Full-process energy management and graded energy saving method for ALC production line

Abstract

The embodiment of the invention provides a full-process energy management and hierarchical energy saving method for an ALC production line, which belongs to the technical field of control, and specifically comprises the following steps: step 1, constructing a universal energy management system, and collecting various types of energy consumption data of each area of the ALC production line in real time through a standardized data collection protocol and interface, visual display and statistical analysis are carried out; step 2, based on the energy consumption data and the equipment state, performing graded energy-saving operation which comprises multi-stage utilization of residual steam of the still kettle based on a dynamic request stack and multi-stage recycling of residual heat based on an energy quality gradient; and step 3, according to a statistical analysis result, dynamically adjusting a control parameter corresponding to the hierarchical energy-saving operation. Through the scheme of the invention, the monitoring real-time performance, the adaptability and the energy-saving effect are improved.

Description

Technical Field

[0001] This disclosure relates to the field of control technology, and in particular to a method for full-process energy management and graded energy saving in an ALC production line. Background Technology

[0002] Currently, most existing ALC factories adopt the "single equipment independent metering" model. For example, the steam consumption of autoclaves is displayed locally by vortex flow meters, and the power consumption depends on manual meter reading in the power distribution cabinet. There is no unified data integration platform, forming "data silos" where "steam data is in the production department and power consumption data is in the power department". Some factories have tried to introduce simple energy consumption statistics software, but it can only achieve "daily energy consumption summary", cannot monitor in real time (data delay exceeds 24 hours), and does not support decision-making functions such as regional energy consumption ranking and trend analysis.

[0003] Traditional autoclave steam transfer is a single-stage transfer process, where steam is transferred from one autoclave to another. When the pressure of the steam-exporting autoclave and the steam-input autoclave is balanced (usually around 0.5 MPa), the remaining steam is directly discharged through the exhaust valve. A few factories use a semi-automated solution with a fixed steam transfer sequence, but this cannot be dynamically adjusted according to the pressure of each autoclave and the production schedule, resulting in limited improvement in the utilization rate of the remaining steam (only up to 50%-60%).

[0004] Existing technologies mostly focus on "single-stage waste heat recovery," which only achieves single-stage heating of boiler soft water by waste steam from the autoclave. They do not involve the utilization of waste heat from condensate in the curing and casting areas. Traditional curing and pre-curing areas still use the "steam direct heating" mode, and condensate is directly discharged into the sewer, completely wasting its heat energy (temperature 80-120℃).

[0005] It is evident that there is an urgent need for a comprehensive energy management and tiered energy-saving method for ALC production lines that offers high real-time monitoring and adaptability, as well as effective energy conservation. Summary of the Invention

[0006] In view of this, the present disclosure provides a method for full-process energy management and graded energy saving in an ALC production line, which at least partially solves some of the problems existing in the prior art.

[0007] This disclosure provides a method for full-process energy management and graded energy saving in an ALC production line, including: Step 1: Build a generalized energy management system. Through standardized data acquisition protocols and interfaces, collect various types of energy consumption data from different areas of the ALC production line in real time, and perform visualization and statistical analysis. Step 2: Based on energy consumption data and equipment status, perform graded energy-saving operations, including multi-stage utilization of autoclave waste steam based on dynamic request stack and multi-stage recovery and utilization of waste heat based on energy quality gradient. Step 3: Based on the statistical analysis results, dynamically adjust the control parameters corresponding to the graded energy-saving operation.

[0008] According to a specific implementation of an embodiment of this disclosure, step 1 specifically includes: Step 1.1: Define attribute codes for different types of energy consumption content and different production process areas; Step 1.2: Based on attribute encoding, energy consumption data is read from the acquisition terminals deployed at each energy consumption node through a predefined communication protocol and a unified data acquisition interface at a preset acquisition cycle. Step 1.3: Store energy consumption data in the controller's standardized data block and simultaneously upload it to the cloud platform; Step 1.4: Display energy consumption data in a multi-level visualization on the cloud platform and perform statistical analysis, including regional energy consumption ratio, unit product energy consumption, and abnormal energy consumption identification.

