Induction temperature control adjusting device based on environment change

Abstract

The invention discloses an induction temperature control adjusting device based on environmental changes, and belongs to the technical field of petrochemical engineering. The device comprises a partition environment induction and execution subsystem, a core controller, a main temperature control system and a main coordinator. The outer surface of a petrochemical container is divided into a plurality of independent control areas, and each area is provided with an environment sensing unit integrated with a miniature anemometer, a sunlight sensor and a surface temperature sensor, and execution mechanisms such as an automatic wind shield and an electric tracing band, so that real-time monitoring of microenvironment parameters is realized. The core controller is internally provided with a transient heat conduction model and can predict material temperature changes and generate control signals, and the partition executing mechanism is driven to conduct pre-compensation on environment thermal disturbance. And the main coordinator coordinates the operation of the main temperature control system according to the material temperature. The problems that a traditional temperature control system is lagged in response and uneven in control are solved, and accurate temperature control, energy conservation, consumption reduction and equipment safety protection are achieved.

Description

Technical Field

[0001] This invention relates to the field of petrochemical technology, specifically to a temperature control device based on environmental changes. Background Technology

[0002] In petrochemical production, large equipment such as storage tanks, reactors, and distillation towers are typically located in the open air. The temperature stability of the materials inside these structures directly affects process safety, product quality, and energy consumption. Due to their large size, significant thermal inertia, and wide contact with the external environment, dynamic changes in environmental factors (such as wind speed, sunlight, ambient temperature, and precipitation) can significantly and unevenly disrupt their thermal equilibrium, posing a significant challenge to maintaining a constant material temperature—a core control objective. Therefore, developing advanced temperature control technologies and devices that can effectively cope with environmental disturbances is of great significance for improving the intelligence level of petrochemical production, ensuring safety, and reducing energy consumption.

[0003] Currently, the temperature control methods commonly used in the petrochemical industry mainly rely on temperature sensors (such as platinum resistance thermometers) installed inside the equipment to monitor material temperature and employ PID (proportional-integral-derivative) control algorithms to regulate temperature by adjusting the flow rate of heat transfer media such as steam, hot water, or cooling water. This control strategy based on a single internal temperature feedback has two fundamental drawbacks. First, it is essentially a lag response mode: the control system only begins to act after environmental changes have already affected the material temperature and caused it to deviate from the set value, failing to anticipate and counteract impending temperature fluctuations. For example, in the event of a sudden strong wind, heat dissipation from the equipment walls increases dramatically, but the internal material temperature decreases slowly due to thermal inertia. By the time the controller detects the deviation and increases the heating power, the material temperature may have already dropped to the lower limit of the process, causing production fluctuations. Second, existing technologies treat large equipment as a homogeneous whole for control, ignoring the spatial non-uniformity of environmental disturbances. In reality, the heat load borne by the windward and leeward sides, and the sunward and shaded sides, differs significantly. This uneven heat exchange leads to temperature gradients on the equipment walls, causing unnecessary thermal stress and affecting equipment lifespan. Simultaneously, to compensate for the temperature in the most unfavorable areas (such as the coldest points), the control system must overheat the entire system, resulting in significant energy waste. The root cause of these shortcomings lies in the lack of real-time, spatial sensing capabilities for external environmental parameters, and the absence of a proactive, zoned compensation control mechanism based on these parameters. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] To address the shortcomings of existing technologies, this invention provides a temperature control device based on environmental changes, which solves the problems mentioned in the background section.

[0006] (II) Technical Solution

[0007] To achieve the above objectives, the present invention is implemented through the following technical solution: a temperature control device based on environmental changes, comprising: a partitioned environmental sensing and execution subsystem, at least two independent control areas dividing the outer surface of a petrochemical container, and a partitioned environmental sensing unit, a partitioned execution mechanism, a core controller, a main temperature control system, and a main coordinator configured for each of the independent control areas;

[0008] The partitioning actuator physically adjusts the heat dissipation or heating conditions of the area according to the control signal; the partitioning actuator is one or more of the following combinations: automatic wind baffle, heat insulation partition, independently controlled electric heating tape or heat tracing coil circuit;

[0009] The input terminal of the core controller is communicatively connected to each of the partitioned environmental sensing units, and its output terminal is communicatively connected to each of the partitioned actuators. It also has a built-in transient heat conduction model based on the heat capacity, thermal conductivity, and environmental convection coefficient of the container wall material. This model is used to map microenvironmental parameters to the surface heat flux density over a future time interval Δt, and further convert it into a predicted material temperature offset value. The core controller is configured to independently generate control signals for the partitioned actuators in each region based on the predicted material temperature offset value and the deviation between the surface temperature of that region and the set temperature.

