Coal chemical waste gas data acquisition and monitoring control system

Abstract

The invention relates to the technical field of coal chemical industry environmental protection engineering and industrial process automation control, in particular to a coal chemical industry waste gas data acquisition and monitoring control system. The data acquisition module is used for acquiring slurry pH value distribution data or catalyst activity surface area data obtained by a plurality of pH sensors or catalyst activity detectors arranged at different heights in a reaction tower; collecting monitoring parameters of a waste gas discharge port; the linkage control unit is used for carrying out feed-forward regulation on medicament addition when the upstream production load parameters and the waste gas inlet parameters jointly indicate that excessive pollutants enter the reaction tower; according to the monitoring parameters of the waste gas discharge port, the dosage of the medicament is adjusted in real time; the first control instruction and the second control instruction jointly control the agent adding mechanism so as to remove pollutants in the waste gas in a chemical absorption or catalytic reaction mode; according to the invention, instantaneous standard exceeding caused by untimely response is effectively avoided.

Description

Technical Field

[0001] This invention relates to the field of environmental protection engineering and industrial process automation control technology in the coal chemical industry, specifically a data acquisition and monitoring control system for coal chemical waste gas. Background Technology

[0002] In the scenario of coal chemical waste gas treatment, waste gas emissions are significantly affected by the production load fluctuations of the upstream gasification and synthesis sections. The reaction tower involves complex chemical absorption and catalytic reaction processes, and the catalyst activity and slurry pH value change dynamically with the operating conditions.

[0003] Existing control schemes generally adopt an end-feedback regulation mode, which adjusts the dosage of reagents in reverse based solely on online monitoring data at the emission outlet, treating the reaction tower as a black box and lacking effective perception of upstream source load and intermediate state within the tower. Although this scheme can meet basic compliance monitoring, the inherent large lag characteristics of physical transmission and chemical reaction cause the system to be unable to respond in time to instantaneous changes in upstream pollutant concentrations, easily leading to instantaneous exceedances of emission standards. At the same time, in order to ensure compliance, excessive reagent dosage is often maintained for a long time, resulting in wasted operating costs and the risk of secondary pollution. In addition, communication barriers between the production system and environmental protection facilities create data silos, and the lack of real-time diagnostic capabilities for hidden faults such as instrument drift and nozzle blockage makes it difficult to guarantee the long-term reliable operation of the system.

[0004] Therefore, how to construct a control system that integrates source prediction, process buffering and end-of-pipe verification to overcome system lag and improve the response speed and control accuracy of waste gas treatment has become an urgent technical problem to be solved. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides a data acquisition and monitoring control system for coal chemical waste gas. Specifically, the technical solution of the present invention includes: This system is used in waste gas treatment systems. The waste gas treatment system includes a waste gas inlet pipe, a reaction tower, and a waste gas outlet connected in sequence. The reaction tower is equipped with nozzles for injecting reagents. The system includes a data acquisition unit for: Collect upstream production load parameters from coal chemical production lines; Collect the exhaust gas inlet parameters of the exhaust gas inlet pipeline; Collect slurry pH distribution data or catalyst active surface area data from multiple pH sensors or catalyst activity detectors installed at different heights inside the reaction tower; Collect monitoring parameters from exhaust gas emission outlets; The linkage control unit, connected to the data acquisition unit and the reagent dosing mechanism of the reaction tower, is used for: When the upstream production load parameters and the exhaust gas inlet parameters jointly indicate that there will be excessive pollutants entering the reaction tower, the first control command is generated to the reagent dosing mechanism based on the slurry pH distribution data or catalyst active surface area data inside the reaction tower, so as to perform feedforward adjustment of reagent dosing. Based on the monitoring parameters of the exhaust gas outlet, a second control command is generated and sent to the reagent dosing mechanism to adjust the reagent dosage in real time; The first control command and the second control command jointly control the reagent dosing mechanism to remove pollutants from the exhaust gas through chemical absorption or catalytic reaction.

[0006] Preferably, the linkage control unit is specifically used for: Based on the changing trend of upstream production load parameters and the real-time values ​​of exhaust gas inlet parameters, determine the pollutant load status in the exhaust gas inlet pipeline; The pollutant load status is compared with a preset threshold. When the threshold is exceeded, the first control command is triggered.

[0007] Preferably, the linkage control unit is specifically used for: The degree of chemical absorption reaction distribution within the reaction tower is determined based on the pH value of the slurry at different heights inside the tower. Alternatively, the real-time effective reaction area of ​​the catalyst can be determined based on the catalyst's active surface area data. Based on the degree distribution or real-time effective reaction area, determine the amount of reagent to be added as required in the first control command.