[0009] According to a specific implementation of this disclosure, the attribute codes corresponding to the energy consumption content include gas consumption, steam consumption, electricity consumption and water consumption, and the attribute codes corresponding to the production process area include boiler area, autoclave area, static curing area, grouping pre-curing area, pouring tower and slurry preparation area.

[0010] According to a specific implementation of an embodiment of this disclosure, the step of multi-stage utilization of residual steam in an autoclave based on a dynamic request stack includes: The status of each autoclave is monitored in real time, and a steam discharge request stack and a steam inlet request stack are constructed and dynamically updated. The steam discharge request stack is sorted from high to low pressure and from long to short request duration, and the steam inlet request stack is sorted from low to high pressure and from long to short request duration. According to the preset matching rules, autoclaves are selected sequentially from the steam pouring request stack and the steam pouring request stack to generate at least one steam pouring matching pair; The generated reverse steam matching pair is subjected to reverse steam operation. Based on the preset pressure rise curve, the valve opening is controlled by PID regulation during the reverse steam process. When a fault is detected in the autoclave or related actuators, the faulty autoclave is automatically removed from the request stack, and a new reverse steam matching pair is generated.

[0011] According to a specific implementation of this disclosure, the step of selecting autoclaves sequentially from the steam discharge request stack and the steam import request stack according to a preset matching rule to generate at least one steam discharge matching pair includes: When the pressures of the two vessels in the first-order reverse steam matching pair reach equilibrium, the remaining residual steam in the steam-out vessel is matched with the next vessel in the steam-in request stack to generate a second-order reverse steam matching pair.

[0012] According to a specific implementation of this disclosure, the step of multi-stage waste heat recovery and utilization based on energy quality gradient includes a three-stage heat exchange process: Primary heat exchange step: When the temperature and pressure of the collected autoclave tail steam reach the first threshold, the primary heat exchange system is started to heat the boiler soft water using the tail steam. Secondary heat exchange step: When the temperature and level of the collected process condensate reach the second threshold, and the temperature of the static curing zone or pre-curing zone is lower than its target temperature range, the secondary heat exchange system is started to use the condensate to circulate and keep the static curing zone and / or pre-curing zone warm. Three-stage heat exchange process: When a request for casting water is received, and the temperature of the wastewater after the first and second heat exchange processes reaches the third threshold, the three-stage heat exchange system is activated to heat the casting slurry using the wastewater.

[0013] According to a specific implementation of this disclosure, the first threshold includes a tail gas temperature ≥120℃ and a pressure ≥0.1MPa; the second threshold includes a condensate temperature ≥70℃ and a liquid level ≥2.0m; and the third threshold includes a wastewater temperature between 50-60℃.

[0014] According to a specific implementation of an embodiment of this disclosure, step 3 specifically includes: Step 3.1: Based on historical and real-time energy consumption data, identify areas with abnormal energy consumption and potential energy-saving potential; Step 3.2: Based on the analysis results, dynamically adjust the control parameters corresponding to the graded energy-saving operation. The control parameters include the sorting weight of the autoclave dynamic request stack and the start-up temperature threshold of each heat exchange system. Step 3.3: Calculate the energy-saving performance index regularly and adjust the heat exchange cycle accordingly.

[0015] The ALC production line full-process energy management and graded energy saving scheme in this embodiment includes: Step 1, constructing a generalized energy management system, collecting various types of energy consumption data from different areas of the ALC production line in real time through standardized data acquisition protocols and interfaces, and performing visualization and statistical analysis; Step 2, executing graded energy saving operations based on energy consumption data and equipment status, wherein the graded energy saving operations include multi-stage utilization of autoclave waste steam based on dynamic request stacks and multi-stage recovery and utilization of waste heat based on energy quality gradients; Step 3, dynamically adjusting the control parameters corresponding to the graded energy saving operations according to the statistical analysis results.

