Coal blending dynamic optimization control system for coke making based on dry quenching

Abstract

The present application belongs to the technical field of coking production in metallurgical industry, and relates to a dynamic optimization and regulation system for coking coal blending based on dry quenching. The present application solves the technical problem that safety and production efficiency are difficult to be considered in the process of dry quenching by constructing a collaborative mechanism of system state determination, real-time optimization and regulation, abnormal diagnosis and periodic closed-loop optimization. The system monitors safety indicators in real time, automatically switches between safety and optimization modes; in the optimization mode, the circulating air volume is pre-adjusted according to the trend of the pushing current, the air volume is adjusted gradually based on the temperature deviation of the coke discharging, and the coke discharging amount is controlled in linkage to maintain the safety of the material level; when the temperature is abnormal, early warning is performed by analyzing the correlation between the coal quality index and the change of the coal blending ratio; the optimization effect is compared periodically, the difference between the coke performance and the corrected steam production is calculated, and the adjustment of the coal blending ratio and the process parameters is guided, so that the safety and stable operation of the dry quenching system is ensured, and the dynamic optimization and precise regulation of the coking coal blending scheme are achieved.

Description

Technical Field

[0001] This invention belongs to the field of coking production technology in the metallurgical industry, and relates to a dynamic optimization and control system for coking coal blending based on dry quenching. Background Technology

[0002] Dry quenching technology, as an important process for energy conservation, emission reduction, and improving coke quality in the coking industry, has been widely applied in modern coking production. This process cools red-hot coke through inert gas circulation and recovers waste heat to produce steam. Its operational stability and energy efficiency directly affect coke quality and system economy.

[0003] During dry quenching operation, the coordinated control of key parameters such as circulating air volume, coke discharge volume, and material level is closely related to the upstream coking coal blending scheme. The coal blending ratio determines the coking characteristics of the coal fed into the furnace and the quality of the coke, which in turn affects the resistance of the coke pushing operation, the cooling behavior of the coke in the dry quenching furnace, and the final coke strength and thermal properties.

[0004] Currently, the dry quenching system still has the following main shortcomings in the formulation of key parameters and coking coal blending schemes:

[0005] In traditional dry quenching systems, existing control strategies lack a proactive pre-regulation mechanism to address the periodic heat load shocks caused by coke pushing operations. The system typically only responds after the disturbance occurs, resulting in a significant response delay. Furthermore, the control of coke discharge temperature and the adjustment of the dry quenching furnace feed level are often performed independently, easily leading to coupled oscillations in system parameters when responding to disturbances, exacerbating operational fluctuations. At its root, these disturbances are closely related to the thermophysical properties of the red-hot coke entering the furnace, which are directly determined by the upstream coking coal blending scheme. However, existing control strategies do not incorporate coal blending information as a feedforward or constraint condition into the control system.

[0006] Furthermore, when the coke discharge temperature remains abnormal, existing analytical methods rely on operators' experience for post-event judgment. Because the abnormal temperature trend is not correlated with changes in key coal quality indicators and coal blending ratios upstream during the same period, the diagnostic process is inefficient and inaccurate. This data fragmentation makes it difficult to accurately trace whether the anomaly stems from improper cooling process control or from changes in the inherent properties of coke caused by changes in coal blending, thus failing to provide decision support for production adjustments.

[0007] Furthermore, there is a lack of effective data loop between existing coal blending optimization and dry quenching operation control. The formulation of coal blending schemes often fails to fully consider their real-time impact on the energy efficiency of the dry quenching system, and the process data of dry quenching is not systematically fed back to guide coal blending optimization, resulting in limited cross-process collaborative optimization capabilities. Summary of the Invention

[0008] In view of this, in order to solve the problems mentioned in the background technology, a dynamic optimization and control system for coking coal blending based on dry quenching is proposed.

[0009] The objective of this invention can be achieved through the following technical solution: a dynamic optimization and control system for coking coal blending based on dry quenching, comprising: a system status determination module: real-time monitoring of dry quenching safety indicators; if any indicator exceeds the safety threshold, the system control status is set to safety mode; otherwise, it is set to optimization mode.

[0010] Real-time optimization and control module: When the system is in optimization mode, before the coke pushing operation, the circulating air volume is dynamically adjusted according to the changing trend of the coke pushing current; during the coke pushing operation, the circulating air volume is gradually adjusted based on the deviation between the coke discharge temperature and the temperature reference value, and the coke discharge volume is adjusted simultaneously to keep the material level within a safe range.