[0008] Preferably, the linkage control unit is specifically used for: When the pollutant load status indicates that the impact load exceeds the steady-state threshold, and the pH distribution of the slurry inside the reaction tower indicates that the pH of the reaction zone is about to fall below the critical value or the active surface area of ​​the catalyst is below the activity threshold, the first control command is executed to start the reagent dosing mechanism for pre-dosing operation. When the pollutant load status indicates that the shock load exceeds the steady-state threshold, but the pH distribution of the slurry inside the reaction tower or the active surface area of ​​the catalyst indicates that the treatment capacity is sufficient, the current reagent dosage shall be maintained.

[0009] Preferably, the system further includes a fault diagnosis unit for: The pollutant removal efficiency is calculated based on the inlet parameters and outlet parameters of the exhaust gas. Estimate the theoretical reagent consumption based on the removal efficiency and the preset theoretical reagent consumption relationship; Obtain the actual consumption of the drug dosing unit; The theoretical consumption is compared with the actual consumption. When the deviation continues to exceed the preset range, an alarm signal indicating nozzle blockage or instrument malfunction is generated.

[0010] Preferably, the upstream production load parameters include the coal feed rate of the gasifier, the synthetic ammonia production index, and the combustion chamber temperature; The inlet parameters of the exhaust gas include the inlet exhaust gas flow rate, the inlet sulfur dioxide concentration, and the inlet nitrogen oxide concentration; The internal state parameters of the reaction tower vary depending on the waste gas treatment process, including the density of the desulfurization tower slurry, the operating frequency of the circulating pump, or the pressure difference of the denitrification catalyst layer and the reaction temperature.

[0011] Preferably, the data acquisition unit is connected in parallel to the programmable logic controllers of the distributed control system and the waste gas treatment system of the coal chemical production line through an industrial communication interface conforming to the OPC or Modbus protocol, in order to obtain upstream production load parameters and waste gas treatment related parameters.

[0012] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention constructs a three-dimensional control architecture of source prediction, process buffering, and end verification by introducing upstream production load parameters and internal state data of the reaction tower. Compared with traditional control that relies solely on emission outlet data, this system overcomes the large lag characteristics of physical transmission and chemical reaction, effectively avoids instantaneous exceedances caused by untimely response, and also prevents cost waste and secondary pollution caused by long-term excessive spraying of reagents to ensure compliance. 2. This invention quantifies the chemical reaction potential energy inside the reaction tower, and the linkage control unit can accurately distinguish between true and false drug shortages. When the processing capacity is sufficient, it uses its own capacity to cope with load shocks and only pre-dosing when necessary. This peak-shaving and valley-filling strategy based on the internal state avoids blindly following the inlet concentration for excessive dosing, reduces the operation frequency of the dosing mechanism, achieves refined cost control, and extends equipment life. 3. The system of this invention uses a fault diagnosis unit to establish a material balance model. By calculating the pollutant removal efficiency and comparing the theoretical and actual reagent consumption, it can diagnose the health status of the equipment in real time. Compared with regular manual inspections, this data correlation analysis-based method can detect hidden faults such as nozzle blockage or instrument drift earlier, thereby avoiding environmental accidents caused by equipment failure and ensuring the long-term stable operation of the system. 4. The data acquisition unit of this invention connects the production line control system and the waste gas treatment controller in parallel through a standard industrial communication protocol, breaking the information silos commonly found in coal chemical enterprises. This design realizes cross-system full-dimensional data fusion and time axis alignment, providing underlying data path support for plant-wide feedforward control, ensuring that environmental protection facilities can obtain advanced control commands when the load at the production source fluctuates, thereby improving overall treatment efficiency. Attached Figure Description

[0013] The present invention will be further explained below with reference to the accompanying drawings and embodiments: Figure 1 This is a structural diagram of the system of the present invention. Detailed Implementation