[0016] The beneficial effects of this disclosure are as follows: The solution utilizes a universal energy management system to achieve precise data collection and visualized management of various types of energy consumption. Combined with the dynamic multi-stage reverse steam technology and gradient waste heat recovery technology of graded energy-saving equipment, a linkage mechanism for energy consumption data-driven energy-saving regulation is formed. Ultimately, this achieves technical effects such as reducing steam consumption by more than 30%, increasing waste steam circulation rate to more than 85%, and shortening the system adaptation cycle to within one week. Attached Figure Description

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

[0018] Figure 1 A schematic diagram of a full-process energy management and graded energy saving method for an ALC production line provided in this embodiment of the disclosure; Figure 2 A schematic diagram illustrating the specific implementation process of an ALC production line full-process energy management and graded energy saving method provided in this embodiment of the disclosure; Figure 3 This is a schematic diagram of the hardware structure corresponding to an ALC production line full-process energy management and graded energy saving method provided in an embodiment of this disclosure. Detailed Implementation

[0019] The embodiments of this disclosure will now be described in detail with reference to the accompanying drawings.

[0020] The following specific examples illustrate the implementation of this disclosure. Those skilled in the art can easily understand other advantages and effects of this disclosure from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this disclosure, and not all of them. This disclosure can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this disclosure. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this disclosure.

[0021] It should be noted that various aspects of embodiments within the scope of the appended claims are described below. It will be apparent that the aspects described herein can be embodied in a wide variety of forms, and any particular structure and / or function described herein is merely illustrative. Based on this disclosure, those skilled in the art will understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number of aspects set forth herein can be used to implement the device and / or practice the method. Additionally, this device and / or method can be implemented using structures and / or functionalities other than one or more of the aspects set forth herein.

[0022] It should also be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this disclosure. The illustrations only show the components related to this disclosure and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0023] Furthermore, specific details are provided in the following description to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that the described aspects can be practiced without these specific details.

[0024] This disclosure provides a method for full-process energy management and graded energy saving in an ALC production line, which can be applied to the management process of an ALC production line in an industrial setting.

[0025] See Figure 1 This is a flowchart illustrating a method for full-process energy management and tiered energy saving in an ALC production line, as provided in an embodiment of this disclosure. Figure 1 and Figure 2 As shown, the method mainly includes the following steps: Step 1: Build a generalized energy management system. Through standardized data acquisition protocols and interfaces, collect various types of energy consumption data from different areas of the ALC production line in real time, and perform visualization and statistical analysis. In practical implementation, the hardware structure corresponding to the ALC production line full-process energy management and graded energy saving method provided in this embodiment is as follows: Figure 3 As shown, a universal energy management system is the core for achieving accurate energy consumption monitoring. Through standardized protocols, modular programs, and a unified interface design, it solves the problems of traditional "data silos" and poor adaptability. The specific process is as follows: Construction of a generalized data acquisition protocol and attribute encoding system Clearly define the attribute coding of the collected content: Standardize the coding of the core energy consumption type of ALC production, and unify the data format to double integer (DInt) to ensure data compatibility. The coding rules are shown in Table 1.

[0026] Table 1

[0027] Regional attribute coding: The core area is divided according to the ALC production process, and the energy consumption monitoring range of each area is clearly defined. The coding rules are shown in Table 2.

[0028] Table 2

[0029] Establish protocol association: Construct a mapping relationship of "content attribute - area attribute - PLC address - offset", and send it to the control layer through the cloud platform backend. It supports online modification of configuration without the need for on-site program reconstruction.

[0030] Generalized control program design and deployment Reserved core data block interface: Configure 7 core data blocks DB1313-DB1319 in the PLC control program, clarify the functional division of each data block and the data storage rules, and support only expanding the data blocks when adding new energy consumption types without refactoring the program, as shown in Table 3.

[0031] Table 3

[0032] Modular program division: The control program is divided into 4 independent modules: configuration parsing, data acquisition, data transmission, and statistical analysis. Each module communicates through a standardized interface. The module functions and modification scope are shown in Table 4.

[0033] Table 4

[0034] Setting up a generalized data acquisition interface: Unified communication mode: RS-485 is used as the standard communication interface, and the communication parameters are set as baud rate 9600bps, even parity, 8 data bits, 1 stop bit, and compatible with mainstream metering equipment protocols (such as MODBUS-RTU for gas meters, DL / T645-2007 for smart meters, and HART protocol for flow meters).

[0035] Simplified cabling design: Only one 485 bus is needed on site to connect all data acquisition terminals (such as flow meters, gas meters, and electricity meters). Compared with the traditional "one device, one line" model, cabling costs are reduced by more than 50%, while also reducing the difficulty of later maintenance.