[0011] Anomaly Diagnosis Module: After real-time optimization and control, if the coke discharge temperature does not decrease effectively within a continuous cycle, the module analyzes its synchronicity with the trends of key coal quality indicators and coal blending ratio changes during the same period. When most comparison results are synchronized, an early warning signal is generated.

[0012] The closed-loop optimization module divides and compares the optimized and baseline operating periods, calculates the difference between coke performance and corrected steam production, and determines the direction and magnitude of adjustment of coal blending ratio and process parameters for the next cycle based on early warning signals.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0014] (1) This invention solves the system fluctuations caused by feedback delay and independent adjustment of single parameters by adjusting the circulating air volume in advance according to the trend of the coking current before the coking operation and coordinating the control of coking temperature and material level during the coking operation. This method combines predictive adjustment with gradual feedback and makes the air volume and coking volume correlated, thereby weakening the influence of periodic disturbances and realizing coordinated and stable control of thermal balance and material balance in the dry quenching furnace.

[0015] (2) This invention solves the problems of low efficiency and poor accuracy of manual diagnosis by continuously comparing the temperature trend with the changes in coal quality and coal blending data during the same period. When the temperature is continuously abnormal, this method can automatically identify coal quality indicators or coal blending ratios that are highly correlated with them and generate targeted early warnings. Thus, abnormal diagnosis is transformed from experience-based inference to data-driven, realizing rapid and targeted identification and early warning of the root causes of production disturbances.

[0016] (3) This invention solves the problem of disconnect between cross-process optimization by quantitatively analyzing the actual impact of coal blending adjustments on coke quality and system energy efficiency, such as corrected steam output. This method uses closed-loop actual production data to guide the adjustment of coal blending ratios and process parameters in the next cycle, so that coal blending optimization not only focuses on coke quality, but also takes into account the economic efficiency of dry quenching operation, and ultimately achieves a synergistic improvement in quality, energy efficiency and cost throughout the entire process. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram showing the connection of each module in the dynamic optimization and control system for coking coal blending based on dry quenching in this invention.

[0019] Figure 2 This is a flowchart illustrating the dynamic adjustment of circulating air volume based on the changing trend of the coke pushing current in this invention.

[0020] Figure 3 This is a flowchart illustrating how the coke discharge rate is synchronously adjusted to maintain the material level within a safe range in this invention. Detailed Implementation

[0021] 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.

[0022] Please see Figure 1 As shown, the present invention provides a dynamic optimization and control system for coking coal blending based on dry quenching, including: a system status determination module, a real-time optimization and control module, an anomaly diagnosis module, and a periodic closed-loop optimization module. The connection relationship between the modules is as follows: the system status determination module and the real-time optimization and control module are connected, the real-time optimization and control module and the anomaly diagnosis module are connected, and the anomaly diagnosis module and the periodic closed-loop optimization module are connected.

[0023] During the operation of a dry quenching system, exceeding safety limits such as the concentration of combustible components in the circulating gas, system pressure, or temperature may lead to serious safety accidents such as explosions, equipment damage, or production interruptions. If only a fixed and conservative operating strategy is adopted, such as always maintaining low air volume and low load, although it can minimize the risk of exceeding safety limits and ensure basic system safety, it will result in the cooling capacity of the dry quenching unit being unable to match the actual heat load, causing excessively high and fluctuating coke discharge temperature, unstable coke quality, and steam output that is significantly lower than the design value, resulting in low economic benefits in the long term.

[0024] Therefore, this invention employs two dynamically switchable control mechanisms: a safety mode and an optimization mode. The system status determination module monitors various safety indicators of dry quenching in real time. If any indicator exceeds a safety threshold, the system control state is set to safety mode; otherwise, the system remains in or switches to optimization mode.

[0025] The safety mode refers to the operating state aimed at ensuring system safety. In this state, the system will suspend all active optimization algorithms that aim to improve energy efficiency or quality, and forcibly switch to a pre-verified, stable and conservative basic control strategy, such as fixed air volume and constant speed coke removal.

[0026] The optimization mode refers to the operating state in which, when all safety indicators are confirmed to be within the safety threshold, the system has the corresponding permissions and computing resources, and implements dynamic control strategies to improve overall operating efficiency and process performance.

[0027] The method for obtaining the safety threshold is as follows: First, the initial theoretical threshold is determined by taking the most stringent rule by comprehensively considering the design specifications, manufacturer parameters and industry regulations. Then, cluster analysis is used to extract the statistical fluctuation range of each indicator under normal operating conditions from historical data. Subsequently, the initial theoretical threshold is compared with the normal fluctuation range. If the upper limit of the normal fluctuation of a certain indicator is continuously lower than its theoretical value, the threshold is tightened according to a certain high percentile of the upper limit, and finally the safety threshold is obtained.

