 2 ×0.6 + carbon conversion rate error 2 ×0.4). When the viscosity fluctuates by ≥30% for 2 consecutive hours (e.g., a sudden increase from 200 mPa·s to 300 mPa·s), the system generates 9 flow points (18, 18.4, 22 m) in 2% increments within ±10% of the current flow rate of 20 m³ / h. 3 The data is collected after each point runs for 5 minutes, and the objective function value is calculated (e.g., carbon conversion rate 95% + effective gas 90% = 185). The flow rate point corresponding to the maximum value (e.g., 19.2 m³ / h) is selected and added to the training set.

[0053] In this embodiment, the system absorbs new data daily through incremental learning, freezes the underlying weights to reduce training costs, and optimizes the output layer to adapt to new operating conditions. The weighted design of the loss function balances the importance of different indicators. When the characteristics of raw materials change drastically, step testing can quickly find temporary optimal parameters and supplement training data. This mechanism allows the model to continuously adapt to fluctuations in raw materials and equipment aging, maintaining long-term adjustment accuracy. Compared to a fixed model, the system has better stability and responsiveness under complex operating conditions.

[0054] like Figure 1As shown, the control method includes: S1: Starting the waste solid slurry conveying through the waste solid slurry feed pipeline; when the waste solid slurry conveying flow rate reaches 50-100 kg / s and is maintained for 10-30 seconds, switching the furnace fuel gas channel to convey waste liquid to the burner head; S2: Real-time acquisition of waste liquid viscosity data from the waste liquid feed system through a viscosity sensor, real-time acquisition of waste liquid flow rate data from the waste liquid feed system through a flow rate sensor, and real-time acquisition of reaction chamber temperature data from the gasifier reaction chamber through a temperature sensor; S3: Inputting the waste liquid viscosity data, waste liquid flow rate data, and reaction chamber temperature data into the controller's machine learning model, and outputting the speed-increasing gas flow rate adjustment parameters; S4: Dynamically adjusting the valve opening of the speed-increasing gas injection unit according to the speed-increasing gas flow rate adjustment parameters, and injecting inert gas or steam into the waste liquid feed system through the speed-increasing gas injection unit; S5: Repeating S2 to S4 to maintain the waste liquid viscosity data at 100-500 mPa·s. The atomization effect meets the vaporization requirements within the applicable range, and the reaction chamber temperature is maintained within the range of 1200-1500℃.

[0055] For example, the operator starts the waste solid slurry conveying pump through the controller and adjusts the pump body frequency converter knob to stabilize the slurry conveying flow rate at 50-100 kg / s (the specific value is determined according to the gasifier design load); after the flow meter shows that the flow rate has remained stable for 10-30 seconds (determined as stable conveying), the controller automatically sends a linkage signal to the three-way valve group - cutting off the connection between the furnace drying fuel gas channel and the fuel gas source, opening the flow path between it and the waste liquid feeding system, and opening the waste liquid conveying of the furnace drying fuel gas channel to ensure the feeding sequence of "slurry first, then waste liquid" and avoid the two materials from mixing in advance in the pipeline, which may cause blockage. After entering the stable operation phase, each sensing unit collects key data at a preset frequency: the viscosity sensor (ultrasonic) transmits one set of waste liquid viscosity data to the controller every second; the flow rate sensor (Doppler) synchronously feeds back the waste liquid flow rate value (example: 1.2m / s), tracking the waste liquid flow status in real time; the temperature sensor (armored thermocouple) continuously transmits back the gasifier reaction chamber temperature data (example: 1350℃), directly reflecting the intensity of the gasification reaction. The controller standardizes the three core data types of waste liquid viscosity, waste liquid flow rate, and reaction chamber temperature collected by S2, and inputs them into a machine learning model trained with historical gasifier operation data (the number of nodes in the model input layer matches the core parameter dimensions; if expansion is needed, auxiliary parameters such as waste solid slurry flow rate and gasifier pressure can be included); the model outputs a target flow rate of gas with increased speed adapted to the current waste liquid state through matching historical similar operating conditions and Gaussian weighted calculations, ensuring that the adjustment parameters meet the actual operating conditions. The controller compares the target flow rate of the accelerating gas with the measured flow rate of the Venturi flow meter, and outputs an opening adjustment signal through PID closed-loop control—increasing the opening of the electric regulating valve of the accelerating gas injection unit from 30% to 35%, simultaneously increasing the injection volume of inert gas (or steam). The core purpose of this adjustment process is to adapt to the current viscosity of the waste liquid through gas shearing and disturbance, optimizing the atomization effect of the waste liquid (rather than changing the viscosity of the waste liquid itself), and ensuring that the diameter of the atomized particles remains stable in the ideal range of 50-100μm. The system repeats the S2-S4 process every 2 seconds to achieve dynamic response to changes in operating conditions: when the viscosity of the waste liquid fluctuates, the model automatically increases the flow rate of the accelerating gas, adapting to the high viscosity waste liquid by enhancing the airflow shear force, and maintaining the atomization effect to meet the standard; when the reaction chamber temperature is below 1200℃ (the critical value for gasification efficiency), the controller simultaneously fine-tunes the flow rate of the accelerating gas, promoting the full mixing and combustion of the waste liquid and oxygen by optimizing atomization, so that the temperature rises back to the reaction range of 1200-1500℃; In this embodiment, the sequence of slurry followed by waste liquid and the flow rate stability determination mechanism avoid sudden changes in pipeline pressure or blockage caused by material impact. High-frequency (2 seconds / cycle) data acquisition combined with a machine learning model can quickly adapt to the inherent fluctuations in waste liquid viscosity, ensuring that the atomization effect does not decrease with changes in raw material characteristics. The closed-loop circulation logic can correct reaction temperature deviations in real time, providing stable process conditions for the efficient gasification of complex multiphase raw materials (waste liquid + waste solid slurry). Compared to traditional manual adjustment (adjustment cycle > 30 seconds) or fixed parameter control, this method controls the carbon conversion rate fluctuation of the gasification reaction to within 2%, significantly reducing the risk of coking at the burner head.