[0010] The main temperature control system is used to regulate the overall temperature of the material inside the petrochemical container; the main coordinator has its input terminal connected to the core controller and the material temperature sensor installed inside the petrochemical container, and its output terminal connected to the main temperature control system; the main coordinator is configured to coordinate and control the start-up, shutdown, or power of the main temperature control system based on the readings of the material temperature sensor.

[0011] Preferably, the zoned environmental sensing unit integrates a miniature anemometer, a solar radiation sensor, and a surface temperature sensor, enabling comprehensive and accurate perception of key environmental disturbance factors (wind, solar radiation) and their direct results (surface temperature).

[0012] Preferably, the partitioned environment sensing and execution subsystem further includes a partitioned topology reconstruction module, which is used to dynamically adjust the merging and division of independent control areas according to the combined direction of the solar radiation vector and the wind speed vector, so that the system partitioning strategy changes from static to dynamic, and can intelligently adapt to the directional changes of environmental disturbances, so as to maximize energy efficiency with the optimal degree of control freedom.

[0013] Preferably, the partitioning actuator further includes a phase change material layer disposed between the electric heating tape and the outer wall of the container. Its phase change temperature is equal to the lower limit of the material's set temperature. By utilizing the latent heat characteristics of the phase change material, it can "smooth out peaks and fill valleys" in a purely physical way, suppressing temperature fluctuations, significantly reducing the start-up frequency and duration of the active heating system, and achieving substantial energy savings.

[0014] Preferably, the core controller further includes a parameter identification module, which is used to correct the convective heat transfer coefficient in the transient heat conduction model in real time based on historical sensor data. The correction algorithm adopts the recursive least squares method with a forgetting factor, which enables the system to have self-learning and self-evolution capabilities, automatically adapt to time-varying factors such as equipment scaling and insulation layer aging, maintain the accuracy of the prediction model in the long term, and solve the industry pain point of model distortion.

[0015] Preferably, the core controller is also equipped with a neighboring zone coupling compensator, which is used to calculate the lateral heat flux density based on the surface temperature gradient of adjacent independent control zones, and to perform feedforward compensation on the control signal of the actuator in this zone. This effectively solves the inherent lateral heat conduction problem of large metal containers, avoids system oscillation or energy loss that may be caused by independent zone control, and improves the stability and efficiency of control.

[0016] Preferably, the partition execution mechanism also integrates an energy metering module, which is used to record the cumulative energy consumption of the electric heating cable in the partition in real time, calculate the carbon emissions in the partition through the carbon emission conversion factor, and upload the data to the factory energy management system. This provides a direct data interface for refined energy management and carbon accounting, meeting the needs of green factories and digital management.

[0017] Preferably, the side of the automatic wind deflector facing the sky is coated with a selective radiation cooling coating with an emissivity ≥0.93 within an 8-13μm atmospheric transmission window. Applying radiation cooling technology to the petrochemical temperature control field enables the actuator to not only block the wind and keep the temperature, but also passively provide cooling capacity at night, thus expanding the system's functionality.

[0018] Preferably, the core controller further includes a fault degradation module, which is used to enable the weighted average of neighboring sensor data as a substitute input when the loss of signal of the partitioned environmental sensor unit is detected, and to send a fault code to the main coordinator at the same time. This greatly enhances the robustness and reliability of the system, and ensures that the entire system can still operate safely and in a degraded manner when a local sensor fails, which meets the high availability requirements of industrial scenarios.

[0019] A temperature control method based on environmental change sensing, applied to the aforementioned temperature control device based on environmental change sensing, includes the following steps:

[0020] S1. Monitor the micro-environmental parameters of each independent control area in real time through the environmental sensing units of each zone;

[0021] S2. The core controller calculates the predicted material temperature deviation based on the micro-environment parameters of each region using the built-in transient heat conduction model, and independently generates control signals to drive the corresponding region's partition actuators to perform pre-compensation for environmental thermal disturbances in that region.

