Multivariate analysis based silicon removal end temperature control system

Abstract

This invention discloses a desiliconization terminal temperature control system based on multi-dimensional analysis, belonging to the field of temperature control technology. It addresses the problems of low dechlorination efficiency, iron oxide powder sintering, and energy waste caused by fixed heating temperatures in existing technologies. Specifically, it achieves full-process optimization through the synergistic effect of a dynamic temperature adjustment unit, a temperature-time adaptive control unit, and a heater status early warning unit, resulting in improved dechlorination efficiency and quality. Staged dynamic temperature adjustment solves the heating adaptation problem at different moisture contents, while time-temperature adaptive control eliminates uneven heating caused by residence time differences, leading to more thorough chloride ion removal and more stable product quality. Significant energy and cost savings are achieved by avoiding energy waste caused by fixed temperatures and reducing iron oxide powder sintering losses and equipment failure maintenance costs.

Description

Technical Field

[0001] This invention relates to the field of temperature control technology, specifically to a silicon removal terminal temperature control system based on multivariate analysis. Background Technology

[0002] After adding flocculant at the silicon removal end, impurities will settle. The faster the settling speed, the better it is for improving the quality of subsequent iron powder. To improve the settling speed, a centrifugal device can be added. Moreover, the lower the chloride ion content in the iron oxide powder, the higher the product quality. A secondary heating device can be added at the end of the silo. During the heating process, some chloride ions will evaporate with the water, further reducing the chloride ion content.

[0003] Currently, in the dechlorination treatment of iron oxide powder at the end of the silicon removal process, it is necessary to remove chloride ions by heating to make them evaporate with the moisture. However, existing technologies usually have two major limitations:

[0004] The heating temperature is mostly fixed. However, the moisture content of iron oxide powder is high in the early stage of heating and low in the later stage. A fixed temperature will cause too much heat to be consumed in the initial stage for water evaporation, resulting in slow heating and low dechlorination efficiency. In the later stage, the iron oxide powder is prone to local sintering or energy waste due to excessive temperature.

[0005] Iron oxide powder in the silo flows by gravity, and the residence time of powder in different areas of the heating zone varies (i.e., residence time distribution). Under a fixed heating mode, the powder in the central area with a fast flow rate is not heated enough, while the powder in the edge area with a slow flow rate is prone to overheating, resulting in uneven dechlorination effect.

[0006] To address the aforementioned technical shortcomings, a solution is proposed. Summary of the Invention

[0007] The purpose of this invention is to solve the problems mentioned above by proposing a silicon removal terminal temperature control system based on multivariate analysis.

[0008] The objective of this invention can be achieved through the following technical solution: a silicon removal terminal temperature control system based on multi-dimensional analysis, including a temperature control platform, wherein the temperature control platform is communicatively connected to a dynamic temperature control unit, a temperature and time adaptation control unit, and a heater status early warning unit.

[0009] During the desilicon removal process, the dynamic temperature control unit dynamically regulates the temperature of the secondary heating device added at the end of the hopper; after determining the temperature regulation pattern, the temperature and time adaptation control unit controls the residence time and temperature adaptation of the powder in the hopper.

[0010] After adapting to the controlled temperature, the heater status early warning unit performs status early warning analysis on the heating device.

[0011] Furthermore, the process of the dynamic temperature control unit is as follows:

[0012] An online humidity sensor is installed on the exhaust pipe of the heating device to detect the relative humidity value of the exhaust gas in real time; based on the recorded exhaust gas humidity change rate during the heating process, and combined with the historical operation process of similar heating devices, the exhaust gas humidity change rate threshold is set, and the first-stage threshold and the second-stage threshold are set.

[0013] If the humidity change rate of the exhaust gas from the corresponding heating device exceeds the threshold of the first stage during the current heating process, it indicates that the current stage is the rapid evaporation period of moisture and is marked as the main drying period. If the humidity change rate of the exhaust gas from the corresponding heating device is lower than the threshold of the next stage during the current heating process, it indicates that the moisture has been completely evaporated and the stage has entered the deep removal period of chloride ions and is marked as the chlorine removal period.

[0014] Furthermore, the peak temperature increase of the heating device during the main drying period is obtained, and the duration of the corresponding peak temperature after the heating device reaches a new peak temperature during the chlorination period is also obtained.