[0056] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and embodiments shown and described herein.

Claims

1. A gasifier burner system with multi-channel coordinated feeding, characterized in that, This includes a waste liquid feeding system, a waste solid slurry feeding pipeline, a furnace fuel gas channel, an acceleration gas injection unit, a sensing unit, and a controller; Among them, the waste liquid feeding system and the waste solid slurry feeding pipeline are physically isolated and connected in parallel. The waste liquid feeding system is equipped with a positive pressure conveying device. The inlet end of the furnace fuel gas channel is connected to the waste liquid feeding system, and the outlet end extends to the burner head to transport waste liquid to the burner head. The waste solid slurry feed line extends independently to the burner head, which is used to form a unique mixing point between the waste liquid and the waste solid slurry at the burner head. The speed-increasing gas injection unit includes a speed-increasing gas inlet and a connecting pipeline. The speed-increasing gas inlet is located near the burner head of the waste liquid feeding system. The connecting pipeline is connected to inert gas or steam for injecting speed-increasing gas into the waste liquid flow. The sensing unit includes a viscosity sensor, a flow rate sensor, and a temperature sensor. The viscosity sensor is installed in the waste liquid feeding system to monitor the viscosity of the waste liquid, the flow rate sensor is installed in the waste liquid feeding system to monitor the flow rate of the waste liquid, and the temperature sensor is installed in the gasifier reaction chamber to monitor the temperature of the reaction chamber. The controller embeds a machine learning model trained on historical gasifier operation data. The controller performs the following operations: starting the waste solid slurry feed pipeline to transport waste solid slurry; when the waste solid slurry is transported stably, switching the furnace drying fuel gas channel to transport waste liquid; and receiving waste liquid viscosity, waste liquid flow rate and reaction chamber temperature data monitored by the sensor unit. The controller outputs the speed-increasing gas flow rate adjustment parameter through the machine learning model, and dynamically adjusts the valve opening of the speed-increasing gas injection unit according to the speed-increasing gas flow rate adjustment parameter to achieve adaptive atomization of waste liquid.

2. The multi-channel coordinated feeding gasifier burner system as described in claim 1, characterized in that, The burner head is equipped with an ignition unit, which includes: a central oxygen channel with an igniter inside; an outer ring oxygen channel serving as the ignition oxygen channel; and a connecting valve connecting the central oxygen channel and the outer ring oxygen channel. During the ignition stage, the connecting valve is opened, allowing some ignition oxygen to flow from the outer ring oxygen channel into the central oxygen channel, where it is pre-mixed with fuel gas from the furnace fuel gas channel inside the burner. The mixed gas is then ejected and comes into contact with the high-pressure spark generated by the igniter to achieve ignition.