[0028] Furthermore, when the system is determined to enter a safe mode, its execution logic ensures the absolute principle of safety priority. Specifically, this includes: when the system is in a safe mode, the system state determination module generates a safety interlock command, the real-time optimization and control module suspends the execution of optimization and adjustment commands, and the entire system automatically degrades and stably operates under the basic control strategy to maintain the basic operation of the dry quenching system.

[0029] Considering the complex on-site environment and long signal transmission distance during the operation of the dry quenching system, and the potential discrepancies between the physical readings of the on-site instruments and the values ​​displayed on the human-machine interface of the control system due to factors such as the accuracy of the instruments and the calibration cycle, signal interference, or data processing delays, it is important to take into account that the dry quenching system is not operating in a way that is not conducive to the development of a dry quenching system.

[0030] Therefore, in one specific embodiment, the system status determination module further includes data reliability verification, including: synchronously acquiring the physical readings of the field instruments and the real-time display values ​​corresponding to the human-machine interface of the control system.

[0031] Calculate the real-time deviation between the physical reading and the displayed value, set the continuous monitoring time to 5 minutes, and determine the data as abnormal when the real-time deviation continuously exceeds the preset percentage of the instrument's range within this time.

[0032] Real-time optimization and control module: When the system is in optimization mode, before the coke pushing operation, the circulating air volume is dynamically adjusted according to the changing trend of the coke pushing current; during the coke pushing operation, the circulating air volume is gradually adjusted based on the deviation between the coke discharge temperature and the temperature reference value, and the coke discharge volume is adjusted simultaneously to keep the material level within a safe range.

[0033] The real-time optimization and control module is activated when the system is in optimization mode. In the complete process of red coke loading-circulation cooling-cold coke discharge in the dry quenching system, the red coke loading stage is characterized by the huge physical sensible heat carried by the red coke itself, usually above 1000°C, and the loading process is completed in a short period of time.

[0034] Therefore, the coke pushing operation during the red-coke loading stage is the source of periodic high heat load disturbances, and its impact affects the entire process before and after red-coke loading. Therefore, this module decomposes the control process into two stages: pre-adjustment before coke pushing and closed-loop correction during coke pushing.

[0035] The first stage: pre-adjustment before focusing.

[0036] Before the coking operation, the different coking states of the coke cake in different carbonization chambers result in varying pushing resistance, which makes the initial heat load of the red-hot coke about to enter the dry quenching furnace uncertain. Traditional control methods cannot detect this change in advance and often passively respond to the strong thermal shock after the coking begins, leading to drastic fluctuations in coke discharge temperature and system pressure.

[0037] Therefore, please refer to Figure 2 As shown, in a specific embodiment of the present invention, before the coke pushing operation, the circulating air volume is dynamically pre-adjusted according to the changing trend of the coke pushing current. The steps include: receiving the coke oven coke pushing plan signal, determining the start time of the coke pushing operation, and collecting the current data of the coke pushing motor in real time during a set period before the start time. The collection frequency is set according to the system response requirements, for example, once per second.

[0038] When the current data shows a monotonically increasing trend over three consecutive monitoring cycles and the cumulative change exceeds the allowable fluctuation range, it indicates that the coke pusher motor needs to output greater torque to overcome the increased friction or deformation resistance caused by the movement of the coke cake, thus indicating that the coke cake ejection resistance has increased. When the current data shows a monotonically decreasing trend over three consecutive monitoring cycles and the cumulative change exceeds the allowable fluctuation range, it indicates that the driving force required to push the coke cake has decreased, thus indicating that the coke cake ejection resistance has decreased.

[0039] The allowable fluctuation range is based on the current data of the coking process under historical normal production conditions of the coking device, the standard deviation of the fluctuation is calculated, and 2-3 times the standard deviation is taken as the allowable fluctuation range.

[0040] If the resistance is determined to be increasing, it means that the heat load of the red-hot coke entering the system may exceed the expected processing capacity of the current cooling system. In this case, the circulating air volume is increased proportionally according to the resistance change before the red-hot coke enters the dry quenching furnace. Similarly, if the resistance is determined to be decreasing, it means that the heat load of the red-hot coke entering the system may be lower than the expected processing capacity. In this case, the circulating air volume is decreased proportionally according to the resistance change before the red-hot coke enters the dry quenching furnace.

[0041] The adjustment ratio is determined by collecting historical data on the changes in coke pushing current and the corresponding changes in coke discharge temperature, testing different air volume adjustment ratios within a safe range, and selecting the ratio with the best effect.

