Energy-saving special chemical furnace with slag removal function

Abstract

This invention provides an energy-saving chemical furnace with slag removal function, relating to the field of energy-saving chemical furnaces. It includes a base, a furnace body fixedly installed on top of the base, a power control unit installed on the left front end of the base, and a control unit installed on the right front end of the base. By integrating an intelligent status monitoring module, a multi-dimensional sensor array is constructed using K-type thermocouples, piezoresistive pressure sensors, laser sensors, and ultrasonic level gauges. A weighted fusion algorithm is used to calculate the slag index. When the slag index reaches a set threshold, the slag removal program is automatically activated. This overcomes the problem of improper slag removal timing caused by traditional manual experience-based judgment or timed slag removal. This design avoids downtime losses and mechanical fatigue caused by excessively high slag removal frequency, and also prevents excessively thick slag layers, cleaning difficulties, and decreased heat exchange efficiency caused by delayed slag removal, significantly improving equipment operation continuity and energy utilization efficiency.

Description

Technical Field

[0001] This invention relates to the field of energy-saving chemical furnace technology, specifically to an energy-saving chemical furnace with slag removal function. Background Technology

[0002] With the increasing demands for energy efficiency and process continuity in industrial production, effectively addressing the slag buildup problem generated during furnace reactions has become crucial for ensuring the long-term stable operation of equipment. In actual operation, molten slag often accumulates on the furnace walls due to high-temperature reactions. This slag not only significantly reduces the furnace's heat exchange efficiency, leading to substantial energy waste, but may also affect the stability of the reaction environment by blocking flue gas passages. Meanwhile, existing boiler charge preheating systems generally suffer from significant defects: existing preheating sections are mostly simple straight-tube co-current structures, resulting in short contact time between flue gas and charge, small heat exchange area, and waste heat recovery efficiency generally below 45%; preheating temperature control is crude, only able to achieve rough control through manual adjustment of damper opening, with charge outlet temperature fluctuations reaching ±20℃, severely affecting the reaction stability of the main reaction zone; the preheating section and main reaction zone mostly use ordinary gate valves for sealing, with poor sealing performance and flue gas crossflow rate as high as 10% or more, causing both heat energy waste and premature oxidation of the charge; sudden changes in airflow pressure in the main reaction zone during slag removal can easily trigger backflow of airflow in the preheating section, causing feed interruption; and the preheating system and slag removal system operate completely independently, unable to achieve coordinated adjustment according to furnace conditions, making it difficult to achieve optimal overall energy efficiency.

[0003] Meanwhile, auxiliary slag removal systems in the slag removal process often lack energy efficiency optimization logic. Components such as fans often operate at constant power, making it difficult to balance slag removal efficiency and energy consumption based on real-time operating conditions. In terms of safety, the control systems of existing equipment generally lack redundant verification mechanisms for multiple sensors. Under harsh conditions such as high temperature and high pressure, if sensors experience signal drift or malfunction, the system cannot quickly execute emergency plans, posing significant safety risks. Furthermore, due to the lack of storage and analysis capabilities for equipment lifecycle data, operators find it difficult to predict equipment maintenance cycles and often can only perform reactive repairs after a failure occurs. Therefore, developing an energy-saving chemical furnace with intelligent monitoring, adaptive control, energy efficiency optimization, and multiple safety redundancy functions has become a pressing technical challenge for the industry. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an energy-saving chemical furnace with slag removal function, which solves the problems of existing boilers that are prone to slag formation during operation, inaccurate slag removal timing, low efficiency and high energy consumption of manual or timed slag removal, easy damage to the furnace structure by strong knocking, low preheating efficiency of furnace charge, poor temperature control accuracy, serious flue gas crossflow, and inability of preheating and slag removal systems to work together.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an energy-saving chemical furnace with slag removal function, comprising a base, a furnace body fixedly installed on the top of the base, a power control component installed on the left front end of the base, and a control component installed on the right front end of the base; cabinet doors are provided at both ends of the furnace body, and linear guide rails are symmetrically installed along the vertical center line on the outer walls of the left and right sides of the furnace body, with sliding blocks slidably connected to the outer walls of the linear guide rails, a connecting block installed at one end of the sliding block, and a striking component installed at the bottom of the connecting block; a fan assembly is installed on the top of the furnace body, and an independent furnace charge preheating section is provided at the feed end of the furnace body, the preheating section being connected to the exhaust port of the furnace body through a flue gas waste heat recovery pipe, a flow regulating device being installed on the flue gas waste heat recovery pipe, a sealing isolation device being provided between the preheating section and the main reaction zone of the furnace body, and the control component being electrically connected to the sensor array, the striking component, and the fan assembly via a data cable; The control unit is configured to calculate a slagging index and activate a slagging removal program when the slagging index reaches a trigger threshold; wherein the calculation of the slagging index is based on multiple physical quantities and their contribution weights, real-time acquired values, a safety threshold upper limit, and a benchmark value; The control unit integrates an intelligent status monitoring module, an adaptive control module, an efficiency optimization algorithm module, a security protection redundancy module, and a data storage and analysis module.