[0022] S3. The main coordinator monitors the temperature of the material inside the container and coordinates the operation of the main temperature control system to achieve the final control of the overall temperature of the material.

[0023] S4. Upload the energy consumption data of each zone actuator to the cloud and optimize the zone control parameters using a digital twin model.

[0024] (III) Beneficial Effects

[0025] This invention provides a temperature control device based on environmental changes, which has the following advantages:

[0026] 1. The invention captures wind speed and solar radiation changes in real time through zoned environmental sensing, and uses a transient heat conduction model to predict future temperature trends, driving the actuator to proactively compensate for environmental thermal disturbances. This transforms the control mode from passive and lagging to proactive and forward-looking, reducing temperature fluctuations by more than 70%, greatly ensuring process stability and product quality.

[0027] 2. This invention, through a zoned independent control architecture, allows for differentiated regulation of different areas of the equipment, effectively mitigating wall temperature gradients caused by uneven environmental loads and reducing thermal stress by more than 50%. Simultaneously, the "on-demand compensation" mechanism avoids overheating of the overall equipment, resulting in measured average energy savings of 25%-40%. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the system of the present invention. Detailed Implementation

[0029] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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.

[0030] Example 1:

[0031] like Figure 1 As shown, this embodiment provides a temperature control and regulation device for a large open-air crude oil storage tank. The crude oil storage tank is 15 meters high and 30 meters in diameter, and its outer surface is divided into 12 independent control zones (3 layers along the height and 4 zones along the circumference).

[0032] A zoned environmental sensing unit is installed on the outer wall of each control zone. This unit integrates: a miniature ultrasonic anemometer (measuring range 0-20 m / s, accuracy ±0.3 m / s); and a solar radiation intensity sensor (measuring range 0-1500 W / m). 2 (Accuracy ±5%); Platinum resistance surface temperature sensor (measuring range -50℃~100℃, accuracy ±0.5℃)

[0033] The zoned execution mechanism adopts two combination forms: an electric heating tape with a power density of 30W / m is installed within 2 meters of the bottom of the crude oil storage tank, and the outer layer is covered with an insulation layer; an automatic wind deflector is installed in the upper part of the storage tank, made of 304 stainless steel, with a height of 1.5 meters, and can achieve stepless adjustment from 0-90°.

[0034] The core controller (202) adopts an industrial-grade PLC (Siemens S7-1500 series) with a built-in transient heat transfer model. The model parameters include: the tank wall material is 12mm thick Q345R steel; the insulation layer is made of rock wool used in crude oil storage tanks; and the initial value of the convective heat transfer coefficient is 12W / (m²). 2 ·K).

[0035] During operation, the system runs according to the following process:

[0036] 1. Each sensor unit collects environmental data once per minute;

[0037] 2. The core controller calculates the temperature change trend of the area within the next 5 minutes based on the current wind speed and solar radiation intensity using a heat conduction model;

[0038] 3. When the predicted temperature is lower than the set value (e.g., 40℃), activate the electric tracing heating tape for the corresponding area in advance.

[0039] 4. When the wind speed in a certain area exceeds 5 m / s, adjust the angle of the wind deflector in that area to reduce heat dissipation.

[0040] 5. The main coordinator monitors the temperature of crude oil inside the tank. When multiple areas need to be heated, the main temperature control system is activated first for heating.

[0041] Example 2:

[0042] The difference between this embodiment and Embodiment 1 is that:

[0043] A phase change material layer is added between the electric heating cable and the tank wall. The material is a paraffin-graphene composite material, and the phase change temperature is set to 38℃.

[0044] The outer surface of the automatic windshield is coated with a SiO2-PDMS radiation cooling coating, achieving an emissivity of 0.95 in the 8-13μm band.

[0045] The core controller has been enhanced with a parameter identification module, which automatically updates the convective heat transfer coefficient model parameters every 24 hours.

[0046] Each partition actuator is equipped with an energy metering module (TI INA226 chip) to record energy consumption data in real time.

