Dry dedusting ash closed ash unloading system

Abstract

The present application relates to dust removal environmental protection technical field, especially a kind of dry dust removal ash closed ash unloading system, and ash unloading device includes dry dust removal box, pressure scraper, centralized ash bin, filter small box, sensor group and valve group;Control platform includes: data acquisition module, for the data acquisition of sensor group;Material level monitoring module, for the data acquisition of data acquisition module, to monitor the material level in centralized ash bin;Ash cleaning module, for the data acquisition of data acquisition module, to obtain ash cleaning signal according to the pressure difference of filter small box, and ash cleaning module executes ash cleaning operation according to ash cleaning signal;Ash unloading module, for the data acquisition of data acquisition module and material level monitoring module, to analyze and obtain ash unloading signal, and ash unloading module executes ash unloading operation according to ash unloading operation signal.The present application solves the problems of poor sealing, insufficient safety, energy waste and material level detection error of traditional ash unloading device technology.

Description

Technical Field

[0001] This invention relates to the field of dust removal and environmental protection technology, and in particular to a dry dust removal system with a closed ash discharge mechanism. Background Technology

[0002] To achieve efficient recovery and environmentally friendly disposal of dry dust collected during blast furnace ironmaking, steel companies need to equip themselves with professional ash unloading systems. Traditional dry dust collection ash unloading systems suffer from several technical defects: insufficient airtightness, employing single-valve structures or ordinary sealing designs, resulting in air leakage rates often exceeding 3.8%, leading to dust dispersion and gas leakage, polluting the environment, wasting energy, and causing system pressure imbalance and a decrease in dust collection efficiency of approximately 12%. Low level of intelligence, lacking collaborative control logic, ash unloading operations rely on manual on-site intervention, making remote one-button control impossible, resulting in low operational efficiency and safety risks such as high-temperature burns and combustible dust explosions. Inadequate ash unloading triggering mechanisms, often relying on single time or material level parameters, easily leading to dust accumulation or over-unloading, exacerbating pipeline blockage and equipment wear. Inaccurate material level detection, traditional detection equipment is easily affected by dust adhesion and high-temperature environments, resulting in large detection deviations and inaccurate judgment of ash unloading timing, further increasing system operational risks. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides a dry dust removal and ash unloading system that solves the issues of poor sealing, insufficient safety, energy waste, and incorrect material level detection in traditional ash unloading devices.

[0004] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0005] A dry dust collection and ash unloading system includes an ash unloading device and a control platform.

[0006] The ash removal device includes a dry dust collection chamber, a pressure-resistant scraper conveyor, a centralized ash silo, and a small filter box.

[0007] The dry dust collector is provided in two parts. The inlet end of the two dry dust collectors is connected to a pressure relief pipe. The outlet end of each dry dust collector is connected to the pressure-resistant scraper conveyor via a first pneumatic ash discharge bell valve and a first ash discharge electric valve, respectively. The pressure-resistant scraper conveyor is connected to the centralized ash silo.

[0008] The centralized ash silo is equipped with radio frequency admittance level gauges at different heights, and a first nitrogen purging pipe is installed at the position corresponding to the radio frequency admittance level gauge. The first nitrogen purging pipe is controlled to open and close by a first nitrogen purging pneumatic valve. An ash discharge pipeline is installed on the side wall at the bottom of the centralized ash silo. The ash discharge pipeline is equipped with a first ash discharge pneumatic valve and is connected to a suction and discharge tanker truck through a conveying pipeline. The top of the centralized ash silo is connected to the filter box through a dust removal pipeline.

[0009] The discharge end of the filter box is connected to a pressure relief pipe, and the discharge end of the filter box is equipped with a dust content detection probe. The discharge end of the filter box is equipped with a clean gas backflush inlet pipe, and the clean gas backflush inlet pipe is equipped with a backflush pneumatic valve and a backflush pneumatic blind valve. The filter box is equipped with a differential pressure sensor.

[0010] The control platform includes:

[0011] The data acquisition module is used for data acquisition from the radio frequency admittance level gauge and the differential pressure sensor.

[0012] The material level monitoring module is used to acquire data from the data acquisition module in order to monitor the material level in the centralized ash silo.

[0013] The dust removal module is used to acquire data from the data acquisition module to obtain a dust removal signal based on the pressure difference of the filter box, and the dust removal module performs a dust removal operation based on the dust removal signal.

[0014] The ash unloading module is used to acquire data from the data acquisition module and the material level monitoring module. The ash unloading module obtains the ash unloading signal based on the ash unloading interval, the pressure difference of the filter box, and the material level of the centralized ash silo. The ash unloading module executes the ash unloading operation based on the ash unloading operation signal.

[0015] Furthermore, when the differential pressure sensor detects that the pressure difference is greater than the first differential pressure threshold, the cleaning module controls the backflush pneumatic valve and the backflush pneumatic blind valve to open, so that the clean coal gas can backflush the filter box.

[0016] Furthermore, the dust removal module uses a cascaded PID algorithm to dynamically adjust the backflushing frequency and duration based on the dust accumulation rate.

[0017] Furthermore, the conveying pipeline is equipped with a wear-resistant pneumatic tungsten carbide ball valve, and the end of the conveying pipeline away from the suction and discharge tank truck is connected to a nitrogen-assisted blowing pipe, which is equipped with a nitrogen-assisted blowing valve; the ash unloading module includes an ash unloading control submodule, which, when it receives the ash cleaning signal, sequentially controls the wear-resistant pneumatic tungsten carbide ball valve, the nitrogen-assisted blowing valve, and the first ash unloading pneumatic valve to open.