[0036] Define data transmission specifications: Use the "Device Address-Data Identifier-Collection Period" triple format to ensure direct integration of data from different brands of devices, as shown in the example below: Steam flow meter for autoclave No. 3: Device address 03, data identifier 03 (instantaneous flow), acquisition cycle 1 second.

[0037] Boiler No. 1 Smart Gas Meter: Device Address 01, Data Identifier 08 (Cumulative Consumption), Data Acquisition Period 1 second Precise deployment and debugging of energy consumption data acquisition terminals Based on regional attribute coding and process requirements, suitable data acquisition terminals are deployed at core energy consumption nodes, and the sensor type, installation location and calculation logic are clearly defined to ensure data accuracy, as shown in Table 5.

[0038] Table 5

[0039] On-site commissioning and calibration: After installation, data calibration of each terminal is performed through PLC program (such as correcting the enthalpy value of steam flow meter according to saturated steam pressure) to ensure that the error of the collected data is ≤±2%, which is far better than the traditional manual meter reading (error ±5%).

[0040] Data collection and visualization launched: Start data acquisition: The PLC control program reads data from each terminal at a 1-second cycle, verifies the data, stores it in the corresponding data block (e.g., steam data to DB1315), and simultaneously uploads it to the cloud platform via 4G / Ethernet.

[0041] Cloud platform visualization: The cloud platform displays energy consumption data in three levels: "Overview - Region - Device," including: Overview page: Real-time energy consumption of the entire plant (gas / steam / electricity / water), energy consumption per unit product, energy-saving effect (steam saved on the same day); Regional page: Energy consumption percentage of each region (pie chart), daily / monthly trends (line chart), ranking of high energy-consuming equipment; Equipment page: Real-time parameters of single equipment, historical data query (last year), and abnormal threshold alarm (such as a sudden increase of 20% in steam flow).

[0042] Step 2: Based on energy consumption data and equipment status, perform graded energy-saving operations, including multi-stage utilization of autoclave waste steam based on dynamic request stack and multi-stage recovery and utilization of waste heat based on energy quality gradient. In practice, the graded energy-saving equipment is based on the principle of "energy gradient utilization". It recovers waste steam from the autoclave through dynamic multi-stage steam reversal technology and recovers waste heat from tail steam and condensate through three-stage heat exchange technology, thereby realizing the tiered utilization of energy. The specific process is as follows: (I) Multi-stage utilization process of residual steam from autoclave: Waste steam from the autoclave is a core waste heat resource in ALC production. Traditional single-stage steam back utilization rate is only 40%. This invention improves the utilization rate to over 85% through dynamic request stack and multi-stage matching technology. The process is as follows: Step 1: Dynamic Request Stack Setup and Update Steam discharge request stack construction: Real-time acquisition of constant pressure end signals from each autoclave (e.g., 1-10), recording "autoclave number - current pressure - request duration (time from constant pressure end to request issuance)", sorted by "pressure from high to low > request duration from long to short", as shown in Table 6.

[0043] Table 6

[0044] Pour into the steam request stack construction: Collect the vacuuming end signal of each autoclave in real time, record "autoclave number - current pressure - request duration (time from vacuuming end to request sending)", and sort them according to "pressure from low to high > request duration from long to short", as shown in Table 7.

[0045] Table 7

[0046] Request stack update frequency: refreshed every 5 seconds to ensure data real-time performance and avoid matching failures due to production schedule changes.

[0047] Step 2: Generation of multi-stage reverse steam queuing sequence First-order steam reversal matching: Take the first-ranked vessel (No. 2, 0.95MPa) from the steam outflow stack and the first-ranked vessel (No. 6, 0.05MPa) from the steam inflow stack to generate a first-order steam reversal pair (No. 2-No. 6), and issue a steam reversal command.

[0048] Second-order reverse steam matching: When the pressure difference between reactor No. 2 and reactor No. 6 is ≤0.02MPa (equilibrium pressure is about 0.5MPa), the system automatically detects the remaining residual steam pressure of reactor No. 2 (about 0.5MPa), takes the second-ranked reactor (No. 8, 0.08MPa) from the steam stack, and generates a second-order reverse steam pair (No. 2-No. 8).