[0014] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0015] Example 1: Please see Figure 1 A data acquisition and monitoring control system for coal chemical waste gas is disclosed, applied to a waste gas treatment system. The waste gas treatment system includes a waste gas inlet pipe, a reaction tower, and a waste gas outlet connected in sequence. The reaction tower is equipped with nozzles for injecting reagents. The system includes: a data acquisition unit for: acquiring upstream production load parameters from the coal chemical production line; acquiring waste gas inlet parameters from the waste gas inlet pipe; acquiring slurry pH distribution data or catalyst active surface area data obtained from multiple pH sensors or catalyst activity detectors installed at different heights inside the reaction tower; and acquiring monitoring parameters from the waste gas outlet. The linkage control unit, connected to the data acquisition unit and the reagent dosing mechanism of the reaction tower, is used to: when the upstream production load parameters and the exhaust gas inlet parameters jointly indicate that there will be excessive pollutants entering the reaction tower, generate a first control command to the reagent dosing mechanism based on the slurry pH distribution data or catalyst active surface area data inside the reaction tower, so as to perform feedforward adjustment of reagent dosing; Based on the monitoring parameters of the exhaust gas outlet, a second control command is generated to the reagent dosing mechanism to adjust the reagent dosage in real time. The first and second control commands jointly control the reagent dosing mechanism to remove pollutants from the exhaust gas through chemical absorption or catalytic reaction.

[0016] This embodiment elaborates on the core architecture and operating logic of the system, aiming to solve the problem of high lag caused by relying solely on emission outlet data for feedback adjustment in the existing technology; The system utilizes a data acquisition unit to construct a comprehensive view of operating conditions. This unit acts as the system's sensory nerve, collecting upstream production load parameters from the coal chemical production line. This is the source data of waste gas fluctuations and has significant predictive power. It also collects waste gas inlet parameters from the waste gas inlet pipeline as the direct input load for the waste gas treatment system. Simultaneously, it collects internal state data from the reaction tower, specifically the slurry pH distribution data or catalyst active surface area data obtained by multiple pH sensors installed at different heights inside the reaction tower for wet desulfurization scenarios, or by catalyst activity detectors for SCR denitrification scenarios. To obtain the catalyst active surface area data, the specific catalyst activity detector employs online soft measurement technology based on reaction kinetics. This detector collects real-time data on the inlet and outlet nitrogen oxide concentration difference of the catalyst layer, reaction temperature, and interlayer pressure difference. It then uses a pre-set Arrhenius reaction rate equation to inversely calculate the current macroscopic reaction rate constant of the catalyst, combined with geometric parameters of the catalyst such as the total catalyst volume. and specific surface area benchmark value The effective active surface area under the current operating conditions was calculated by using a porous media diffusion model, thus realizing the online quantification of this microscopic physical quantity in the internal environment of an industrial reaction tower. To ensure the sufficiency of the above computational model and to support the algorithm calls in Example 3, the specific physical modeling formulas are defined as follows: The first step is to calculate the current macroscopic reaction rate constant based on the concentration difference between the inlet and outlet. The calculation formula is as follows: , in, Flue gas flow rate under standard conditions, unit: , here Refers to the standard physical atmospheric environment, i.e., 0℃, 101.325kPa operating conditions. The effective volume of the catalyst layer, in units of , and These are the measured inlet and outlet nitrogen oxide concentrations, respectively. This refers to the real-time absolute temperature inside the reactor. This represents the real-time absolute pressure inside the reactor; the formula here not only explicitly introduces the calculation boundary constraint factor, but also... The value is set to Its physical meaning is the lowest detection limit of a gas analyzer or the background noise benchmark, used to prevent the denominator from being zero or the logarithm from being undefined in mathematical calculations; Additional measures were added to address the thermal expansion effect of gases. The correction item converts the standard flow rate into the actual operating flow rate within the reactor, thereby eliminating the residence time calculation deviation caused by temperature changes and ensuring the calculated value. It can accurately reflect the dynamic characteristics under high-temperature conditions; among which Functions are used to process That is, complete removal, or This means that under extreme operating conditions with no pollutant inlet, errors such as negative infinity or division by zero in the logarithmic field occur during program execution, ensuring the robustness of the control algorithm and code stability under ideal operating conditions. The second step involves calculating the effective active surface area based on a variant of the Arrhenius equation and a porous media diffusion model. That is, in Example 3 The calculation formula is as follows: , in, The effective volume of the catalyst layer, The specific surface area of ​​the catalyst is the reference value, in units of The values ​​are derived from the design parameters of the catalyst at the time of manufacture or the calibration values ​​in a brand-new state; Pre-exponential factor, For activation energy, Let be the ideal gas constant. The absolute temperature of the reaction region; To measure the interlayer pressure difference, For the new catalyst at the current real-time flue gas flow rate and temperature The reference pressure difference is obtained by referring to the pressure-flow characteristic curve of the new catalyst; The pore blockage sensitivity coefficient, ranging from 0.5 to 1.0, is determined by the pore structure characteristics of the catalyst and is used to correct the nonlinear effect of dust accumulation on surface area masking. This formula clarifies how to inversely map the microscopic active surface area from macroscopic rate and pressure difference parameters. Specifically, it introduces... The function is designed to increase physical boundary constraints and prevent pressure differentials caused by severe catalyst blockage. Far exceeding the reference value The negative surface area is calculated under extreme working conditions to ensure that the input data of the subsequent control algorithm has physical authenticity; The key to this step is to treat the reaction tower as a chemical battery with buffer capacity, rather than a black box; to collect monitoring parameters from the exhaust gas outlet as the final compliance verification data; and on this basis, the linkage control unit executes a dual closed-loop control strategy: in the feedforward control stage, when the upstream production load parameters and the exhaust gas inlet parameters jointly indicate that there will be excessive pollutants entering the reaction tower, the unit does not wait for the exhaust gas outlet data to deteriorate, but generates a first control command to the reagent dosing mechanism based on the slurry pH distribution data or catalyst active surface area data inside the reaction tower, i.e., the current chemical defense capability, to perform feedforward adjustment of the reagent dosing; in the feedback control stage, a second control command is generated to the reagent dosing mechanism based on the monitoring parameters of the exhaust gas outlet to perform real-time fine-tuning of the reagent dosing amount; The first and second control commands jointly control the reagent dosing mechanism through weighted or logical superposition. In this embodiment, by introducing upstream load parameters and internal state data of the reaction tower, a three-dimensional control architecture of source prediction, process buffering, and end verification is constructed. Compared with traditional control that relies solely on emission outlet CEMS data, this system can overcome the large lag characteristics caused by physical transmission and chemical reaction, effectively avoiding instantaneous exceedances due to untimely response, and also preventing cost waste and secondary pollution caused by long-term excessive spraying of reagents to ensure compliance.