[0018] Furthermore, the pressure-resistant scraper conveyor is equipped with a second nitrogen purging pipe, and the second nitrogen purging pipe is equipped with a second nitrogen purging pneumatic valve;

[0019] The ash unloading module also includes a pre-ash unloading control submodule and a post-ash unloading control submodule. The pre-ash unloading control submodule is used to start the first nitrogen purging pneumatic valve and the second nitrogen purging pneumatic valve for a preset time and then close them before the wear-resistant pneumatic tungsten carbide ball valve is opened. After the first nitrogen purging pneumatic valve and the second nitrogen purging pneumatic valve are closed, the pressure-resistant scraper conveyor and the suction and discharge tanker are started in sequence and then the wear-resistant pneumatic tungsten carbide ball valve is opened.

[0020] The post-ash unloading control submodule is used for reverse control of the equipment and valves in the post-ash unloading control submodule and the pre-ash unloading control submodule, and controls the opening of the first nitrogen purging pneumatic valve and the second nitrogen purging pneumatic valve during the shutdown process.

[0021] Furthermore, the control platform also includes a self-cleaning module, which is used to control the opening and closing of the first nitrogen purging pneumatic valve, so as to perform a cleaning operation on the radio frequency admittance level gauge before and after the cleaning operation.

[0022] Furthermore, after performing the dust removal operation, the self-cleaning module collects data from three sets of the radio frequency admittance level gauges. When the data fluctuation range of the radio frequency admittance level gauges is greater than the fluctuation threshold, the cleaning is repeated once and the data is collected again. If the data fluctuation range of the radio frequency admittance level gauges is still greater than the fluctuation threshold, a cleaning failure signal is issued.

[0023] Furthermore, the centralized ash silo is equipped with a first temperature sensor and a first pressure sensor, and the data acquisition module is also used to acquire data from the first temperature sensor and the first pressure sensor; the control platform also includes a correction module, which is used to correct the material level data based on the data from the data acquisition module.

[0024] The correction module corrects the data of the radio frequency admittance level gauge by ±1% for every 10°C increase in temperature when the temperature value of the first temperature sensor is greater than the temperature correction threshold, based on the data from the first temperature sensor.

[0025] The correction module corrects the data of the radio frequency admittance level gauge based on the data from the first pressure sensor. When the pressure value of the first pressure sensor deviates from the standard operating range, the correction module compensates by ±0.8% for every ±5kPa.

[0026] Furthermore, the control platform also includes an energy consumption optimization module, which is used to dynamically adjust the frequency conversion frequency of the pressure-resistant scraper conveyor according to the material level of the centralized ash silo, and the energy consumption optimization module adjusts the nitrogen blowing pressure according to the nitrogen consumption and the amount of clean coal gas recovered.

[0027] Furthermore, the control platform also includes a regulation module, which comprises a cascaded PID submodule and a feedforward compensation submodule.

[0028] The cascaded PID submodule includes a main controller and a secondary controller. The main controller is used to output control indicators, including the pressure difference of the filter box, the material level control accuracy of the centralized ash silo, and the energy consumption optimization coefficient. The secondary controller is used to output actuator parameters, including nitrogen pressure, nitrogen flow rate, backflushing duration of the filter box, and backflushing interval of the filter box.

[0029] The feedforward compensation submodule is used for input of known interference variables, and the feedforward compensation submodule superimposes the output feedforward correction amount to the output of the secondary controller. The known interference variables include dust, nitrogen fan speed, and initial material level deviation.

[0030] The beneficial effects of this invention are:

[0031] Employing a fully enclosed design and multi-stage sealing structure, the system utilizes a completely sealed connection architecture consisting of a dry dust collector housing, ash discharge valve group, pressure-resistant scraper conveyor, centralized ash silo, and suction / discharge tanker to prevent dust dispersion and gas leakage. The dust content at the outlet of the filter housing is monitored in real time and strictly controlled to ≤3mg / Nm³, meeting the comprehensive emission standards for air pollutants. An ash discharge triggering mechanism, implemented through coordinated control of three parameters—differential pressure, material level, and time—adapts to complex operating conditions, preventing dust accumulation or excessive ash discharge. Unmanned operation is possible during ash removal and discharge, increasing efficiency by over 45% compared to traditional manual operation. A comprehensive, high-precision intelligent material level monitoring system is constructed, employing a radio frequency admittance level gauge with nitrogen self-cleaning function, redundantly backed by a primary temperature sensor. Combined with temperature and pressure compensation algorithms, the material level detection error is ≤±5%, solving the problem of dust and high-temperature interference in traditional detection equipment. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the ash unloading device according to a preferred embodiment of the present invention.

[0033] Figure 2 This is a block diagram of the control platform according to a preferred embodiment of the present invention.

[0034] Figure 3 This is a schematic diagram of the ash removal process according to a preferred embodiment of the present invention.

[0035] Figure 4 This is a schematic diagram of ash unloading control according to a preferred embodiment of the present invention.

[0036] Figure 5 This is a schematic diagram of the operation process of the control module in a preferred embodiment of the present invention.

[0037] Figure 6 This is a timing diagram of the ash unloading process according to a preferred embodiment of the present invention.

[0038] Figure 7 This is a flowchart of the material level monitoring process during the operation of the data acquisition module in a preferred embodiment of the present invention.

[0039] Figure 8 This is a flowchart of the material level monitoring process during the operation of the self-cleaning module in a preferred embodiment of the present invention.

[0040] Figure 9 This is a flowchart of the material level monitoring process during the operation of the modified module in a preferred embodiment of the present invention.