[0015] If the peak temperature increase of the heating device during the main drying period exceeds the peak temperature increase threshold, or if the duration of the corresponding peak value after the heating device reaches a new peak temperature during the chlorine discharge period does not exceed the duration threshold, it is inferred that the current heating device needs dynamic temperature adjustment, and a dynamic temperature adjustment signal is generated and sent to the temperature control platform. If the peak temperature increase of the heating device during the main drying period does not exceed the peak temperature increase threshold, and the duration of the corresponding peak value after the heating device reaches a new peak temperature during the chlorine discharge period exceeds the duration threshold, it is inferred that the current dynamic temperature setting of the heating device is qualified, and a dynamic temperature satisfaction signal is generated and sent to the temperature control platform.

[0016] Furthermore, the process of temperature-time adaptation control unit is as follows:

[0017] The powder flow position in the hopper is divided into several sub-regions. When the residence time of the powder in the non-adjacent sub-region is within the set time range, the deviation value of the temperature rise rate of the powder passing through the corresponding sub-region is collected. At the same time, when the residence time of the powder in the non-adjacent sub-region is not within the set time range, the deviation value of the temperature fluctuation span of the powder passing through the corresponding sub-region is obtained.

[0018] The deviation values ​​of the temperature rise rate corresponding to the sub-region through which the powder passes and the deviation values ​​corresponding to the temperature fluctuation span of the sub-region through which the powder passes are compared with the speed deviation threshold and the span deviation threshold, respectively.

[0019] Furthermore, if the deviation value of the temperature rise rate of the powder passing through the corresponding sub-region exceeds the speed deviation threshold, or the deviation value of the temperature fluctuation span of the powder passing through the corresponding sub-region exceeds the span deviation threshold, it is inferred that the time and temperature need to be adaptively controlled, an adaptive control signal is generated and sent to the temperature control adjustment platform.

[0020] If the deviation value of the temperature rise rate of the powder passing through the corresponding sub-region does not exceed the speed deviation threshold, and the deviation value of the temperature fluctuation span of the powder passing through the corresponding sub-region does not exceed the span deviation threshold, then it is inferred that the time temperature does not need adaptive control, and a fixed temperature signal is generated and sent to the temperature control adjustment platform.

[0021] Furthermore, after receiving the adaptive control signal, the temperature control platform performs synchronous analysis and temperature regulation based on the residence time of the powder in the sub-regions and the temperature fluctuation of the corresponding residence stage. That is, if the residence time is extended, temperature fluctuation will occur, and temperature control will be performed; otherwise, no control will be performed.

[0022] Furthermore, the process of the heater status early warning unit is as follows:

[0023] When the powder moving speed fluctuates, the deviation of the powder temperature control fluctuation span under the same range of residence time in different sub-regions is obtained. At the same time, the increasing rate of the proportion of sub-regions that have not reached the set temperature is obtained. The deviation of the powder temperature control fluctuation span and the increasing rate of the proportion of sub-regions that have not reached the set temperature under the same range of residence time in different sub-regions are compared with the fluctuation span deviation threshold and the proportion increasing rate threshold, respectively.

[0024] Furthermore, if the deviation of the powder temperature control fluctuation span exceeds the fluctuation span deviation threshold under the same residence time range in different sub-regions, or if the rate of increase of the proportion of sub-regions that have not reached the set temperature exceeds the proportion increase rate threshold, it is inferred that the heating device status analysis is abnormal, a status warning signal is generated and sent to the temperature control adjustment platform.

[0025] If the deviation of the powder temperature control fluctuation span under the same residence time range in different sub-regions does not exceed the fluctuation span deviation threshold, and the rate of increase of the proportion of sub-regions that have not reached the set temperature does not exceed the rate of increase of the proportion threshold, then it is inferred that the heating device status analysis is normal, a status stability signal is generated and sent to the temperature control adjustment platform.

[0026] Compared with the prior art, the beneficial effects of the present invention are:

[0027] The system divides the process into "main drying period" and "deep dechlorination period" based on the rate of change in exhaust gas humidity, enabling dynamic temperature adaptation and avoiding the drawbacks of fixed temperatures. The main drying period uses a low temperature (e.g., 150℃) to reduce energy consumption from moisture evaporation, while the deep dechlorination period increases the temperature (e.g., 220℃) to ensure complete evaporation of chloride ions, balancing efficiency and dechlorination effect. By judging the threshold of temperature increase peak and peak constant duration, the system accurately triggers adjustment signals to avoid overheating or underheating, reducing the risk of iron oxide powder sintering.