[0017] Example 2: The linkage control unit is specifically used to: determine the pollutant load status in the exhaust gas inlet pipeline based on the changing trend of upstream production load parameters and the real-time value of exhaust gas inlet parameters; compare the pollutant load status with a preset threshold, and trigger the execution of the first control command when the threshold is exceeded.

[0018] This embodiment mathematically models the judgment logic of the linkage control unit and introduces the concept of pollutant impact index. The system performs a trend extraction step to determine whether the production load is in a steady state, a surge, or a sudden drop based on the changing trend of the upstream production load parameters, i.e., the first derivative or difference. The system calculates the pollutant load status in the exhaust gas inlet pipeline based on the changing trend of the upstream production load parameters and the real-time value of the exhaust gas inlet parameters. To address the issues of vectors not being directly differentiable and the inconsistency in dimensions caused by directly adding different physical parameters, this embodiment employs a weighted aggregation algorithm to map multidimensional vectors into a single scalar. The specific calculation model uses normalization as follows: , , in, The pollutant impact index, derived from real-time calculations, is a dimensionless quantified value representing the pollutant load state. The polymerization scalar value is a parameter of the upstream production load, derived from the coal feed rate of the gasifier. Synthetic ammonia production index and combustion chamber temperature Weighted coefficient and reference benchmark value The result of normalized weighted summation The weighting coefficients are determined by analyzing the Pearson correlation coefficients between various parameters and pollutant emission peaks in historical operational data. Stronger correlations result in greater weights, and the following conditions must be met: This is used to quantify the contribution of different load parameters to pollutant formation. For time variables, The pollutant concentration in the exhaust gas inlet parameters is derived from the inlet sensor; the symbols used throughout the text are consistent with [symbol name missing]. , The trend-weighted time constant is derived from preset model parameters and is typically set to a range of 0.5h-2.0h to adjust the sensitivity to the rate of load change. To ensure dimensional balance in the formula, we define... It has a time dimension, such as h in hours, and is used to cancel out derivative terms. The generated Dimensions are ensured, so that the first term is a dimensionless value; at the same time, the physical transmission lag time is explicitly introduced into the formula. The calculation method is based on pipeline distance. Divide by average gas velocity ,item Indicates the use of The upstream load change rate before the time step is used to match the current inlet concentration. This mathematically corrects the time phase difference and resolves the technical contradiction that the original scalar multiplication could not compensate for time lag. The static load weighting and dimensionless normalization coefficients are derived from the preset model parameters, and their units are taken as... For example, the value is ,in The base concentration constant is used to eliminate and normalize the physical dimensions of the concentration value, ensuring that the two terms on the right side of the formula have the same dimensionless property so that algebraic addition can be performed. The system executes a threshold triggering step in response to the calculated pollutant load status. Exceeding the preset threshold The system determines that an impact load exceeding the normal processing capacity is about to occur, and thus immediately triggers the execution of the first control command to start the pre-adjustment mechanism. In this embodiment, by calculating the pollutant impact index including the time delay compensation derivative term, the system not only focuses on the current pollutant concentration, but also keenly captures the acceleration of the upstream load. This trend-based judgment logic enables the linkage control unit to have predictive capabilities, and can identify risks in advance before the peak of the exhaust gas concentration reaches the reaction tower, solving the time lag problem of responding to emergencies in traditional control.