[0041] Figure 10 This is a flowchart of the material level monitoring process during the operation of the alarm module in a preferred embodiment of the present invention.

[0042] In the diagram, 1-Dust collector housing, 10-Pressure relief pipe, 111-First pneumatic ash discharge bell valve, 112-First electric ash discharge valve, 2-Pressure-resistant scraper conveyor, 21-Second nitrogen purging pipe, 211-Second nitrogen purging pneumatic valve, 3-Centralized ash silo, 31-First nitrogen purging pipe, 311-First nitrogen purging pneumatic valve, 32-Ash discharge pipeline, 321-First ash discharge pneumatic valve, 33-Conveying system Pipeline, 331-Wear-resistant pneumatic tungsten carbide ball valve, 34-Tank discharge truck, 35-Nitrogen-assisted blowing pipe, 351-Nitrogen-assisted blowing valve, 36-Bin wall vibrator, 37-Nitrogen cannon device, 38-Humidification pipeline, 381-Humidifier, 382-Ash discharge star valve, 383-Second ash discharge pneumatic valve, 4-Filter box, 401-Dust removal pipeline, 402-Third ash discharge pneumatic valve, 404-Unloading 41-Pneumatic blind flange valve for ash removal; 411-Clean gas backflushing inlet pipe; 412-Backflushing pneumatic valve; 42-Vent pneumatic valve; 51-RF admittance level gauge; 52-Dust content detection probe; 53-Differential pressure sensor; 54-First temperature sensor; 55-First pressure sensor; 56-Second pressure sensor; 57-Second temperature sensor; 61-Data acquisition module; 62-Level monitoring module; 63-Ash cleaning module; 64-Ash unloading module; 641-Ash unloading control submodule; 642-Pre-ash unloading control submodule; 643-Post-ash unloading control submodule; 65-Self-cleaning module; 66-Correction module; 67-Energy consumption optimization module; 68-Control module; 681-Cascade PID submodule; 682-Feedforward compensation submodule; 69-Alarm module. Detailed Implementation

[0043] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0044] It should be noted that when a component is described as "fixed to" another component, it can be directly on the other component or may have a component in between. When a component is considered "connected to" another component, it can be directly connected to the other component or may have a component in between. When a component is considered "set on" another component, it can be directly set on the other component or may have a component in between. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0045] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0046] Please also see Figure 1 to

[0047] A preferred embodiment of the present invention provides a dry dust removal system with a closed ash discharge device and a control platform.

[0048] like Figure 1 As shown, the ash removal device includes a dry dust collection box 1, a pressure-resistant scraper conveyor 2, a centralized ash silo 3, and a small filter box 4.

[0049] There are two dry dust collector boxes 1. The inlet ends of the two dry dust collector boxes 1 are connected to the pressure relief pipe 10. The outlet ends of the two dry dust collector boxes 1 are respectively connected to the first pneumatic ash discharge bell valve 111 and the first ash discharge electric valve 112 and connected to the pressure-resistant scraper machine 2. The pressure-resistant scraper machine 2 is connected to the centralized ash silo 3.

[0050] The pressure scraper conveyor 2 is equipped with a second nitrogen purging pipe 21, and the second nitrogen purging pipe 21 is equipped with a second nitrogen purging pneumatic valve 211.

[0051] The centralized ash silo 3 is equipped with radio frequency admittance level gauges 51 at different heights, and a first nitrogen purge pipe 31 is installed at the position corresponding to the radio frequency admittance level gauge 51. The first nitrogen purge pipe 31 is controlled to open and close by a first nitrogen purge pneumatic valve 311. An ash discharge pipe 32 is installed on the side wall at the bottom of the centralized ash silo 3. The ash discharge pipe 32 is equipped with a first ash discharge pneumatic valve 321, and the ash discharge pipe 32 is connected to the suction and discharge tank truck 34 through a conveying pipe 33. The top of the centralized ash silo 3 is connected to the filter box 4 through a dust removal pipe 401.

[0052] The conveying pipeline 33 is equipped with a wear-resistant pneumatic tungsten carbide ball valve 331, and the end of the conveying pipeline 33 away from the suction and discharge tank truck 34 is connected to a nitrogen blowing pipe 35, which is equipped with a nitrogen blowing valve 351.

[0053] In this embodiment, a first temperature sensor 54 and a first pressure sensor 55 are installed inside the centralized ash silo 3. The centralized ash silo 3 is also equipped with a silo wall vibrator 36 and a nitrogen cannon device 37.

[0054] A humidification mechanism is provided at the bottom of the centralized ash silo 3; the humidification mechanism includes a humidification pipe 38, one end of which is connected to the centralized ash silo 3, and the other end is provided with a humidifier 381. A ash discharge star valve 382 and a second ash discharge pneumatic valve 383 are arranged sequentially along the direction close to the centralized ash silo 3.

[0055] The discharge end of the filter housing 4 is connected to the pressure relief pipe 10, and a dust content detection probe 52 is installed at the discharge end of the filter housing 4. A clean gas backflushing inlet pipe 41 is installed at the discharge end of the filter housing 4, and a backflushing pneumatic valve 411 and a backflushing pneumatic blind valve 412 are installed on the clean gas backflushing inlet pipe 41. A differential pressure sensor 53 is installed in the filter housing 4. The dust removal pipeline 401 is equipped with a third ash discharge pneumatic valve 402 and an ash discharge pneumatic blind valve 403.