[0049] Multi-stage expansion rule: For production lines with more than 10 reactors, it can be expanded to 3 stages of steam reversal (such as reactor No. 2-reactor No. 6-reactor No. 8-reactor No. 10). The pressure difference after each stage matching must be ≥0.2MPa to ensure steam reversal efficiency.

[0050] Step 3: Precise control of the reverse steam process (PID regulation) Initial stage of steam reversal (pressure boosting stage): The steam reversal valve of the steam reversal vessel (No. 2) is 100% fully open, and the steam reversal valve of the steam reversal vessel (No. 6) adjusts the opening degree according to the preset pressure boosting curve (0.1MPa / min) through PID control to avoid pressure shock causing the billet to crack (traditional manual operation is prone to overshoot).

[0051] Pressure balancing stage: When the pressure difference between the two reactors is ≤0.02MPa, the system automatically closes the steam transfer valve of reactor No. 2 and switches reactor No. 6 to "steam inlet valve", and continues to increase the pressure to the target pressure (1.0MPa) according to the original process curve.

[0052] Process monitoring parameters: Real-time monitoring of the temperature (≥150℃) and pressure fluctuation (≤±0.03MPa) of the steam transfer pipeline. If the threshold is exceeded, the valve opening will be finely adjusted.

[0053] Step 4: Exception Handling and Process Self-Healing Fault detection: Real-time monitoring of the steam valve opening feedback and pressure sensor data. If the following occurs: "valve jamming (opening feedback deviation from command > 10%)", "no sensor data (lasting 3 seconds)", or "overheating of the vessel (> 200℃)", it is determined to be a fault.

[0054] Fault handling mechanism: Automatic removal of faulty requests: Mark faulty requests as "faulty" from the request stack and remove them from the matching process; Regenerate the queue stack: Reorder the remaining normal vessels (e.g., if vessel 2 fails, pour steam out of the steam stack and take vessel 4, pour steam into the steam stack and take vessel 6, generating a new first-order pair of vessels 4-6). Audible and visual alarms and recording: The cloud platform triggers audible and visual alarms (displaying the faulty vessel number and fault type), and records the fault time and handling measures for easy traceability later.

[0055] (2) Three-stage recovery process for waste steam and condensate waste heat: To address the problem of traditional waste heat recovery methods being "single-stage and lacking gradient," this invention designs a three-stage heat exchange process based on the principle of "high-grade waste heat being used extensively and low-grade waste heat being used rudimentarily," achieving 100% recovery of waste heat from exhaust steam and condensate. The process is as follows: Step 1: Primary heat exchange (tail steam - boiler soft water) - high-grade tail steam utilization Tail steam collection: The low-pressure tail steam (below 0.3MPa, temperature 120-150℃) discharged after the autoclave is collected through pipelines to the exhaust steam distributor cylinder, which is equipped with pressure and temperature sensors.

[0056] Heat exchange start-up conditions: When the exhaust gas temperature in the steam distribution cylinder is ≥120℃ and the pressure is ≥0.1MPa, the system automatically starts the exhaust gas booster pump (30m head) to introduce the exhaust gas into the primary heat exchange water tank (5m³ volume, with insulation layer).

[0057] Soft water heating: When the temperature of the primary heat exchange tank is ≥90℃ and the liquid level is ≥1.5m (monitored by the liquid level sensor), the heat exchange circulation pump (flow rate 50m³ / h) is started to heat the boiler soft water through the shell and tube heat exchanger (heat exchange area 10m²), raising the soft water temperature from 20℃ to 60℃.

[0058] Stop conditions: When the exhaust steam temperature is <100℃ or the water tank level is <1.0m, the booster pump and circulation pump are shut down, and the first-stage heat exchange is stopped; the heated soft water is transported to the boiler feedwater system through pipelines to replace part of the cold water.

[0059] Step 2: Secondary heat exchange (condensate - static / pre-curing zone) - utilization of medium-grade waste heat Condensate collection: Condensate generated during the autoclave curing process (temperature 80-120℃, pressure 0.2-0.4MPa) is collected through a steam trap into a secondary insulated water tank (volume 8m³, insulation layer thickness 50mm, temperature loss ≤5℃ / h).