[0042] Second stage: Closed-loop correction during focus pushing.

[0043] During the coke pushing operation, the concentrated loading of a large amount of red coke causes a sudden increase in the heat load inside the dry quenching furnace, and the coke discharge temperature fluctuates accordingly. In order to control the temperature, the circulating air volume needs to be adjusted, which in turn directly affects the settling and discharge rate of coke in the system.

[0044] If the coke discharge rate is not synchronized with the coke discharge rate, it can easily cause drastic fluctuations in the material level. This leads to mutual interference between the two control loops of temperature control and material level stabilization: on the one hand, increasing the air volume to cool down may accelerate coke discharge and cause the material level to drop too quickly; on the other hand, restricting coke discharge to stabilize the material level may cause high-temperature coke to remain and exacerbate the temperature rise.

[0045] Such conflicts between control objectives can create a vicious cycle of positive feedback, causing continuous oscillations in system parameters.

[0046] Therefore, in one specific embodiment, during the coke pushing operation, the gradual adjustment of the circulating air volume based on the deviation between the coke discharge temperature and the temperature reference value includes:

[0047] During the coke pushing operation, the coke discharge temperature is collected in real time. Based on the coke discharge temperature during the period when the system was in the optimization mode in the previous production shift, the temperature reference value is calculated by the arithmetic mean method. Furthermore, the real-time deviation between the current coke discharge temperature and the temperature reference value is calculated, and the trend of deviation change is continuously monitored.

[0048] When the real-time deviation continues to increase over three or more consecutive sampling periods, and the deviation increment in adjacent sampling periods is greater than the historical temperature fluctuation amplitude for the same period, an initial adjustment is performed on the circulating air volume. If, after the initial adjustment, the coke discharge temperature does not fall back to the allowable deviation range of the temperature reference value (e.g., ±3℃) within a subsequent fixed observation period of 10 minutes, the circulating air volume is adjusted again with equal amplitude.

[0049] The historical temperature fluctuation amplitude is determined by calculating the standard deviation of the coke discharge temperature data from the same operating period of the most recent 30 production shifts.

[0050] The initial adjustment is set as follows: during the production stabilization period, based on the current coke discharge temperature, the circulating air volume is adjusted by multiple amplitudes, the time it takes for the coke discharge temperature to return to the target range under each amplitude, and the standard deviation of the temperature after return within the stabilization monitoring period are recorded, and the adjustment amplitude with the best effect is selected as the fixed parameter for the initial adjustment.

[0051] Repeat the above observation and adjustment process. If the upper limit of the circulating air volume adjustment is reached, stop the adjustment and trigger an over-limit alarm. If the coke discharge temperature is still higher than the safety limit at this time, switch the system control state to safety mode. The upper limit of the circulating air volume adjustment is set to the rated maximum air volume value of the circulating fan.

[0052] Further, please refer to Figure 3 As shown, the synchronous adjustment of the coke discharge rate to keep the material level within a safe range includes: adjusting the coke discharge rate in the opposite direction based on the real-time position of the current system material level each time the circulating air volume is adjusted.

[0053] If the current system material level is higher than the safety zone threshold, such as 55%, then the direction of coke discharge adjustment is the same as the direction of circulating air volume adjustment to enhance the cooling effect in a coordinated manner, and the adjustment range is in a fixed ratio with the adjustment range of circulating air volume, for example, 0.8 times the air volume adjustment range.

[0054] If the current system material level is lower than or equal to the partition threshold, the adjustment direction of the coke discharge volume is reversed with the adjustment direction of the circulating air volume to prioritize material level safety.

[0055] It should be added that when the system material level is lower than or equal to the zone threshold, a material level stabilization operation is prioritized, that is, the direction of coke discharge adjustment is opposite to the direction of circulating air volume adjustment, to prevent the material level from further decreasing to a dangerous level. During this process, the system will temporarily relax the convergence requirements for coke discharge temperature deviation, and resume coordinated control of coke discharge temperature after the material level recovers to the upper part of the safe range.

[0056] Anomaly Diagnosis Module: After real-time optimization and control, if the coke discharge temperature does not decrease effectively within a continuous cycle, the module analyzes its synchronicity with the trends of key coal quality indicators and coal blending ratio changes during the same period. When most comparison results are synchronized, an early warning signal is generated.

[0057] Considering that the gradual adjustment of the circulating air volume in the real-time optimization and control module is triggered by the abnormal deviation of the coke discharge temperature, if the air volume has reached the upper limit of adjustment after several consecutive adjustment cycles, but the abnormal coke discharge temperature is still not eliminated, it indicates that the abnormality may not be caused by insufficient adjustment of the cooling medium, but is related to changes in key coal quality indicators or adjustments in the coal blending ratio.