[0056] In this embodiment, the top of the filter box 4 is provided with a venting pneumatic valve 42, a second pressure sensor 56 and a second temperature sensor 57, and a pressure relief pneumatic blind valve 43 and a pressure relief backflush pneumatic valve 44 are provided between the discharge end of the filter box 4 and the pressure relief pipe 10.

[0057] The control platform includes:

[0058] The data acquisition module 61 is used for data acquisition from the radio frequency admittance level gauge 51 and the differential pressure sensor 53.

[0059] The material level monitoring module 62 is used to acquire data from the data acquisition module 61 in order to monitor the material level in the centralized ash silo.

[0060] The dust removal module 63 is used to acquire data from the data acquisition module 61, so as to obtain the dust removal signal based on the pressure difference of the filter box, and the dust removal module 63 performs the dust removal operation according to the dust removal signal.

[0061] When the differential pressure sensor 53 detects that the ash removal module 63 is greater than the first differential pressure threshold, the ash removal module 63 controls the backflush pneumatic valve 411 and the backflush pneumatic blind valve 412 to open so that the clean coal gas can backflush the filter box 4.

[0062] The dust removal module 63 uses a cascaded PID algorithm and dynamically adjusts the backflushing frequency and duration according to the dust accumulation rate.

[0063] In this embodiment, adaptive differential pressure feedback regulation dynamically adjusts the dust removal strategy based on the pressure difference inside and outside the filter bag in the filter housing 4. When the pressure difference exceeds 3 kPa, clean gas backflushing is automatically initiated for dust removal, with a backflushing pressure of 0.4-0.6 MPa. Through a cascaded PID algorithm, the backflushing frequency (reduced from the default 5 min / time to 4 min / time) and duration (extended from 10 s to 15 s) are dynamically adjusted according to the dust accumulation rate (pressure difference rise rate > 0.5 kPa / h), extending the filter bag's service life to more than 2 years.

[0064] The ash unloading module 64 is used to acquire data from the data acquisition module 61 and the material level monitoring module 62. The ash unloading module 64 obtains the ash unloading signal based on the ash unloading interval, the pressure difference of the filter box, and the material level in the centralized ash silo. The ash unloading module 64 also executes the ash unloading operation based on the ash unloading operation signal. In this embodiment, a three-parameter coordinated control of pressure difference, material level, and time is adopted. The ash unloading operation is automatically triggered when the pressure difference of the filter box reaches 50kPa±10kPa, the material level gauge detects a high material level, or the ash unloading interval reaches 7 days.

[0065] The ash removal module 64 includes an ash removal control submodule 641. When the ash removal control submodule 641 receives the ash removal signal, it sequentially controls the wear-resistant pneumatic tungsten carbide ball valve 331, the nitrogen-assisted blowing valve 351, and the first ash removal pneumatic valve 321 to open.

[0066] The ash unloading module 64 also includes a pre-ash unloading control submodule 642 and a post-ash unloading control submodule 643. The pre-ash unloading control submodule 642 is used to start the first nitrogen purging pneumatic valve 311 and the second nitrogen purging pneumatic valve 211 for a preset time before the wear-resistant pneumatic tungsten carbide ball valve 331 is opened, and then closes them. After the first nitrogen purging pneumatic valve 311 and the second nitrogen purging pneumatic valve 211 are closed, the pressure-resistant scraper conveyor 2 and the suction and discharge tank truck 34 are started in sequence before the wear-resistant pneumatic tungsten carbide ball valve 331 is opened.

[0067] The post-ash discharge control submodule 643 is used for reverse-order control of equipment and valves in the ash discharge control submodule 641 and the pre-ash discharge control submodule 642, and controls the opening of the first nitrogen purging pneumatic valve 311 and the second nitrogen purging pneumatic valve 211 during the closing process.

[0068] In this embodiment, the ash unloading module 64 performs time-sequential safe conveying. It strictly adheres to the principles of safety first and orderly sequence to ensure a leak-free and risk-free conveying process. The ash unloading process is as follows: Figure 3 and Figure 4 As shown.

[0069] Before unloading ash: Start nitrogen purging to replace the coal gas in the pipeline for 10 minutes (adjustable range 5-15 minutes).

[0070] Equipment startup: Start in the following order: "Pressure scraper conveyor 2 → suction and discharge tank truck 34 → valve". The pressure scraper conveyor should be delayed for 2 seconds, and the tank truck should be delayed for 5 seconds to avoid excessive starting inrush current.

[0071] Valve operation: Open valves in the following order: "wear-resistant pneumatic tungsten carbide ball valve 331 → nitrogen-assisted blowing valve → ash discharge pneumatic valve", with an interval of ≤5s. Verify valve position by using limit switches.

[0072] After unloading the ash: Close the equipment and valves in reverse order, and simultaneously start the nitrogen purging pipeline to remove residual dust.

[0073] In this embodiment, the dust removal process and the dust unloading process are staggered by the valve signal to avoid mutual interference that could lead to excessive dust content.

[0074] The control platform also includes a self-cleaning module 65, which is used for the opening and closing control of the first nitrogen purging pneumatic valve 311 to perform a cleaning operation on the radio frequency admittance level gauge 51 before and after the cleaning operation.

[0075] After performing the dust removal operation, the self-cleaning module 65 collects data from three sets of radio frequency admittance level gauges 51. When the data fluctuation range of the radio frequency admittance level gauges 51 is greater than the fluctuation threshold, the cleaning is repeated once and the data is collected again. If the data fluctuation range of the radio frequency admittance level gauges 51 is still greater than the fluctuation threshold, a cleaning failure signal is issued.