[0060] Temperature monitoring and triggering: Real-time monitoring of the temperature in the resting area (target 40-45℃) and the temperature in the pre-seasoning area (target 35-40℃). When the temperature in either area is lower than the lower limit of the target value (e.g., resting area < 40℃), and the temperature of the secondary water tank is ≥ 70℃ and the liquid level is ≥ 2.0m, the heat exchange circulation pump of the corresponding area is started.

[0061] Zone heating: Curing area: The circulating pump delivers condensate to the finned heat exchanger (heat exchange area 15m²), and at the same time starts the axial flow fan (air volume 10000m³ / h) to maintain the temperature of the curing area at 40-45℃ through hot air circulation. Pre-curing area: Same process as the static curing area, maintain temperature 35-40℃; Advantages: It replaces the traditional "steam direct heating" mode, completely eliminating the heat energy waste from direct discharge of condensate (traditional waste rate exceeds 50%), and reduces steam consumption in the static / pre-curing area to 0.

[0062] Step 3: Three-stage heat exchange (wastewater - casting water) - utilization of low-grade waste heat Wastewater collection: The hot water discharged after the secondary heat exchange (temperature 50-60℃, pressure 0.1MPa) is introduced into the tertiary hot water tank (volume 3m³) through pipelines. The tank is equipped with temperature sensors and liquid level sensors.

[0063] Heating of water for pouring: When the concrete mixer sends a "water supply request" signal, the system automatically starts the sewage pump (flow rate 20m³ / h) to deliver hot water at 50-60℃ from the three-stage water tank to the mixer water tank. After mixing with tap water, the temperature of the raw slurry is raised from 20℃ to 35℃ (the optimal temperature for pouring process).

[0064] Effects: Reduces the amount of steam required for heating the raw slurry by more than 30%, while avoiding temperature fluctuations in the slurry caused by the direct addition of cold water (traditional fluctuations ±5℃, this solution ±1℃), thus improving the quality of the green body forming.

[0065] Specifically, the parameter configuration for the three-stage heat exchange is shown in Table 8.

[0066] Table 8

[0067] Step 3: Based on the statistical analysis results, dynamically adjust the control parameters corresponding to the graded energy-saving operation.

[0068] In practice, a closed-loop mechanism of "data collection-analysis-control-feedback" is used to achieve dynamic adaptation between energy-saving measures and energy consumption status, ensuring continuous optimization of energy-saving effects. The process is as follows: Energy consumption data analysis and anomaly identification The cloud platform generates energy consumption analysis reports on a daily / weekly / monthly basis, including: Regional energy consumption ratio: Identify high-energy-consuming areas (e.g., autoclaves account for 60% of steam consumption); Unit product energy consumption: Compare with industry benchmarks (e.g., 0.25t steam / m³ product) to analyze energy-saving potential; Abnormal energy consumption identification: Algorithms detect sudden increases in energy consumption (such as steam flow exceeding the historical average by 20%) and locate abnormal equipment (such as pipeline leaks).

[0069] Dynamic adjustment of energy-saving parameters Adjust energy-saving parameters based on analysis results: Multi-stage steam reversal: If the utilization rate of residual steam in a certain reactor is low (<80%), adjust the request stack sorting weight (e.g., increase the pressure weight). Three-stage heat exchange: If the temperature in the winter resting area reaches the standard slowly, lower the start-up temperature threshold of the second-stage heat exchange (e.g., from 70℃ to 65℃).

[0070] System operation status monitoring and fault handling Real-time monitoring system core parameters: communication status (whether the 485 bus is disconnected), equipment status (valve opening, pump operating current), energy consumption data (whether it exceeds the threshold). Troubleshooting process: Minor faults (such as data delays): The system automatically retryes the connection and resends data; Moderate fault (such as pump overload): Triggers audible and visual alarm, automatically switches to standby pump; Severe failure (such as PLC offline): The cloud platform pushes alarm information to the administrator's mobile phone and simultaneously activates the local emergency program (to maintain basic production).

[0071] Energy saving effect evaluation and feedback Regularly (monthly) assess energy-saving effects: calculate steam savings, gas savings, and equivalent carbon dioxide emission reductions; Feedback optimization: Adjust closed-loop parameters (such as optimizing heat exchange cycle) based on evaluation results to continuously improve energy efficiency.