[0019] Example 3: The linkage control unit is specifically used to: determine the degree distribution of chemical absorption reaction in the reaction tower based on the pH value of the slurry at different heights inside the reaction tower; or, determine the real-time effective reaction area of ​​the catalyst based on the catalyst active surface area data; and determine the amount of reagent to be added as required in the first control command based on the degree distribution or the real-time effective reaction area.

[0020] This embodiment further specifies how to determine the dosage of reagents based on the internal state of the reaction tower. The core is the introduction of the concept of chemical reaction potential energy, which is used to characterize the remaining pollutant treatment capacity of the reaction tower at the current moment. The system acquires the internal state distribution. For wet desulfurization systems, the pH value of the slurry at different heights inside the reaction tower, such as the upper, middle and lower parts of the spray layer, is collected. For SCR denitrification systems, the active surface area data of the catalyst layer is collected. The system assesses reaction capacity by determining the degree distribution of chemical absorption reactions within the reaction tower based on the pH value of the slurry at different heights. For example, if the pH value at the bottom is still high, it indicates that the slurry still has absorption capacity. Alternatively, it determines the real-time effective reaction area of ​​the catalyst based on the catalyst's active surface area data. Based on the degree distribution or real-time effective reaction area, the increased reagent dosage required in the first control command is determined. To ensure the rigor of the physical meaning in the calculation process, the specific calculation logic incorporates dimensional standardization, and the calculation formula is as follows: , , in, The chemical reaction potential energy within the current reaction tower is derived from real-time calculations. Its physical meaning is a normalized index of remaining buffer capacity, and it is a dimensionless value. The number of sensor or catalyst layers depends on the system configuration. For the first The state variables collected by the layer sensors refer to different physical quantities depending on the process: in wet desulfurization, they refer to the slurry pH value; in SCR denitrification, they refer to the catalyst active surface area data calculated in Example 1. In this calculation model, they are also quantified as the catalyst activity index. The critical value required to maintain the minimum reaction efficiency is derived from the process settings. For the first The weights and normalization coefficients corresponding to the layer heights are derived from the model parameters; To address the issue of the significant difference between pH value (dimensionless and logarithmically scaled) and catalyst surface area (units of area and numerical value), this embodiment employs the reciprocal method of characteristic scale for determination. Set as: , in, and These are the upper and lower limits of the measurement range for this type of sensor, respectively, thereby mapping different physical dimensions to normalized dimensionless values, ensuring... The calculation of values ​​possesses mathematical additivity and physical equivalence. For pH sensors, and Determine the physical range of the sensor; for the active surface area of ​​the catalyst. The theoretical maximum active surface area of ​​the catalyst in its virgin state is taken. Take the minimum active surface area corresponding to the catalyst scrapping standard; The dosage increase corresponding to the first control command is derived from the calculation output. The pollutant impact index is directly taken from the result calculated in Example 2. Its physical meaning is the predicted pollutant impact load, and it is a dimensionless value. The reference flow coefficient, in units of L / h or kg / h, is used to map dimensionless calculation results into actual physical quantities. Its value corresponds to the standard reagent dosage flow rate required for the system to treat the average pollutant concentration under rated operating conditions. This represents the conversion coefficient of the reagent, which is derived from the stoichiometry and is a dimensionless value used to correct for excess coefficients required in actual engineering. Based on this, the feedback adjustment amount corresponding to the second control command Calculated using incremental PID algorithm: , in, = - , To pre-set emission standards, This is the current monitoring value at the emission outlet. , , For proportional, integral, and differential coefficients; final dosage of reagent. = + ; This embodiment quantifies the chemical reaction potential energy inside the reaction tower, enabling the linkage control unit to accurately distinguish between true and false drug shortages; even if the inlet concentration increases, the overall pH value inside the tower remains high, i.e., the potential energy... The large concentration indicates that the internal buffer capacity of the tower is sufficient to cope with the situation, and there is no need to significantly increase the dosage. This control strategy based on the internal state avoids blindly following the inlet concentration and overdosing, thus achieving refined cost control.