3. The gasifier burner system with multi-channel coordinated feeding as described in claim 1, characterized in that, The controller is configured to execute a waste liquid feeding optimization program, including: after confirming that the waste solid slurry feed pipeline has been stably fed and the gasifier is operating normally, pressurizing the waste liquid tank to the set pressure; sequentially opening the circulation valve on the waste liquid circulation pipeline and the second shut-off valve on the outlet pipeline; after receiving the valve opening feedback signal, starting the waste liquid pump and establishing the start-up circulation flow; adjusting the outlet pressure of the waste liquid pump to be higher than the outlet pressure of the waste solid slurry pump; issuing a waste liquid feeding command, closing the waste liquid nitrogen purging valve, and opening the waste liquid programmable valve at the burner head; within a preset delay time, detecting whether the waste liquid pressure is maintained higher than the waste solid slurry pressure, and verifying that all key shut-off valves on the waste liquid pipeline are in the open state; If all the above conditions are met, the waste liquid feeding is considered successful; otherwise, the waste liquid system will trip. After the waste liquid is successfully fed, the oxygen flow rate is dynamically adjusted according to the temperature of the reaction chamber.

4. The gasifier burner system with multi-channel coordinated feeding as described in claim 1, characterized in that, The controller is also pre-set with waste liquid fault interlock control logic: when the waste liquid delivery flow rate is detected to be lower than the safety threshold, the trip interlock is triggered. The interlock action includes: immediately opening the nitrogen purging valve of the furnace fuel gas channel for purging, stopping the waste liquid pump at the same time, and interlocking to close all shut-off valves on the waste liquid feed pipeline; when feeding is resumed after the fault is cleared, the control logic ensures that the waste liquid first establishes pressure and flow through the circulation pipeline. Only when the waste liquid pressure is stable and exceeds the pressure of the waste solid slurry pipeline is feeding allowed to be fed to the burner head again.

5. The gasifier burner system with multi-channel coordinated feeding as described in claim 1, characterized in that, The inlet end of the furnace fuel gas channel is connected to a three-way valve group to achieve dual-mode switching. The first interface of the three-way valve group is connected to the fuel gas source, the second interface is connected to the output end of the waste liquid feeding system, and the third interface is connected to the inlet pipeline of the furnace fuel gas channel. The three-way valve group is equipped with a linkage control module. When the gasifier enters the furnace baking stage, the linkage control module drives the three-way valve group to open the flow path between the first and third interfaces and cut off the second interface. When the gasifier enters the normal operation stage, the linkage control module drives the three-way valve group to open the flow path between the second and third interfaces and cut off the first interface. A backflow prevention check valve is installed between the outlet end of the furnace fuel gas passage and the burner head to prevent the high-temperature medium in the reaction chamber from flowing back into the furnace fuel gas passage.

6. The gasifier burner system with multi-channel coordinated feeding as described in claim 1, characterized in that, The outer wall of the waste slurry feed pipeline is covered with a steam tracing layer, and 0.8-1.2MPa saturated steam is introduced into the tracing layer to maintain the pipeline temperature ≥80℃; An inert gas backflush port is provided at the end of the pipeline near the burner head. This port is connected to the inert gas source through a high-pressure solenoid valve, and the signal terminal of the high-pressure solenoid valve is connected to the controller. The controller is pre-set with anti-clogging logic. When the flow rate sensor detects that the flow rate of the waste solid slurry is below 0.6 m / s for 5 consecutive seconds, the feed valve is closed and the high-pressure solenoid valve is opened. The pipeline is pulsed backflushed 3 times with 1.5-2.0 MPa nitrogen, each lasting 0.5 seconds. After the backflushing is completed, the flow rate monitoring is restarted.