[0072] The ALC production line full-process energy management and graded energy saving method provided in this embodiment achieves accurate collection and visualized management of various types of energy consumption through a generalized energy management system. Combined with the dynamic multi-stage reverse steam technology and gradient waste heat recovery technology of graded energy-saving equipment, a linkage mechanism for energy consumption data-driven energy-saving regulation is formed. Ultimately, this achieves technical effects such as reducing steam consumption by more than 30%, increasing waste steam circulation rate to more than 85%, and shortening the system adaptation cycle to within one week.

[0073] Specifically, the method disclosed herein is achieved through: 1. Standardized energy management system: Standardized data collection content attributes (gas / steam / electricity / water coding) and area attributes (boiler / autoclave / restoration coding); The DB1313-DB1319 reserved data block control program design supports rapid adaptation to different ALC production lines; Based on the RS-485 universal data acquisition interface, it is compatible with metering equipment from multiple brands.

[0074] 2. Multi-stage utilization technology of residual steam from autoclaves: A method for establishing a dynamic request stack based on "pressure-request duration"; Multi-order reverse steam queuing sequence generation algorithm (supports 1-3 order extension); The PID regulation and steam inlet switching logic after pressure balancing, and the automatic rejection mechanism for faulty vessels.

[0075] 2. Three-stage heat exchange system and control logic: A three-stage heat exchange process designed according to energy quality gradients: "exhaust steam-soft water", "condensate-static / pre-curing", and "wastewater-irrigation water". Automatic start / stop and parameter adjustment logic for heat exchange based on temperature and liquid level thresholds (e.g., starting the booster pump when the tail gas temperature of the primary heat exchange is ≥120℃).

[0076] 3. Energy consumption closed-loop management solution: A linkage mechanism linking real-time energy consumption data collection, statistical analysis, visualization, and dynamic adjustment of energy-saving measures; Solution for implementing regional energy consumption ranking and daily / monthly / yearly trend analysis functions on the cloud platform.

[0077] The beneficial effects of the embodiments disclosed herein are as follows: 1. Precise and efficient energy consumption monitoring: Data acquisition real-time performance: acquisition cycle of 1 second, data error ≤ ±2%, far superior to traditional manual statistics (error ±5% + 24-hour delay). High degree of visualization: The cloud platform provides an overview of energy consumption and trend analysis. Managers can remotely view the energy consumption ratio of each region via computer / mobile phone and quickly locate high-energy-consuming links.

[0078] 2. The utilization rate of waste steam and waste heat has been greatly improved: Multi-stage reverse steam technology enables residual steam circulation rate of ≥85%, which reduces residual steam loss by more than 60% compared to traditional single-stage reverse steam (40%). The three-stage heat exchange system achieves 100% recovery of waste heat from exhaust steam and condensate, reduces steam consumption in the static / pre-curing zone to zero, and reduces steam consumption in the casting zone by 30%.

[0079] 3. Highly adaptable: The standardized protocol and interface design enables deployment of ALC production lines of different sizes (such as 5-reactor / 10-reactor / 15-reactor) within one week, reducing adaptation costs by 50%. It supports adding new data collection items (such as adding "air compressor energy consumption"), which only requires modifying the DB data block configuration and does not require refactoring the program.

[0080] 4. Stable operation and easy to use: A robust anomaly handling mechanism (fault alarm, automatic removal of faulty vessels) ensures the system can operate continuously without failure for ≥3000 hours. The energy-saving measures operate fully automatically (steam switching and heat exchange require no manual intervention), requiring only one person per day to view cloud platform data, thus reducing management costs.

[0081] It should be understood that the various parts of this disclosure can be implemented in hardware, software, firmware, or a combination thereof.

[0082] The above description is merely a specific embodiment of this disclosure, but the scope of protection of this disclosure 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 disclosure should be included within the scope of protection of this disclosure. Therefore, the scope of protection of this disclosure should be determined by the scope of the claims.