[0076] In this embodiment, a pre-cleaning procedure is implemented: To address the detection deviation caused by dust adhesion to the sensor probe in high-temperature and high-dust environments, the module automatically initiates a nitrogen self-cleaning procedure before and after level acquisition. Before and after ash removal, the RF admittance level gauge probe is purged with nitrogen three times (5 seconds on, 5 seconds off each time), with a purging pressure of 0.4-0.6 MPa, thoroughly removing dust from the probe surface. The acquired raw level signal is filtered by a PLC algorithm to remove high-frequency interference, and the digital signal is verified using a "two-out-of-three" voting logic (taking the median value from three consecutive samples) to eliminate instantaneous fluctuations and ensure the reliability of the basic data.

[0077] This embodiment improves the accuracy of material level detection through self-cleaning and data fusion. The material level gauge undergoes three nitrogen self-cleaning cycles (5 seconds on, 5 seconds off each time) before and after ash unloading, with a purging pressure of 0.4-0.6 MPa, to remove dust adhering to the probe surface. Cross-validation is performed by combining material level change trends with ash unloading time (e.g., after 30 minutes of high-level ash unloading, the material level should decrease by ≥30%), resulting in a material level detection error of ≤±5%. In cases of high temperature (>200℃) or abnormal pressure (>50kPa), an automatic compensation algorithm is activated (correcting ±1% for every 10℃ increase in temperature and ±0.8% for every ±5kPa in pressure).

[0078] The data acquisition module 61 is also used to acquire data from the first temperature sensor 54 and the first pressure sensor 55; the control platform also includes a correction module 66, which is used to correct the material level data based on the data from the data acquisition module 61.

[0079] Based on the data from the first temperature sensor 54, the correction module 66 corrects the data of the radio frequency admittance level gauge 51 by ±1% for every 10°C increase when the temperature value of the first temperature sensor 54 is greater than the temperature correction threshold.

[0080] The correction module 66 corrects the data of the RF admittance level gauge 51 by compensating ±0.8% for every ±5kPa when the pressure value of the first pressure sensor 55 deviates from the standard operating range, based on the data from the first pressure sensor 55.

[0081] The correction module 66 addresses the impact of high temperature and pressure changes on material level detection. It incorporates a dynamic compensation algorithm to perform secondary corrections on the pre-processed material level data. In this embodiment, when the silo temperature exceeds 200℃, the material level value is adjusted according to a rule of "correcting ±1% for every 10℃ increase" to offset the effect of dielectric constant changes caused by high temperature. When the silo pressure deviates from the standard operating range (0-50kPa), compensation is applied at a rate of "correcting ±0.8% for every ±5kPa" to correct for material compaction or agglomeration interference caused by pressure changes. The final output material level data error is ≤±5%, significantly higher than the accuracy of traditional detection equipment.

[0082] The control platform also includes an energy consumption optimization module 67, which is used to dynamically adjust the frequency of the pressure-resistant scraper conveyor 2 according to the material level of the centralized ash silo 3, and to adjust the nitrogen blowing pressure according to the nitrogen consumption and the amount of clean coal gas recovered.

[0083] In this embodiment, the frequency of the pressure scraper conveyor is dynamically adjusted according to the material level in the centralized ash silo (50Hz for high material level, 40Hz for medium material level, and 30Hz for low material level). The nitrogen-assisted blowing pressure is optimized by combining nitrogen consumption and net coal gas recovery (increased by 0.1-0.2MPa when the material level drops slowly, and maintained at 0.4MPa when the material level drops normally). During the low material level ash discharge stage (20%-40%), the vibrator start-stop interval is automatically extended (adjusted from "10s on, 10s off" to "8s on, 12s off"), and the nitrogen flow rate is reduced to 0.71-1.13m / s (optimized parameters for low material level ash discharge). "Fan energy consumption is reduced by 12%~15%, and nitrogen consumption is reduced by more than 10%."

[0084] In this embodiment, the control platform further includes a regulation module 68, which includes a cascaded PID submodule 681 and a feedforward compensation submodule 682.

[0085] The cascaded PID submodule 681 includes a main controller and a secondary controller. The main controller is used to output control indicators, including the pressure difference of the filter box 4, the material level control accuracy of the centralized ash silo 3, and the energy consumption optimization coefficient. The secondary controller is used to output actuator parameters, including nitrogen pressure, nitrogen flow rate, backflushing time of the filter box 4, and backflushing interval of the filter box 4.

[0086] The feedforward compensation submodule 682 is used for the input of known disturbance variables, and the feedforward compensation submodule 682 superimposes the output feedforward correction amount to the output of the secondary controller. The known disturbance variables include dust, nitrogen fan speed, and initial material level deviation.

[0087] The operation process of control module 68 is as follows: Figure 5 As shown, the control module 68 in this embodiment can perform pressure adaptive control. The control module 68 monitors the pressure changes of the centralized ash hopper (0-50kPa) and the filter box (0-250kPa) in real time. When the pressure deviates from the set range of ±5kPa, it automatically adjusts the nitrogen supply or the opening of the pressure relief valve to maintain the system pressure stability and avoid excessive pressure leading to sealing failure.

[0088] In response to the temperature variation of dust collectors (100-240℃), the feedforward compensation submodule 682 adjusts the preheating time of the seal and the nitrogen purging pressure in advance. In high-temperature environments (>200℃), the nitrogen purging pressure of the seal is increased by 0.05MPa to offset the effect of high temperature on the sealing material and ensure stable sealing performance.