7. The gasifier burner system with multi-channel coordinated feeding as described in claim 1, characterized in that, The accelerating gas injection unit's accelerating gas inlet is located on the side wall of the straight pipe section at the end of the furnace fuel gas passage. The end straight pipe section is located within a range of 1-3 times the pipe diameter upstream of the burner head. The axis of the accelerating gas inlet forms an angle of 30-60° with the axis of the end straight pipe section, and the accelerating gas nozzle direction is inclined towards the burner head. A Venturi flow meter and an electric regulating valve are installed in series on the connecting pipeline. The Venturi flow meter detects the actual flow rate of the accelerating gas in real time and feeds it back to the controller. The controller controls the opening of the electric regulating valve in a closed loop based on the deviation between the target flow rate output by the machine learning model and the measured flow rate. Both the viscosity sensor and the flow rate sensor are integrated into the outer wall of the end straight pipe section of the furnace fuel gas passage. The viscosity sensor is an ultrasonic viscometer, with its transmitting and receiving probes symmetrically embedded on both radial sides of the end straight pipe section. It calculates the real-time viscosity by measuring the attenuation rate of ultrasonic waves in the waste liquid. The flow rate sensor is a Doppler flow meter, with its transducer installed on the downstream end face of the end straight pipe section. It calculates the flow rate by detecting the frequency shift of the reflected waves from suspended particles in the waste liquid. The temperature sensor is a sheathed thermocouple, with its probe inserted from the side wall of the gasifier reaction chamber and extending to the flame core area of ​​the burner head.

8. The gasifier burner system with multi-channel coordinated feeding as described in claim 1, characterized in that, The input parameters for the machine learning model further include the waste solid slurry flow rate monitoring value and the gasifier operating pressure value; The machine learning model generates the parameters for adjusting the gas flow rate through the following steps: Based on real-time waste liquid viscosity, waste liquid flow rate, reaction chamber temperature, waste solid slurry flow rate, and gasifier pressure, the most similar K operating scenarios in the historical operating condition database are matched. Extract the optimal atomized gas flow rate setpoints for K sets of scenarios, and calculate the target flow rate baseline value Q0 using a Gaussian weighted algorithm; Based on the deviation ΔT between the current reaction chamber temperature and the set temperature, the flow rate value is proportionally adjusted: Q tar =Q0×[1+α·ΔT], where α is the temperature compensation coefficient, 0<α≤0.05, and the controller will... tar This is converted into an opening command for the electric regulating valve.

9. The gasifier burner system with multi-channel coordinated feeding as described in claim 8, characterized in that, The controller calculates the mass flow ratio of waste liquid to waste solid slurry in real time, R=Q. l / Q s ; When R deviates from the set range [0.9, 1.1], proportional coordination adjustment is activated: If R > 1.1, then according to ΔP l =-0.05·(R-1.1)·P l0 Reduce the waste liquid conveying pressure, and simultaneously adjust according to ΔP s =+0.1·(R-1.1)·P s0 Increase the conveying pressure of waste solid slurry; If R < 0.9, then according to ΔP l =+0.07·(0.9-R)·P l0 Increase the waste liquid conveying pressure, and simultaneously according to ΔP s =-0.12·(0.9-R)·P s0 Reduce the conveying pressure of waste solid slurry; Where P l0 P s0 The adjusted gas flow rate Q is based on the reference pressure value. tar Synchronous correction to Q mtar =Q tar ·[1-0.2·|R-1|].

10. A multi-channel cooperative feeding control method based on the system of claim 1, characterized in that, include: S1: Start the waste solid slurry conveying through the waste solid slurry feed pipeline. When the waste solid slurry conveying flow rate reaches 50-100kg / s and is maintained for 10-30 seconds, switch the furnace fuel gas channel to convey the waste liquid to the burner head. S2: Real-time acquisition of waste liquid viscosity data from the waste liquid feeding system via a viscosity sensor, real-time acquisition of waste liquid flow rate data from the waste liquid feeding system via a flow rate sensor, and real-time acquisition of reaction chamber temperature data from the gasifier reaction chamber via a temperature sensor. S3: Input the waste liquid viscosity data, waste liquid flow rate data and reaction chamber temperature data into the machine learning model of the controller, and output the gas flow rate adjustment parameters. This machine learning model is trained with historical gasifier operation data. S4: Based on the speed-increasing gas flow rate adjustment parameters, dynamically adjust the valve opening of the speed-increasing gas injection unit, and inject inert gas or steam into the waste liquid feeding system. S5: Repeat S2 to S4 to maintain the atomization effect that meets the vaporization requirements when the waste liquid viscosity data is within the suitable range of 100-500 mPa·s, and maintain the reaction chamber temperature data within the range of 1200-1500℃.

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