[0028] The system divides the area into sub-regions based on the powder flow location, collects temperature deviation data accordingly, and adapts to the different residence times in different regions. Based on the threshold judgments of temperature rise rate deviation and temperature fluctuation range deviation, it achieves time-temperature adaptive control to ensure that the powder in the center and edge areas achieves qualified heating effects. This avoids localized insufficient or overheating caused by residence time distribution, and improves the uniformity and stability of the dechlorination effect.

[0029] 3. Monitor the temperature control fluctuation range of different sub-regions and the growth rate of the proportion of sub-regions that do not meet the standards to identify heating device abnormalities in advance; generate status warning signals in a timely manner to trigger hardware maintenance and operation node adjustments, thereby reducing equipment downtime due to failure; implement maintenance measures in combination with the powder movement location to improve maintenance efficiency and reduce equipment operating costs. Attached Figure Description

[0030] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0031] Figure 1 This is a system principle block diagram of the present invention. Detailed Implementation

[0032] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0034] Please see Figure 1As shown, the silicon removal terminal temperature control system based on multi-dimensional analysis includes a temperature control platform, which is communicatively connected to a dynamic temperature control unit, a temperature and time adaptation control unit, and a heater status early warning unit.

[0035] The temperature control platform has a communication connection that sends dynamic temperature control signals to the dynamic temperature control unit.

[0036] After receiving the dynamic temperature control signal, the dynamic temperature control unit dynamically controls the temperature of the secondary heating device added at the end of the silane during the desiliconization process. When the iron oxide powder is heated in the secondary heating device, chloride ions evaporate with the moisture. The powder has a high moisture content in the early stage of heating, which gradually decreases in the later stage. If the heating temperature is fixed throughout the process, the initial heating may be slow and inefficient because too much heat is used for moisture evaporation. In the later stage, the iron oxide powder may be locally sintered or energy may be wasted due to excessive temperature.

[0037] An online humidity sensor is installed on the exhaust pipe of the heating device to detect the relative humidity value of the exhaust gas in real time; based on the recorded exhaust gas humidity change rate during the heating process, and combined with the historical operation process of similar heating devices, the exhaust gas humidity change rate threshold is set, and the first-stage threshold and the second-stage threshold are set.

[0038] If the humidity change rate of the exhaust gas from the heating device exceeds the threshold of the first stage during the current heating process, it indicates that the current period is a period of rapid moisture evaporation and is marked as the main drying period.

[0039] If the humidity change rate of the exhaust gas of the corresponding heating device during the current heating process is lower than the threshold of the next stage, it indicates that the moisture has been completely evaporated and the deep removal of chloride ions has begun, and it is marked as the chlorine removal period.

[0040] The peak temperature increase of the heating device during the main drying period was obtained, and the duration of the corresponding peak value after the heating device reached a new peak temperature during the chlorination period was also obtained.

[0041] If the peak temperature increase of the heating device exceeds the peak temperature increase threshold during the main drying period, or if the duration of the corresponding peak temperature after the heating device reaches a new peak temperature during the chlorine removal period does not exceed the duration threshold, it is inferred that the heating device needs dynamic temperature adjustment. A dynamic temperature adjustment signal is generated and sent to the temperature control platform. After receiving the dynamic temperature adjustment signal, the temperature control platform performs dynamic temperature control. During the "main drying period," the system uses a lower heating temperature (e.g., 150℃) to avoid wasting energy on overheating the water. During the "deep dechlorination period," the system automatically raises the heating temperature to a higher set value (e.g., 220℃) to provide sufficient energy for the complete volatilization of chloride ions.

[0042] If the temperature increase peak of the heating device during the main drying period does not exceed the temperature increase peak threshold, and the corresponding peak value remains constant for a duration exceeding the duration threshold after the heating device reaches a new temperature peak during the chlorine discharge period, it is inferred that the current dynamic temperature setting of the heating device is qualified, and a dynamic temperature satisfaction signal is generated and sent to the temperature control platform.

[0043] The temperature control platform generates a temperature-time adaptation control signal and sends it to the temperature-time adaptation control unit.

[0044] After receiving the temperature and time adaptation control signal, the temperature and time adaptation control unit performs residence time temperature adaptation control on the powder in the hopper. The iron oxide powder in the hopper flows by gravity, and the residence time of the powder in different parts of the heating zone is different (there is a residence time distribution). Under a fixed heating temperature, the powder with a fast flow rate in the center may be underheated, while the powder with a slow flow rate at the edge may be overheated.