[0089] In this embodiment, the control module 68 sends the core control targets (such as a stable differential pressure value of 1.5-2.5 kPa and a material level control accuracy of ±5%) to the PID main controller, which then dynamically adjusts the execution parameters. At high material levels, the main controller outputs a command to increase the nitrogen flow rate, and the PID secondary controller adjusts the flow velocity from 1.13 m / s to 1.7 m / s. When the dust temperature exceeds 200°C, the feedforward compensation algorithm pre-corrects the nitrogen pressure (for every 10°C increase, the nitrogen pressure within the current real-time pressure based on the "0.4-0.6 MPa" benchmark range is increased by 0.03 MPa, and the backflushing interval is shortened by 10%), offsetting the reduced dust flowability caused by high temperatures.

[0090] In this embodiment, the basic parameter thresholds are as follows: stable pressure difference of the filter box is 1.5-2.5 kPa, material level control accuracy is ±5%, and energy consumption optimization coefficient is ≥0.85; nitrogen pressure control range is 0.4-0.6 MPa, nitrogen flow rate control range is 0.71-2.12 m / s, filter box backflushing time is 10-30 s / time, and backflushing interval is 5-30 min; dust temperature adaptability range is 100-240℃, nitrogen fan speed stability range is 1500-2500 r / min, and initial material level deviation allowable value is ±8%.

[0091] PID parameter tuning standards: Main controller (differential pressure control): proportional coefficient 2.5-3.5, integral time 60-120s, derivative time 15-30s, control cycle 5s; Main controller (level control): proportional coefficient 1.8-2.8, integral time 30-60s, derivative time 10-20s, control cycle 3s; Sub-controller (nitrogen pressure): proportional coefficient 3.0-4.0, integral time 20-40s, derivative time 5-10s, control cycle 2s; Sub-controller (nitrogen flow rate): proportional coefficient 2.2-3.2, integral time 15-30s, derivative time 3-8s, control cycle 1s; Sub-controller (backflushing control): proportional coefficient 1.5-2.5, integral time 40-80s, derivative time 8-15s, control cycle 4s.

[0092] The cascade control logic of the cascade PID submodule 681 is as follows: The main loop collects the filter box pressure difference, centralized ash silo level, and energy consumption data in real time, compares them with the set target value to calculate the deviation, and outputs the set value of the secondary loop; the secondary loop tracks the set value of the main loop, adjusts the nitrogen blower operating parameters and backflush valve action sequence in real time, and quickly suppresses local disturbances.

[0093] Feedforward compensation logic of feedforward compensation submodule 682: temperature feedforward (for every 10°C increase above 200°C, the nitrogen pressure is increased by 0.03MPa in advance and the backflushing interval is shortened by 10% based on the current real-time pressure within the "0.4-0.6MPa" reference range), fan status feedforward (when the speed fluctuation exceeds ±100r / min, the frequency converter frequency is corrected in advance), and material level deviation feedforward (when the deviation exceeds ±8%, the nitrogen flow rate is adjusted proportionally).

[0094] The control platform alarm module 69 of this embodiment can perform leakage early warning and handling: the integrated interlocking control technology integrates the dust content detection probe (response time ≤1s) and the data of the first pressure sensor. When the dust content at the outlet of the filter box is >3mg / Nm³ or the pressure difference at the sealing part is abnormal, the emergency procedure is immediately activated, the ash unloading process is cut off, the relevant valves are closed, nitrogen is turned on to purge and seal the leak point, and the fault information is pushed to the operation and maintenance terminal.

[0095] In this embodiment, the alarm module 69 can realize data linkage and fault early warning:

[0096] Linked with ash unloading trigger: When the high level gauge detects a value ≥ 80% of the full silo, the level trigger condition in the "differential pressure-level-time" three-parameter coordinated control is triggered, and the ash unloading process is started; when the low level gauge detects a value ≤ 20% of the full silo, it serves as the core criterion for determining whether ash unloading is complete.

[0097] Linked with parameter control: The real-time material level drop rate (e.g., ≤0.3m / h) is fed back to the cascade PID + feedforward compensation algorithm, triggering the vibration frequency adjustment (from 10s / time to 8s / time) and the nitrogen blowing pressure increase (0.1-0.2MPa) to avoid dust bridging and pipe blockage.

[0098] Linked with fault warning: When the material level data remains unchanged for more than 30 minutes or the deviation between the main and backup sensor data is greater than ±8%, an alarm message of "material level monitoring abnormal" will be immediately pushed to the operation and maintenance terminal, prompting you to check the sensor or clean the dust in the bin.

[0099] This embodiment features full-process data traceability and optimization: the module automatically records data such as material level change curves, cleaning times, and compensation corrections for each ash unloading cycle, storing this data in a working condition classification library. The data is categorized and archived according to material level ranges (low material level 20%~40%, medium material level 40%~60%, high material level 60%~80%), providing a basis for the timing machine algorithm to optimize the timing parameters of each state. Every 50 ash unloading cycles, the material level trigger threshold and compensation coefficient are optimized based on ash unloading efficiency and energy consumption data, continuously improving monitoring accuracy and working condition adaptability.

[0100] like Figure 6As shown, in this embodiment, the ash unloading process is divided into 11 ordered states using a timing machine, specifically including:

[0101] State classification: Standby state (S0), pre-verification state (S1), level gauge purging state (S2), nitrogen replacement state (S3), equipment start-up state (S4), valve opening state (S5), sealed ash discharge state (S6), ash cleaning state (S7), equipment shutdown state (S8), data archiving state (S9), fault handling state (S10).