[0058] Therefore, it is necessary to determine whether there is a source disturbance directly related to the characteristics of red coke entering the furnace. In one specific implementation, the anomaly diagnosis module includes: continuing to monitor the coke discharge temperature during the gradual adjustment of the circulating air volume and while the system remains in the optimization mode.

[0059] If the average value of the coke discharge temperature in each of the three consecutive fixed observation periods is not lower than the average value of the corresponding period before the adjustment was started, it indicates that the coke discharge temperature has not been effectively suppressed after the active cooling intervention has been implemented and the abnormal state still exists. Therefore, it is determined that the temperature abnormality is persistent.

[0060] The system retrieves historical data from the moment the temperature anomaly was determined to be persistent, including the coke discharge temperature, key coal quality indicators such as volatile matter, caking index, and sulfur content, as well as the coal blending ratio over a specified historical period, such as the past 24 hours.

[0061] For the same time interval, the rise and fall of coke discharge temperature between consecutive sampling points is marked, and the rise and fall of corresponding key coal quality indicators or coal blending ratio values ​​between the same consecutive sampling points is marked simultaneously.

[0062] If the marking results are compared, and the coke discharge temperature shows an increasing trend in three or more consecutive sampling points, and the key coal quality indicators or coal blending ratios in the corresponding intervals also show an increasing trend, it indicates that the deterioration trend of the coke discharge temperature and the change trend of specific coal quality factors are consistent in direction and have a positive correlation during this period. Then, a synchronous change of the two is recorded.

[0063] After performing the above comparisons throughout the entire historical period, the number of times changes were synchronized for a specific coal quality indicator or coal blending ratio is counted. A result is achieved when the proportion of synchronized occurrences recorded within the historical period exceeds one-half of the total number of occurrences.

[0064] This indicates that the trend consistency between the abnormal coke discharge temperature and this specific factor is statistically significant, and this factor can be identified as the main suspected root cause of this temperature anomaly. Thus, an early warning signal is generated that indicates the correlation between the abnormal coke discharge temperature and specific coal quality indicators such as volatile matter or coal blending ratio among the above-mentioned key coal quality indicators.

[0065] The closed-loop optimization module divides and compares the optimized and baseline operating periods, calculates the difference between coke performance and corrected steam production, and determines the direction and magnitude of adjustment of coal blending ratio and process parameters for the next cycle based on early warning signals.

[0066] Traditional coal blending and dry quenching process control are often carried out independently. Coal blending decisions usually rely on routine analysis of raw coal and offline testing of cold coke strength, while rarely assessing in real time the actual impact on boiler steam output and coke discharge temperature control in the quenching process.

[0067] Meanwhile, the operation and adjustment of the dry quenching system mainly focuses on the stability of the cooling process itself, and fails to feed back changes in operating status such as temperature distribution and cooling rate to the prediction of coke thermal properties such as post-reaction strength and the correction of coal blending scheme.

[0068] This fragmented decision-making approach makes it impossible to establish a dynamic relationship between coal blending, dry quenching, quality, and energy efficiency, making it difficult to form an effective closed loop for parameter optimization.

[0069] Therefore, in a specific embodiment of the present invention, the calculation of the difference between coke performance and corrected steam output includes: after the end of each production shift, marking the time period as the optimized running segment according to the start and end times of the system being in the optimized mode during that shift, and marking the production period of the same duration in the previous production shift that was also in the optimized mode as the baseline running segment.

[0070] If no optimized mode period of the same duration existed in the previous shift, the longest optimized mode period from the previous shift was selected, and its duration was set to match the current optimized runtime period as the baseline. If no optimized mode period existed in the previous shift, the process automatically traced back, but only up to the most recent five production shifts. If no suitable optimized mode period could be found within the last five shifts, the parameters under the current production plan were used as the baseline for calculation.

[0071] It should be explained that the optimization mode represents the state in which the system performs active regulation. In this state, the conservative strategy of the safety mode degraded operation can be eliminated from the interference of energy efficiency and quality data, ensuring that the comparison objects (optimization period and baseline period) are under the same control logic framework, so that the performance comparison has baseline consistency.

[0072] Choosing time slots with adjacent shifts and the same duration minimizes fluctuations caused by long-term factors such as production plans and equipment status, ensuring that differences accurately reflect the impact of recent control measures and changes in coal blending. When adjacent shifts cannot provide a benchmark time slot, an earlier time slot of the same type is used to ensure that the closed-loop optimization cycle is not interrupted.