[0045] The powder flow position in the hopper is divided into several sub-regions. When the residence time of the powder in the non-adjacent sub-region is within the set time range, the deviation value of the temperature rise rate of the powder passing through the corresponding sub-region is collected. At the same time, when the residence time of the powder in the non-adjacent sub-region is not within the set time range, the deviation value of the temperature fluctuation span of the powder passing through the corresponding sub-region is obtained.

[0046] The deviation values ​​of the temperature rise rate corresponding to the sub-region through which the powder passes and the deviation values ​​corresponding to the temperature fluctuation span of the sub-region through which the powder passes are compared with the speed deviation threshold and the span deviation threshold, respectively:

[0047] If the deviation value of the temperature rise rate of the powder passing through the corresponding sub-region exceeds the speed deviation threshold, or the deviation value of the temperature fluctuation span of the powder passing through the corresponding sub-region exceeds the span deviation threshold, it is inferred that the time and temperature need adaptive control. An adaptive control signal is generated and sent to the temperature control platform. After receiving the signal, the temperature control platform performs synchronous analysis and temperature regulation based on the residence time of the powder in the sub-region and the temperature fluctuation of the corresponding residence stage. That is, if the residence time is extended, temperature fluctuation occurs and temperature control is performed; otherwise, no control is performed.

[0048] If the deviation value of the temperature rise rate of the powder passing through the corresponding sub-region does not exceed the speed deviation threshold, and the deviation value of the temperature fluctuation span of the powder passing through the corresponding sub-region does not exceed the span deviation threshold, then it is inferred that the time temperature does not need adaptive control, and a fixed temperature signal is generated and sent to the temperature control adjustment platform.

[0049] The temperature control platform generates a heater status warning signal and sends it to the heater status warning unit.

[0050] After receiving the heater status warning signal, the heater status warning unit performs status warning analysis on the heating device;

[0051] When the powder moving speed fluctuates, the deviation of the powder temperature control fluctuation span under the same range of residence time in different sub-regions is obtained, and the increasing rate of the percentage of sub-regions that have not reached the set temperature is also obtained.

[0052] The increasing rates of the powder temperature control fluctuation range deviation and the proportion of sub-regions that did not reach the set temperature under the same residence time range for different sub-regions were compared with the fluctuation range deviation threshold and the proportion increase rate threshold, respectively:

[0053] If the deviation of the powder temperature control fluctuation span exceeds the fluctuation span deviation threshold under the same residence time range in different sub-regions, or if the increase rate of the proportion of sub-regions that have not reached the set temperature exceeds the proportion increase rate threshold, it is inferred that the heating device status analysis is abnormal, a status warning signal is generated and sent to the temperature control adjustment platform. After receiving the signal, the temperature control adjustment platform performs hardware maintenance on the heating device and makes targeted adjustments to the heating device operation time nodes based on the powder movement position.

[0054] If the deviation of the powder temperature control fluctuation span under the same residence time range in different sub-regions does not exceed the fluctuation span deviation threshold, and the rate of increase of the proportion of sub-regions that have not reached the set temperature does not exceed the rate of increase of the proportion threshold, then it is inferred that the heating device status analysis is normal, a status stability signal is generated and sent to the temperature control adjustment platform.

[0055] Thresholds, preset values, preset ranges, etc. are set for result comparison and analysis to determine whether they are good or bad. The value of these thresholds is determined by a combination of large-scale model analysis of sample data and human experience. They can also be adjusted appropriately based on seasonal or common-sense influences.

[0056] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A silicon removal terminal temperature control system based on multivariate analysis, characterized in that, It includes a temperature control platform, which is connected to a dynamic temperature control unit, a temperature and time adaptation control unit, and a heater status early warning unit. During the desilicon removal process, the dynamic temperature control unit dynamically regulates the temperature of the secondary heating device added at the end of the hopper; after determining the temperature regulation pattern, the temperature and time adaptation control unit controls the residence time and temperature adaptation of the powder in the hopper. After adapting to the controlled temperature, the heater status early warning unit performs status early warning analysis on the heating device; The process of the dynamic temperature control unit is as follows: An online humidity sensor is installed on the exhaust pipe of the heating device to detect the relative humidity value of the exhaust gas in real time; based on the recorded exhaust gas humidity change rate during the heating process, and combined with the historical operation process of similar heating devices, the exhaust gas humidity change rate threshold is set, and the first-stage threshold and the second-stage threshold are set. If the humidity change rate of the exhaust gas from the corresponding heating device exceeds the threshold of the first stage during the current heating process, it indicates that the current stage is the rapid evaporation period of moisture and is marked as the main drying period; if the humidity change rate of the exhaust gas from the corresponding heating device is lower than the threshold of the next stage during the current heating process, it indicates that the moisture has been completely evaporated and the stage has entered the deep removal period of chloride ions and is marked as the chlorine removal period. The peak temperature increase of the heating device during the main drying period was obtained, and the duration of the corresponding peak value after the heating device reached a new peak temperature during the chlorination period was also obtained. If the peak temperature increase of the heating device during the main drying period exceeds the peak temperature increase threshold, or if the duration of the corresponding peak value after the heating device reaches a new peak temperature during the chlorine discharge period does not exceed the duration threshold, it is inferred that the current heating device needs dynamic temperature adjustment, and a dynamic temperature adjustment signal is generated and sent to the temperature control platform. If the peak temperature increase of the heating device during the main drying period does not exceed the peak temperature increase threshold, and the duration of the corresponding peak value after the heating device reaches a new peak temperature during the chlorine discharge period exceeds the duration threshold, it is inferred that the current dynamic temperature setting of the heating device is qualified, and a dynamic temperature satisfaction signal is generated and sent to the temperature control platform.