[0102] Key timing parameters: Level gauge purging 3 times (5s on, 5s off each time, total duration 30s), nitrogen purging duration 10min (adjustable 5-15min), valve opening interval ≤5s (all valves open ≤30s), vibrator timing "10s on, 10s off", backflushing 3 times (10s interval each time, duration 10-30s), equipment shutdown interval ≤5s (full shutdown duration ≤60s), data archiving duration ≤30s.

[0103] Jump constraints: The state jumps in the order of “S0→S1→S2→S3→S4→S5→S6→S7→S8→S9”, and cross-state execution is prohibited; the fault handling state (S10) has the highest priority. If any state triggers a fault, the jump will start immediately. After the fault is cleared, the process will resume from the breakpoint.

[0104] Timing accuracy control standards include:

[0105] The allowable deviation for valve action interval is ±0.5s. If the deviation is exceeded, subsequent actions will be paused and the valve status will be rechecked. The allowable deviation for purging / backflushing duration is ±10%. If the deviation is exceeded, the timing parameters for the next operation will be automatically corrected. The allowable deviation for equipment start / stop delay is ±1s. If the deviation continues for 3 times, an equipment status alarm will be triggered. The allowable deviation for total ash unloading time is ±15%. If the deviation is exceeded, the parameters for the next ash unloading will be adjusted based on the material level data.

[0106] In this embodiment, parameter benchmarks and execution instructions are provided for each stage of the state machine, and the state machine ensures the orderly execution of the control logic through timing constraints. In the S6 closed ash unloading state, the state machine controls the start and stop timing of the vibrator, and the control module 68 dynamically adjusts the vibration frequency. When the state machine detects that the valve opening timeout (>10s), the control module 68 suspends the subsequent process, pushes fault information, and triggers the valve retry logic.

[0107] Ash removal includes the following three operation methods:

[0108] Automatic operation mode: When the control conditions and process equipment interlock conditions are met, the system automatically completes the entire ash unloading operation without manual intervention.

[0109] HMI manual operation mode: When the interlock conditions are met, the operator can control the machine manually according to the process sequence through the host computer and view the operating parameters in real time.

[0110] Manual operation mode at the machine: Only the basic safety interlock of the equipment itself is retained for equipment maintenance and debugging. It adopts a reset / self-reset selection switch, and is equipped with a maintenance accident switch, a local operation permission indicator, and an equipment status indicator.

[0111] In this embodiment, a radio frequency admittance level gauge 51 with three measuring points and nitrogen self-cleaning function is used in conjunction with a first temperature sensor 54 to form a redundant monitoring architecture. Simultaneously, temperature and pressure sensors are linked to achieve synchronous acquisition of multiple parameters. The radio frequency admittance level gauge 51 is installed at key locations for high, medium, and low level detection in the centralized ash silo. It utilizes the principle of radio frequency admittance to detect changes in the dielectric constant of the material and outputs a real-time simulated level signal with a sampling frequency of 1 time / second to ensure data real-time performance. The first temperature sensor 54 serves as a backup; when the main sensor malfunctions or data fluctuations exceed a threshold (±5%), it automatically switches to become the core detection device, ensuring continuous level monitoring. The temperature sensor (monitoring range 100-400℃) and pressure sensor (monitoring range 0-50kPa) synchronously collect environmental parameters within the silo, providing a basis for level data compensation.

[0112] like Figure 7 The diagram shown is a flowchart of the material level monitoring process during the operation of the data acquisition module 61. Figure 8 Flowchart for material level monitoring during the operation of self-cleaning module 65; Figure 9 To revise the material level monitoring flowchart during the operation of module 66; Figure 10 This is a flowchart of the material level monitoring process during the operation of alarm module 69.

[0113] This embodiment demonstrates significant energy consumption optimization. By dynamically adjusting the frequency of the pressure scraper conveyor and the timing of nitrogen purging and backflushing, blower energy consumption is reduced by 12%~15%, and nitrogen consumption is reduced by more than 10%. It offers flexible retrofitting and new construction: retrofitting can be performed while the dry process system is in production, with a cycle of ≤15 days and an ash removal interval of ≤7 days, without affecting normal production; it supports modular installation and is suitable for retrofitting and new construction projects of various blast furnaces with capacities ranging from 2000 to 5000 m³.

Claims

1. A dry dust collection and ash unloading system, characterized in that, Includes ash unloading device and control platform, The ash removal device includes a dry dust collection chamber, a pressure-resistant scraper conveyor, a centralized ash silo, and a small filter box. The dry dust collector is provided in two parts. The inlet end of the two dry dust collectors is connected to a pressure relief pipe. The outlet end of each dry dust collector is connected to the pressure-resistant scraper conveyor via a first pneumatic ash discharge bell valve and a first ash discharge electric valve, respectively. The pressure-resistant scraper conveyor is connected to the centralized ash silo. The centralized ash silo is equipped with radio frequency admittance level gauges at different heights, and a first nitrogen purging pipe is installed at the position corresponding to the radio frequency admittance level gauge. The first nitrogen purging pipe is controlled to open and close by a first nitrogen purging pneumatic valve. An ash discharge pipeline is installed on the side wall at the bottom of the centralized ash silo. The ash discharge pipeline is equipped with a first ash discharge pneumatic valve and is connected to a suction and discharge tanker truck through a conveying pipeline. The top of the centralized ash silo is connected to the filter box through a dust removal pipeline. The discharge end of the filter box is connected to a pressure relief pipe, and the discharge end of the filter box is equipped with a dust content detection probe. The discharge end of the filter box is equipped with a clean gas backflush inlet pipe, and the clean gas backflush inlet pipe is equipped with a backflush pneumatic valve and a backflush pneumatic blind valve. The filter box is equipped with a differential pressure sensor. The control platform includes: The data acquisition module is used for data acquisition from the radio frequency admittance level gauge and the differential pressure sensor. The material level monitoring module is used to acquire data from the data acquisition module in order to monitor the material level in the centralized ash silo. The dust removal module is used to acquire data from the data acquisition module to obtain a dust removal signal based on the pressure difference of the filter box, and the dust removal module performs a dust removal operation based on the dust removal signal. The ash unloading module is used to acquire data from the data acquisition module and the material level monitoring module. The ash unloading module obtains the ash unloading signal based on the ash unloading interval, the pressure difference of the filter box, and the material level of the centralized ash silo. The ash unloading module executes the ash unloading operation based on the ash unloading operation signal.