[0073] Coke samples produced during the optimized and baseline operating periods were obtained separately, and their cold strength and hot performance data were measured. The total boiler steam output, coke output, and average atmospheric temperature during each period were also obtained simultaneously.

[0074] Divide the coke production output in the optimized operating period and the baseline operating period by the total boiler steam production in the corresponding period to obtain the initial unit coke steam production for each period.

[0075] The average atmospheric temperature of the optimized operating period is compared with that of the baseline operating period to obtain the temperature change. If the temperature change is positive, it means that the ambient temperature of the optimized operating period is higher than that of the baseline period. The increase in atmospheric temperature will reduce the heat transfer temperature difference of the boiler and have an adverse effect on the steam production efficiency. Therefore, the initial unit coke steam production of the optimized operating period is adjusted downward by a preset ratio.

[0076] If the change is negative, it means that the ambient temperature is lower during the optimization period, which is conducive to boiler steam production. In this case, the change is adjusted upward according to the preset ratio to obtain the unit coke steam output after the optimization period is corrected.

[0077] The cold strength difference value is obtained by subtracting the corresponding value of the baseline operating period from the cold strength of the coke sample during the optimized operating period. The hot performance difference value and the corrected unit coke steam production difference value are calculated in the same way.

[0078] The corrected difference in unit coke steam production reflects the change in energy recovery efficiency of the dry quenching system under the same coke output, and this efficiency change is a key factor affecting the operating cost of the process. Therefore, by adjusting the process parameters based on this difference, a closed-loop optimization of energy efficiency and operational economy is achieved.

[0079] Furthermore, the step of determining the adjustment direction and magnitude of the coal blending ratio and process parameters for the next cycle by combining the early warning signal includes: receiving the early warning signal and obtaining the cold intensity difference value, the hot performance difference value and the corrected unit coke steam production difference value, and determining the adjustment direction and magnitude of the coal blending ratio and key dry quenching parameters.

[0080] The adjustment direction is determined based on the correlation between the coal quality indicators indicated by the warning signal and the temperature anomaly, as well as the positive or negative nature of each difference value. Specifically: if the warning signal indicates that a certain coal quality indicator is positively correlated with the temperature anomaly, then the proportion of that indicator is reduced or increased accordingly based on its relative value to the benchmark value in the current period; if both the cold strength and hot performance difference values ​​are negative, then the proportion of strongly caking coal is increased; if the difference value of the unit coke steam production after correction is negative, then the operation of improving boiler efficiency is implemented.

[0081] The adjustment range is determined based on the proportion of synchronous changes in the early warning signal and the absolute value of each difference value. Specifically, the adjustment range of coal blending is positively correlated with the synchronization ratio of the early warning signal and negatively correlated with the absolute value of the quality difference value; the adjustment range of dry quenching parameters is proportional to the absolute value of the energy efficiency difference value.

[0082] For example, after a periodic assessment, when the input is positively correlated with volatile matter, the synchronization ratio is 80%, and the average volatile matter value in the current period is higher than the benchmark, while the difference between cold and hot intensity values ​​is negative, the corrected difference in unit coke steam production is -0.2%.

[0083] The system determines the adjustment direction as follows: reducing the proportion of high-volatile coal and increasing the proportion of highly caking coal, while strengthening boiler maintenance to improve heat exchange efficiency. The adjustment range is: reducing the volatile matter content by 0.5 to 1.0 percentage points, increasing the proportion of highly caking coal by 0.3 to 0.8 percentage points, and correspondingly shortening the boiler soot blowing cycle, for example, from once every 8 hours to once every 7.2 hours.

[0084] Furthermore, the periodic closed-loop optimization module also includes a parameter update and state reset unit, used to: write the determined coal blending ratio and the adjustment direction and magnitude of the key dry quenching parameters into the coal blending setting unit and the dry quenching process controller of the production control system, respectively.

[0085] After the parameters are updated, the system control state is automatically reset to optimization mode to start the next control cycle. If the parameter update fails, the original parameters are retained and a message indicating update failure is issued.

[0086] In summary, this invention constructs a dynamic collaborative control system covering the entire process, from state determination and real-time control to anomaly diagnosis and closed-loop optimization. Firstly, by monitoring safety indicators in real time, the system intelligently switches between safe and optimized modes to ensure operational safety. In optimized mode, the system proactively adjusts the circulating air volume based on the coke pushing current trend, and during the coke pushing process, it implements gradual adjustments to the air volume and coordinated regulation of the coke discharge rate based on the coke discharge temperature deviation to stabilize the cooling process and the material level within the furnace.