[0021] Example 4: The linkage control unit is specifically used to: execute the first control command and start the reagent dosing mechanism to perform pre-dosing operation when the pollutant load status indicates that the impact load exceeds the steady-state threshold, and the pH distribution of the slurry inside the reaction tower indicates that the pH of the reaction zone is about to fall below the critical value or the active surface area of ​​the catalyst is below the activity threshold; when the pollutant load status indicates that the impact load exceeds the steady-state threshold, but the pH distribution of the slurry inside the reaction tower or the active surface area of ​​the catalyst indicates that the treatment capacity is sufficient, maintain the current reagent dosing amount.

[0022] This embodiment employs a logic judgment strategy based on the idea of ​​peak shaving and valley filling, utilizing the physical and chemical volume of the reaction tower as a buffer. The system evaluates the pre-dosing scenario. When the pollutant load status indicates that the impact load exceeds the steady-state threshold, and at the same time, the pH distribution of the slurry inside the reaction tower indicates that the pH of the reaction zone is about to fall below the critical value or the active surface area of ​​the catalyst is below the activity threshold, the system determines that the current buffering capacity is insufficient to resist the impact. In this case, the first control command is immediately executed to start the reagent dosing mechanism for pre-dosing operation, rapidly increasing the chemical potential energy inside the tower. The system assesses buffering scenarios. In response to a pollutant load indicating that the impact load exceeds the steady-state threshold, but the pH distribution of the slurry inside the reaction tower or the active surface area of ​​the catalyst indicates sufficient treatment capacity, the system determines that the chemical capacity of the reaction tower itself is sufficient to absorb the fluctuation. In this case, the current reagent dosage is maintained, and no additional pre-dosing is performed. This embodiment transforms the reaction tower from a passive channel into an active accumulator. When the treatment capacity is sufficient, it uses its own capacity to withstand the load impact, and only uses additional reagent dosing when necessary. This strategy greatly reduces the operating frequency of reagent dosing mechanisms such as pumps and valves, extends equipment life, smooths the chemical reaction process, and avoids scaling or corrosion problems caused by drastic fluctuations in reagent concentration.

[0023] Example 5:

[0024] The system also includes a fault diagnosis unit, which is used to: calculate the pollutant removal efficiency based on the exhaust gas inlet parameters and exhaust gas outlet monitoring parameters; estimate the theoretical reagent consumption based on the removal efficiency and the preset theoretical reagent consumption relationship; obtain the actual consumption of the reagent dosing mechanism; compare the theoretical consumption with the actual consumption, and generate an alarm signal indicating nozzle blockage or instrument failure when the deviation continues to exceed the preset range.

[0025] This embodiment addresses the common problems of difficult-to-detect instrument drift and nozzle blockage during exhaust gas treatment through a fault diagnosis unit. This unit is based on exhaust gas inlet parameters... and exhaust gas emission monitoring parameters Calculate pollutant removal efficiency ; Based on removal efficiency Exhaust gas flow rate The theoretical reagent consumption is estimated by relating it to the pre-defined theoretical reagent consumption ratio, i.e., the stoichiometric ratio. To ensure consistency of physical dimensions, unit conversions, mole-mass conversions, and density corrections are introduced in the formula as follows: , in, This represents the theoretical drug consumption, derived from calculations. The unit conversion factor has a value of [value]. Used to convert milligrams (mg) to kilograms. Theoretical stoichiometry, or molar ratio, is derived from chemical reaction equations. The exhaust gas flow rate is collected by a flow meter and is the same as that in Example 1 in this system. For the same physical quantity, the unit is usually 1. , The inlet and outlet pollutant concentrations are derived from online analyzers, and the units are typically [units missing]. The symbols are consistent throughout the text. The value represents the molecular weight of the drug, expressed in g / mol. The value represents the molecular weight of the pollutant, in g / mol. This is a parameter representing the density of the reagent, in kg / L; if If the mass flow rate is kg / h, then set... The value is a dimensionless 1, meaning that density division is not performed to preserve... Use mass flow rate units to match the comparison benchmark; if If the volumetric flow rate is L / h, then Take the actual density of the drug in kg / L, then divide by in the formula. Converting mass flow rate to volumetric flow rate ensures dimensional consistency in subsequent formulas; The system obtains the actual consumption from the reagent dosing mechanism, such as a flow meter or level gauge. The system performs deviation analysis, compares theoretical consumption with actual consumption, and calculates the deviation rate. To eliminate ambiguity in code implementation and establish a clear comparison benchmark, the deviation rate is used here. The calculation formula is strictly defined in the form of relative error, and includes protection against division by zero. The calculation formula is as follows: , in, This indicates that the absolute value operation is used to ensure that whether the actual consumption is lower due to nozzle blockage or higher due to pipeline leakage / instrument drift, the deviation can be uniformly quantified as a positive value; the denominator introduces... ,in Pick This is to establish a safety boundary for numerical computation, preventing issues caused by system downtime or extremely low levels of contaminants at the inlet. To prevent division by zero errors from occurring, the integrity of the algorithm logic is ensured. Response to deviation rate If the value continuously exceeds a preset range, such as by more than 15% and lasts for more than 30 minutes, an alarm signal indicating nozzle blockage or instrument malfunction is generated. This embodiment can diagnose the health status of the equipment in real time by establishing a material balance model. Compared with regular manual inspections, this diagnostic method based on data correlation analysis can detect hidden faults earlier, such as poor atomization effect caused by partial nozzle blockage, thereby avoiding environmental accidents caused by equipment failure.