2. The dry dust removal and ash unloading system according to claim 1, characterized in that: When the ash removal module obtains that the differential pressure sensor is greater than the first differential pressure threshold, the ash removal module controls the backflush pneumatic valve and the backflush pneumatic blind valve to open so that the clean coal gas can backflush and clean the filter box.

3. The dry dust removal and ash unloading system according to claim 2, characterized in that: The dust removal module uses a cascaded PID algorithm and dynamically adjusts the backflushing frequency and duration based on the dust accumulation rate.

4. The dry dust removal and ash unloading system according to claim 1, characterized in that: The conveying pipeline is equipped with a wear-resistant pneumatic tungsten carbide ball valve, and the end of the conveying pipeline away from the suction and discharge tank truck is connected to a nitrogen-assisted blowing pipe, which is equipped with a nitrogen-assisted blowing valve. The ash unloading module includes an ash unloading control submodule. When the ash unloading control submodule receives the ash cleaning signal, it sequentially controls the wear-resistant pneumatic tungsten carbide ball valve, the nitrogen-assisted blowing valve, and the first ash unloading pneumatic valve to open.

5. A dry dust removal and ash unloading system according to claim 4, characterized in that: The pressure-resistant scraper conveyor is equipped with a second nitrogen purging pipe, and the second nitrogen purging pipe is equipped with a second nitrogen purging pneumatic valve; The ash unloading module also includes a pre-ash unloading control submodule and a post-ash unloading control submodule. The pre-ash unloading control submodule is used to start the first nitrogen purging pneumatic valve and the second nitrogen purging pneumatic valve for a preset time and then close them before the wear-resistant pneumatic tungsten carbide ball valve is opened. After the first nitrogen purging pneumatic valve and the second nitrogen purging pneumatic valve are closed, the pressure-resistant scraper conveyor and the suction and discharge tanker are started in sequence and then the wear-resistant pneumatic tungsten carbide ball valve is opened. The post-ash unloading control submodule is used for reverse control of the equipment and valves in the post-ash unloading control submodule and the pre-ash unloading control submodule, and controls the opening of the first nitrogen purging pneumatic valve and the second nitrogen purging pneumatic valve during the shutdown process.

6. The dry dust removal and ash unloading system according to claim 1, characterized in that: The control platform also includes a self-cleaning module, which is used to control the opening and closing of the first nitrogen purging pneumatic valve, so as to perform a cleaning operation on the radio frequency admittance level gauge before and after the cleaning operation.

7. A dry dust removal and ash unloading system according to claim 6, characterized in that: After performing the dust removal operation, the self-cleaning module collects data from three sets of radio frequency admittance level gauges. When the data fluctuation range of the radio frequency admittance level gauges is greater than the fluctuation threshold, the cleaning is repeated once and the data is collected again. If the data fluctuation range of the radio frequency admittance level gauges is still greater than the fluctuation threshold, a cleaning failure signal is issued.

8. A dry dust removal and ash unloading system according to claim 1, characterized in that: The centralized ash silo is equipped with a first temperature sensor and a first pressure sensor. The data acquisition module is also used to acquire data from the first temperature sensor and the first pressure sensor. The control platform also includes a correction module, which is used to correct the material level data based on the data from the data acquisition module. The correction module corrects the data of the radio frequency admittance level gauge by ±1% for every 10°C increase in temperature when the temperature value of the first temperature sensor is greater than the temperature correction threshold, based on the data from the first temperature sensor. The correction module corrects the data of the radio frequency admittance level gauge based on the data from the first pressure sensor. When the pressure value of the first pressure sensor deviates from the standard operating range, the correction module compensates by ±0.8% for every ±5kPa.

9. A dry dust removal and ash unloading system according to claim 1, characterized in that: The control platform also includes an energy consumption optimization module, which is used to dynamically adjust the frequency conversion frequency of the pressure-resistant scraper conveyor according to the material level of the centralized ash silo, and adjust the nitrogen blowing pressure according to the nitrogen consumption and the amount of clean coal gas recovered.

10. A dry dust removal and ash unloading system according to claim 9, characterized in that: The control platform also includes a regulation module, which comprises a cascaded PID submodule and a feedforward compensation submodule. The cascaded PID submodule includes a main controller and a secondary controller. The main controller is used to output control indicators, including the pressure difference of the filter box, the material level control accuracy of the centralized ash silo, and the energy consumption optimization coefficient. The secondary controller is used to output actuator parameters, including nitrogen pressure, nitrogen flow rate, backflushing duration of the filter box, and backflushing interval of the filter box. The feedforward compensation submodule is used for input of known interference variables, and the feedforward compensation submodule superimposes the output feedforward correction amount to the output of the secondary controller. The known interference variables include dust, nitrogen fan speed, and initial material level deviation.

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