2. The silicon removal terminal temperature control system based on multivariate analysis according to claim 1, characterized in that, The process of temperature-time adaptation control unit is as follows: The powder flow position in the hopper is divided into several sub-regions. When the residence time of the powder in the non-adjacent sub-region is within the set time range, the deviation value of the temperature rise rate of the powder passing through the corresponding sub-region is collected. At the same time, when the residence time of the powder in the non-adjacent sub-region is not within the set time range, the deviation value of the temperature fluctuation span of the powder passing through the corresponding sub-region is obtained. The deviation values ​​of the temperature rise rate corresponding to the sub-region through which the powder passes and the deviation values ​​of the temperature fluctuation span corresponding to the sub-region through which the powder passes are compared with the speed deviation threshold and the span deviation threshold, respectively.

3. The silicon removal terminal temperature control system based on multivariate analysis according to claim 2, characterized in that, If the deviation value of the temperature rise rate of the powder passing through the corresponding sub-region exceeds the speed deviation threshold, or the deviation value of the temperature fluctuation span of the powder passing through the corresponding sub-region exceeds the span deviation threshold, it is inferred that the time and temperature need to be adaptively controlled, an adaptive control signal is generated and sent to the temperature control adjustment platform. If the deviation value of the temperature rise rate of the powder passing through the corresponding sub-region does not exceed the speed deviation threshold, and the deviation value of the temperature fluctuation span of the powder passing through the corresponding sub-region does not exceed the span deviation threshold, then it is inferred that the time temperature does not need adaptive control, and a fixed temperature signal is generated and sent to the temperature control adjustment platform.

4. The silicon removal terminal temperature control system based on multivariate analysis according to claim 3, characterized in that, After receiving the adaptive control signal, the temperature control platform performs synchronous analysis and temperature regulation based on the residence time of the powder in the sub-regions and the temperature fluctuation of the corresponding residence stage. That is, if the residence time is extended, temperature fluctuation will occur, and temperature control will be performed; otherwise, no control will be performed.

5. The silicon removal terminal temperature control system based on multivariate analysis according to claim 1, characterized in that, The process of the heater status early warning unit is as follows: When the powder moving speed fluctuates, the deviation of the powder temperature control fluctuation span under the same range of residence time in different sub-regions is obtained. At the same time, the increasing rate of the proportion of sub-regions that have not reached the set temperature is obtained. The deviation of the powder temperature control fluctuation span and the increasing rate of the proportion of sub-regions that have not reached the set temperature under the same range of residence time in different sub-regions are compared with the fluctuation span deviation threshold and the proportion increasing rate threshold, respectively.

6. The silicon removal terminal temperature control system based on multivariate analysis according to claim 5, characterized in that, If the deviation of the powder temperature control fluctuation span exceeds the fluctuation span deviation threshold under the same residence time range in different sub-regions, or if the rate of increase of the proportion of sub-regions that have not reached the set temperature exceeds the rate of increase of the proportion threshold, it is inferred that the heating device status analysis is abnormal, a status warning signal is generated and sent to the temperature control adjustment platform. If the deviation of the powder temperature control fluctuation span under the same residence time range in different sub-regions does not exceed the fluctuation span deviation threshold, and the rate of increase of the proportion of sub-regions that have not reached the set temperature does not exceed the rate of increase of the proportion threshold, then it is inferred that the heating device status analysis is normal, a status stability signal is generated and sent to the temperature control adjustment platform.

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