[0026] Example 6: In this embodiment, the upstream production load parameters include the coal feed rate of the gasifier, the synthetic ammonia production index, and the combustion chamber temperature; the waste gas inlet parameters include the inlet waste gas flow rate, the inlet sulfur dioxide concentration, and the inlet nitrogen oxide concentration; the internal state parameters of the reaction tower vary depending on the waste gas treatment process, including the desulfurization tower slurry density, the circulating pump operating frequency, or the denitrification catalyst layer pressure difference and the reaction temperature.

[0027] This embodiment clearly defines the specific parameters collected by the system to ensure the feasibility of the technical solution. Upstream production load parameters are determined, including the coal feed rate to the gasifier, which directly determines the base amount of total sulfur and total nitrogen generated in the crude gas; the ammonia production index, reflecting the load level of subsequent processes; and the combustion chamber temperature, which affects the formation rate of thermal nitrogen oxides. The parameters of the exhaust gas inlet are determined, including the inlet exhaust gas flow rate for calculating the total amount of pollutants, and the inlet sulfur dioxide concentration and inlet nitrogen oxide concentration as the main control target pollutants; the internal state parameters of the reaction tower are determined, including the slurry density of the desulfurization tower, which reflects the supersaturation of gypsum in the slurry and affects the absorption efficiency; the operating frequency of the circulating pump characterizes the gas-liquid contact intensity; and the pressure difference of the denitrification catalyst layer directly reflects whether the catalyst is blocked or has ash accumulation. Furthermore, the reaction temperature affects the chemical reaction rate constant. This embodiment clearly defines the specific set of parameters, enabling those skilled in the art to accurately select the sensor type and installation location; in particular, the introduction of auxiliary parameters such as combustion chamber temperature and catalyst layer pressure difference significantly improves the system's perception granularity for complex operating conditions, ensuring that the data acquisition unit can capture key variables affecting exhaust gas treatment efficiency.

[0028] Example 7: The data acquisition unit connects in parallel to the programmable logic controllers of the distributed control system and the waste gas treatment system of the coal chemical production line through an industrial communication interface conforming to the OPC or Modbus protocol, in order to obtain upstream production load parameters and waste gas treatment-related parameters.

[0029] This embodiment details the communication architecture design of the data acquisition unit, aiming to break down the information silos commonly found in coal chemical enterprises. The data acquisition unit performs parallel connection operations through an industrial communication interface conforming to the OPC protocol, particularly the OPCUA architecture or ModbusTCP protocol: on one hand, it connects to the distributed control system (DCS) of the coal chemical production line to read load data from upstream gasification, synthesis, and other processes; on the other hand, it connects to the programmable logic controller (PLC) of the waste gas treatment system to read the operating status and sensor data of the waste gas treatment equipment. During this process, the system employs a two-way handshake mechanism to ensure data timestamp synchronization, thereby guaranteeing the alignment of upstream load parameters with waste gas inlet parameters on the time axis. This embodiment achieves cross-system data fusion, namely between DCS and PLC, through a standardized industrial communication protocol. This solves the problem that traditional environmental protection facilities operate as isolated systems and cannot obtain data from the source of production. It provides underlying data path support for realizing plant-wide feedforward control and ensures the timeliness and accuracy of control command generation.