[0087] When abnormal temperatures persist after regulation, the system automatically initiates diagnostics, analyzes the synchronicity between temperature trends and changes in coal quality indicators, and generates a correlation warning. Finally, at the end of each operating cycle, the system comprehensively and quantitatively evaluates the cold and hot performance of coke and the differences in corrected steam production. Combined with the warning signals, it dynamically determines the direction and magnitude of adjustments to the coal blending ratio and key dry quenching process parameters for the next cycle. This forms a continuously iterative, self-optimizing closed loop, achieving the synergistic optimization goals of safe and stable operation of the dry quenching system, uniform and controllable coke quality, and improved energy recovery efficiency.

[0088] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, in the form of a computer program product.

[0089] Those skilled in the art will recognize that the algorithmic steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this application.

[0090] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0091] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0092] Finally, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A dynamic optimization and control system for coking coal blending based on dry quenching, characterized in that, include: System status determination module: Real-time monitoring of dry quenching safety indicators. If any indicator exceeds the safety threshold, the system control status is set to safe mode; otherwise, it is set to optimization mode. Real-time optimization and control module: When the system is in optimization mode, before the coke pushing operation, the circulating air volume is dynamically adjusted according to the changing trend of the coke pushing current; during the coke pushing operation, the circulating air volume is gradually adjusted based on the deviation between the coke discharge temperature and the temperature reference value, and the coke discharge volume is adjusted simultaneously to keep the material level within a safe range. The step of dynamically adjusting the circulating air volume according to the changing trend of the coke pushing current before the coke pushing operation includes: Receive the coke oven pushing plan signal and determine the start time of the pushing operation; During a set period before the start time, the current data of the coke pusher motor is collected in real time. When the current data shows a monotonically increasing trend over multiple consecutive monitoring cycles and the cumulative change exceeds the allowable fluctuation range, it is determined that the resistance to pushing out the coke cake has increased. When the current data shows a monotonically decreasing trend over multiple consecutive monitoring cycles and the cumulative change exceeds the allowable fluctuation range, it is determined that the resistance to pushing out the coke cake has decreased. If the resistance is determined to be rising, the circulating air volume is increased proportionally according to the magnitude of the resistance change before the red coke enters the dry quenching furnace. Similarly, if it is determined that the resistance has decreased, the circulating air volume should be reduced proportionally according to the magnitude of the resistance change before the red coke enters the dry quenching furnace. Anomaly Diagnosis Module: After real-time optimization and control, if the coke discharge temperature does not decrease effectively within a continuous cycle, analyze its synchronicity with the trend of changes in key coal quality indicators and coal blending ratio during the same period. When most comparison results are synchronized, an early warning signal is generated. The closed-loop optimization module divides and compares the optimized and baseline operating periods, calculates the difference between coke performance and corrected steam production, and determines the direction and magnitude of adjustment of coal blending ratio and process parameters for the next cycle based on early warning signals.

2. The dynamic optimization and control system for coking coal blending based on dry quenching as described in claim 1, characterized in that, The system status determination module also includes data reliability verification, including: Acquire the physical readings of field instruments and the corresponding real-time display values ​​on the human-machine interface of the control system; The system calculates the real-time deviation between the physical reading and the displayed value. When the real-time deviation continues to exceed a preset percentage of the instrument's range, the data is determined to be abnormal, and the physical reading is used to overwrite the system's displayed value.

3. The dynamic optimization and control system for coking coal blending based on dry quenching as described in claim 1, characterized in that, Setting the system control state to safe mode includes: When the system is in safe mode, the system status determination module generates a safety interlock command, the real-time optimization and control module suspends the execution of the optimization and adjustment command, and switches to a preset conservative control strategy to maintain the basic operation of the dry quenching system.

4. The dynamic optimization and control system for coking coal blending based on dry quenching as described in claim 1, characterized in that, The gradual adjustment of the circulating air volume based on the deviation between the coke discharge temperature and the temperature reference value includes: During the coke pushing operation, the coke discharge temperature is collected in real time; The temperature baseline value is calculated based on the coke discharge temperature during the period when the system was in optimization mode in the previous production shift. Calculate the real-time deviation between the current coke discharge temperature and the temperature reference value; When the real-time deviation continues to increase over three or more consecutive sampling periods, and the deviation increment of adjacent sampling periods is greater than the historical temperature fluctuation amplitude for the same period, an initial adjustment is performed on the circulating air volume. If, after the initial adjustment, the coke discharge temperature does not fall back to the allowable deviation range of the temperature reference value within the subsequent fixed observation period, the circulating air volume will be adjusted again with equal amplitude. Repeat the above observation and adjustment process. If the upper limit of the circulating air volume adjustment is reached, stop the adjustment and trigger an over-limit alarm. If the coke discharge temperature is still higher than the safety limit at this time, the system control state will be switched to safety mode.