Claims

1. A method for full-process energy management and graded energy saving in an ALC production line, characterized in that, include: Step 1: Build a generalized energy management system. Through standardized data acquisition protocols and interfaces, collect various types of energy consumption data from different areas of the ALC production line in real time, and perform visualization and statistical analysis. Step 2: Based on energy consumption data and equipment status, perform graded energy-saving operations, including multi-stage utilization of autoclave waste steam based on dynamic request stack and multi-stage recovery and utilization of waste heat based on energy quality gradient. Step 3: Based on the statistical analysis results, dynamically adjust the control parameters corresponding to the graded energy-saving operation.

2. The method according to claim 1, characterized in that, Step 1 specifically includes: Step 1.1: Define attribute codes for different types of energy consumption content and different production process areas; Step 1.2: Based on attribute encoding, energy consumption data is read from the acquisition terminals deployed at each energy consumption node through a predefined communication protocol and a unified data acquisition interface at a preset acquisition cycle. Step 1.3: Store energy consumption data in the controller's standardized data block and simultaneously upload it to the cloud platform; Step 1.4: Display energy consumption data in a multi-level visualization on the cloud platform and perform statistical analysis, including regional energy consumption ratio, unit product energy consumption, and abnormal energy consumption identification.

3. The method according to claim 2, characterized in that, The attribute codes corresponding to the energy consumption content include gas, steam, electricity and water consumption, and the attribute codes corresponding to the production process areas include boiler area, autoclave area, curing area, pre-curing grouping area, pouring tower and slurry preparation area.

4. The method according to claim 1, characterized in that, The steps for multi-stage utilization of residual steam in an autoclave based on a dynamic request stack include: The status of each autoclave is monitored in real time, and a steam discharge request stack and a steam inlet request stack are constructed and dynamically updated. The steam discharge request stack is sorted from high to low pressure and from long to short request duration, and the steam inlet request stack is sorted from low to high pressure and from long to short request duration. According to the preset matching rules, autoclaves are selected sequentially from the steam pouring request stack and the steam pouring request stack to generate at least one steam pouring matching pair; The generated reverse steam matching pair is subjected to reverse steam operation. Based on the preset pressure rise curve, the valve opening is controlled by PID regulation during the reverse steam process. When a fault is detected in the autoclave or related actuators, the faulty autoclave is automatically removed from the request stack, and a new reverse steam matching pair is generated.

5. The method according to claim 4, characterized in that, The step of selecting autoclaves sequentially from the steam discharge request stack and the steam import request stack according to preset matching rules to generate at least one steam discharge matching pair includes: When the pressures of the two vessels in the first-order reverse steam matching pair reach equilibrium, the remaining residual steam in the steam-out vessel is matched with the next vessel in the steam-in request stack to generate a second-order reverse steam matching pair.

6. The method according to claim 1, characterized in that, The steps for multi-stage waste heat recovery and utilization based on energy quality gradient include a three-stage heat exchange process: Primary heat exchange step: When the temperature and pressure of the collected autoclave tail steam reach the first threshold, the primary heat exchange system is started to heat the boiler soft water using the tail steam. Secondary heat exchange step: When the temperature and level of the collected process condensate reach the second threshold, and the temperature of the static curing zone or pre-curing zone is lower than its target temperature range, the secondary heat exchange system is started to use the condensate to circulate and keep the static curing zone and / or pre-curing zone warm. Three-stage heat exchange process: When a request for casting water is received, and the temperature of the wastewater after the first and second heat exchange processes reaches the third threshold, the three-stage heat exchange system is activated to heat the casting slurry using the wastewater.

7. The method according to claim 6, characterized in that, The first threshold includes a tail gas temperature ≥120℃ and a pressure ≥0.1MPa; the second threshold includes a condensate temperature ≥70℃ and a liquid level ≥2.0m; and the third threshold includes a wastewater temperature between 50-60℃.

8. The method according to claim 1, characterized in that, Step 3 specifically includes: Step 3.1: Based on historical and real-time energy consumption data, identify areas with abnormal energy consumption and potential energy-saving potential; Step 3.2: Based on the analysis results, dynamically adjust the control parameters corresponding to the graded energy-saving operation. The control parameters include the sorting weight of the autoclave dynamic request stack and the start-up temperature threshold of each heat exchange system. Step 3.3: Calculate the energy-saving performance index regularly and adjust the heat exchange cycle accordingly.

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