[0030] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A data acquisition and monitoring control system for coal chemical waste gas, characterized in that, This system is applied to an exhaust gas treatment system, which includes an exhaust gas inlet pipe, a reaction tower, and an exhaust gas outlet connected in sequence. The reaction tower is equipped with nozzles for injecting reagents. The system includes a data acquisition unit for: Collect upstream production load parameters from coal chemical production lines; Collect the exhaust gas inlet parameters of the exhaust gas inlet pipeline; Collect slurry pH distribution data or catalyst active surface area data from multiple pH sensors or catalyst activity detectors installed at different heights inside the reaction tower; Collect monitoring parameters from the exhaust gas emission outlet; The linkage control unit, connected to the data acquisition unit and the reagent dosing mechanism of the reaction tower, is used for: When the upstream production load parameters and the exhaust gas inlet parameters jointly indicate that there will be excessive pollutants entering the reaction tower, a first control command is generated to the reagent dosing mechanism based on the slurry pH distribution data or catalyst active surface area data inside the reaction tower, so as to perform feedforward adjustment of reagent dosing; Based on the monitoring parameters of the exhaust gas outlet, a second control command is generated and sent to the reagent dosing mechanism to adjust the reagent dosage in real time; The first control command and the second control command jointly control the reagent dosing mechanism to remove pollutants from the waste gas through chemical absorption or catalytic reaction.

2. The coal chemical waste gas data acquisition and monitoring control system according to claim 1, characterized in that, The linkage control unit is specifically used for: Based on the changing trend of the upstream production load parameters and the real-time value of the exhaust gas inlet parameters, the pollutant load status in the exhaust gas inlet pipeline is determined. The pollutant load status is compared with a preset threshold. When the threshold is exceeded, the first control command is triggered.

3. The coal chemical waste gas data acquisition and monitoring control system according to claim 1, characterized in that, The linkage control unit is specifically used for: The degree of chemical absorption reaction distribution within the reaction tower is determined based on the pH value of the slurry at different heights inside the reaction tower. Alternatively, the real-time effective reaction area of ​​the catalyst can be determined based on the catalyst active surface area data. Based on the degree distribution or the real-time effective reaction area, determine the amount of reagent to be added as required in the first control command.

4. The coal chemical waste gas data acquisition and monitoring control system according to claim 1, characterized in that, The linkage control unit is specifically used for: When the pollutant load status indicates that the impact load exceeds the steady-state threshold, and the pH distribution of the slurry inside the reaction tower indicates that the pH of the reaction zone is about to fall below the critical value or the active surface area of ​​the catalyst is below the activity threshold, the first control command is executed to start the reagent dosing mechanism for pre-dosing operation. When the pollutant load status indicates that the shock load exceeds the steady-state threshold, but the slurry pH distribution inside the reaction tower or the catalyst active surface area indicates sufficient treatment capacity, the current reagent dosage shall be maintained.

5. The coal chemical waste gas data acquisition and monitoring control system according to claim 1, characterized in that, The system also includes a fault diagnosis unit for: The pollutant removal efficiency is calculated based on the exhaust gas inlet parameters and the exhaust gas outlet monitoring parameters. Based on the removal efficiency and the preset theoretical reagent consumption relationship, estimate the theoretical reagent consumption; Obtain the actual consumption of the drug dosing mechanism; The theoretical consumption is compared with the actual consumption. When the deviation continues to exceed the preset range, an alarm signal indicating nozzle blockage or instrument malfunction is generated.

6. The coal chemical waste gas data acquisition and monitoring control system according to claim 1, characterized in that: The upstream production load parameters include the coal feed rate of the gasifier, the synthetic ammonia production index, and the combustion chamber temperature. The waste gas inlet parameters include the inlet waste gas flow rate, the inlet sulfur dioxide concentration, and the inlet nitrogen oxide concentration; The internal state parameters of the reaction tower vary depending on the waste gas treatment process, including the density of the desulfurization tower slurry, the operating frequency of the circulating pump, or the pressure difference of the denitrification catalyst layer and the reaction temperature.

7. The coal chemical waste gas data acquisition and monitoring control system according to claim 1, characterized in that, The data acquisition unit is connected in parallel to the distributed control system of the coal chemical production line and the programmable logic controller of the waste gas treatment system through an industrial communication interface conforming to the OPC or Modbus protocol, in order to obtain the upstream production load parameters and the waste gas treatment related parameters.

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