5. The dynamic optimization and control system for coking coal blending based on dry quenching as described in claim 4, characterized in that, The synchronous adjustment of the coke discharge rate to maintain the material level within a safe range includes: Each time the circulating air volume is adjusted, the coke discharge rate is adjusted in the opposite direction based on the real-time position of the current system material level: If the current system material level is higher than the safe zone threshold, the direction of coke discharge adjustment is the same as the direction of circulating air volume adjustment, and the adjustment range is proportional to the adjustment range of circulating air volume. If the current system material level is lower than or equal to the zone threshold of the safe range, then the direction of coke discharge adjustment is opposite to the direction of circulating air volume adjustment.

6. The dynamic optimization and control system for coking coal blending based on dry quenching as described in claim 1, characterized in that, The anomaly diagnosis module includes: During the gradual adjustment of the circulating air volume, and while the system remains in optimized mode, the coke discharge temperature continues to be monitored. If the average value of the coke discharge temperature is not lower than the average value of the corresponding period before the adjustment is started within three consecutive fixed observation periods, it is determined that the temperature abnormality is continuous. Get the coke discharge temperature, key coal quality indicators and coal blending ratio values ​​for a set historical period starting from the moment when the temperature abnormality was determined to be continuous. For the same time interval, the rise and fall of coke discharge temperature between consecutive sampling points is marked, and the rise and fall of corresponding key coal quality indicators or coal blending ratio values ​​between the same consecutive sampling points is marked simultaneously. Compare the marking results. If the coke discharge temperature increases sequentially between three or more consecutive sampling points, and the key coal quality indicators or coal blending ratio values ​​in the corresponding interval also increase sequentially, then record a time when the two changes are synchronized. When the proportion of synchronization times recorded in the historical period exceeds one-half of the total number of times, an early warning signal is generated indicating that the abnormal coke discharge temperature is related to a specific coal quality indicator or coal blending ratio among the above-mentioned key coal quality indicators.

7. The dynamic optimization and control system for coking coal blending based on dry quenching as described in claim 1, characterized in that, The calculated difference between coke performance and corrected steam production includes: At the end of each production shift, based on the start and end times of the system being in optimization mode during that shift, the time period is marked as the optimized running segment, and the production segment of the same duration that was also in optimization mode in the previous production shift is marked as the baseline running segment. Coke samples produced during the optimized and baseline operating periods were obtained separately, and their cold strength and hot performance data were measured. The total boiler steam output, coke output, and average atmospheric temperature for each period were also obtained simultaneously. Divide the coke production output in the optimized operating period and the baseline operating period by the total boiler steam output in the corresponding period to obtain the initial unit coke steam output for each of the two periods. The temperature change is obtained by comparing the average atmospheric temperature of the optimized operating period with that of the baseline operating period. If the temperature change is positive, the initial unit coke steam output of the optimized running segment will be adjusted downward by a preset ratio; if the change is negative, it will be adjusted upward by a preset ratio to obtain the corrected unit coke steam output of the optimized running segment. The difference in cold intensity is obtained by subtracting the corresponding value of the baseline operating period from the cold intensity of the coke sample during the optimized operating period. The difference in hot performance and the difference in unit coke steam production were calculated in the same manner.

8. The dynamic optimization and control system for coking coal blending based on dry quenching as described in claim 7, characterized in that, The method of determining the direction and magnitude of adjustments to the coal blending ratio and process parameters for the next cycle based on early warning signals includes: Upon receiving the aforementioned warning signal, and obtaining the cold-state intensity difference value, hot-state performance difference value, and corrected unit coke steam production difference value, the adjustment direction and magnitude of the coal blending ratio and key dry quenching parameters are determined. The adjustment direction is determined based on the correlation between the coal quality indicators indicated by the early warning signal and the temperature anomaly, as well as the positive or negative value of each difference. The adjustment range is determined based on the proportion of synchronous changes in the warning signal and the absolute value of each difference.

9. The dynamic optimization and control system for coking coal blending based on dry quenching as described in claim 8, characterized in that, The periodic closed-loop optimization module also includes a parameter update and state reset unit, used for: The determined coal blending ratio and the adjustment direction and magnitude of the key dry quenching parameters are written into the coal blending setting unit and the dry quenching process controller of the production control system, respectively. After the parameters are updated, the system control status will be automatically reset to optimization mode to start the next control cycle.

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