[0047] Implementation results: Under the same environmental conditions, compared with the traditional temperature control system, this device reduces the temperature fluctuation range of the storage tank from ±5℃ to ±1.5℃, and achieves an energy saving rate of more than 35%. At the same time, it effectively reduces the thermal stress caused by uneven temperature.

[0048] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An environmental change-based inductive temperature control adjustment device, characterized by, The system comprises: a partitioned environment sensing and execution subsystem, at least two independently controlled areas divided from the outer surface of the petrochemical container, and a partitioned environment sensing unit, a partitioned execution mechanism, a core controller, a main temperature control system, and a main coordinator configured for each of the independently controlled areas; the partitioned execution mechanism physically adjusts the heat dissipation or heating conditions of the area according to the control signal; the partitioned execution mechanism is a combination of one or more of an automatic wind shield, a heat insulation partition, an independently controlled electric heat tracing band, or a heat tracing coil circuit; the input end of the core controller is communicatively connected with each of the partitioned environment sensing units, the output end thereof is communicatively connected with each of the partitioned execution mechanisms, and the core controller is internally provided with a transient heat conduction model based on the heat capacity, thermal conductivity, and environmental convection coefficient of the container wall material, for mapping the micro-environment parameters to the surface heat flux density in the future Δt time and further converting the surface heat flux density to a material temperature offset prediction value; the core controller is configured to independently generate a control signal for the partitioned execution mechanism of each area based on the material temperature offset prediction value of each area and the deviation of the surface temperature of the area from the set temperature; the main temperature control system is used for overall temperature adjustment of the material in the petrochemical container; the input end of the main coordinator is communicatively connected with the core controller and a material temperature sensor arranged in the petrochemical container, and the output end thereof is communicatively connected with the main temperature control system; the main coordinator is configured to coordinate the start-stop or power of the main temperature control system based on the readings of the material temperature sensor.

2. The environmental change-based inductive temperature control adjustment device of claim 1, wherein: The partitioned environment sensing unit is integrated with a micro anemometer, a sunshine sensor, and a surface temperature sensor.

3. The ambient change based sensing temperature control adjustment device of claim 1, wherein: The partitioned environment sensing and execution subsystem further comprises a partitioned topology reconstruction module for dynamically adjusting the merging and division of the independently controlled areas according to the combined direction of the sunshine vector and the wind speed vector.

4. The ambient change based sensing temperature control adjustment device of claim 1, wherein: The partitioned execution mechanism further comprises a phase change material layer arranged between the electric heat tracing band and the outer wall of the container, and the phase change temperature of the phase change material layer is equal to the lower limit of the set temperature of the material.

5. The environmentally responsive sensing and temperature control device of claim 1, wherein: The core controller further comprises a parameter identification module for real-time correction of the convective heat transfer coefficient in the transient heat conduction model based on historical sensing data, and the correction algorithm is selected as a recursive least square method with a forgetting factor.

6. The environmentally responsive sensing and temperature control device of claim 1, wherein: The core controller is further provided with a neighboring area coupling compensator for calculating the transverse heat flux density according to the surface temperature gradient of the adjacent independently controlled areas and feeding forward compensating the control signal of the partitioned execution mechanism of the area.

7. The ambient change based sensing temperature control adjustment device of claim 1, wherein: The partitioned execution mechanism is further integrated with an electric power metering module for real-time recording of the cumulative energy consumption of the electric heat tracing band of the area, calculating the carbon emission of the area through a carbon emission conversion coefficient, and uploading to a factory energy management system.

8. An environmental change-based inductive temperature control adjustment method applied to the environmental change-based inductive temperature control adjustment device of any one of claims 1-7, characterized in that, The method comprises the following steps: S1, real-time monitoring of the micro-environment parameters of each independently controlled area through each partitioned environment sensing unit; S2, the core controller calculates the material temperature offset prediction value through the built-in transient heat conduction model based on the micro-environment parameters of each area, and independently generates a control signal to drive the partitioned execution mechanism of the corresponding area to act, so as to pre-compensate the environmental thermal disturbance of the area. S3, the master coordinator monitors the temperature of the material in the container and coordinates the operation of the master temperature control system to achieve the final control of the overall temperature of the material; S4, upload the energy consumption data of each partition execution mechanism to the cloud, and optimize the partition control parameters by using the digital twin model.

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