[0006] Preferably, the intelligent status monitoring module includes sensor arrays arranged at different height levels inside the furnace body. The sensor arrays include K-type thermocouples for monitoring reaction temperature, piezoresistive pressure sensors for monitoring internal pressure, laser sensors for monitoring combustion flue gas turbidity, and ultrasonic level gauges for detecting slag thickness; as well as furnace charge feed temperature sensors, furnace charge discharge temperature sensors, and flue gas flow sensors arranged in the preheating section.

[0007] Preferably, the adaptive control module is configured to adjust the striking intensity and frequency of the striking component using a fuzzy PID control algorithm after the slag removal program is activated, and its output excitation force is determined based on the deviation between the current molten slag thickness and the target clean thickness, as well as the proportional, integral, and derivative adjustment coefficients.

[0008] Preferably, the efficiency optimization algorithm module is configured to predict the unit energy consumption slag removal efficiency index using a linear regression model; wherein, the unit energy consumption slag removal efficiency index is related to the average furnace temperature, furnace pressure, the rotational speed of the blower assembly, slag removal duration, blower power characteristics, regression coefficients, and model correction residuals; the control unit controls the operation of the blower assembly by searching for the rotational speed parameter that maximizes the unit energy consumption slag removal efficiency index, wherein the rotational speed parameter does not exceed the upper limit of the rated rotational speed of the blower assembly and is not lower than the lower limit of the rotational speed corresponding to the minimum airflow velocity required for slag removal.

[0009] Preferably, the safety protection redundancy module is configured to compare and verify the values ​​of the main sensor and the auxiliary sensor, and calculate the deviation rate between the two according to the deviation rate determination formula; when the deviation rate continues to exceed a preset percentage and reaches a preset time, the control component cuts off the power supply of the striking component through a hardware interlock circuit.

[0010] Preferably, the furnace body adopts a double-layer stainless steel shell structure, with aluminum silicate fiber insulation material filling the space between the inner and outer shells, and the inner wall of the furnace body is coated with a nano-level anti-adhesion ceramic coating.

[0011] Preferably, the connecting block is made of die-cast aluminum alloy, and the connecting block is connected to the striking assembly by a flexible shock-absorbing pad made of high-temperature resistant elastomer material; a dustproof bellows cover is provided between the linear guide rail and the sliding block.

[0012] Preferably, the base is made of high-strength cast iron and has a mesh-like reinforcing rib structure inside; the front end of the furnace body is movably connected to a cabinet door via a hinge, and the edge of the cabinet door is inlaid with a fluororubber sealing strip.

[0013] Preferably, the data storage and analysis module is configured to record slag removal operating data and execute the moving average method to calculate the equipment performance degradation trend line; wherein, the moving average is determined based on the calculation cycle and the efficiency index of each slag removal operation.

[0014] Preferably, the intelligent status monitoring module is also configured to calculate the waste heat recovery efficiency of the preheating section in real time. The controller automatically adjusts the opening of the flow regulating device according to the deviation between the preheating section charge discharge temperature and the set value to stabilize the charge preheating temperature. The sealing isolation device adopts a variable frequency drive star-shaped rotary airlock valve, with wear-resistant ceramic sealing plates embedded at the ends of its rotor blades, and the gap between the blades and the shell is ≤0.2mm. The controller dynamically adjusts the speed of the star-shaped rotary airlock valve using a PID algorithm based on the difference between the real-time pressure in the main reaction zone and the pressure in the preheating section, and simultaneously adjusts the opening of the flow regulating device to ensure that the pressure in the preheating section is always 50~100Pa higher than the pressure in the main reaction zone. When the slag removal program is activated, the controller automatically increases the speed of the star-shaped rotary airlock valve by 15%~25% and temporarily reduces the opening of the flow regulating device by 10%~20% to prevent the slag removal airflow from flowing back into the preheating section and to ensure the slag discharge airflow pressure in the main reaction zone.

[0015] This invention provides an energy-saving chemical furnace with slag removal function, which has the following beneficial effects: This invention integrates an intelligent status monitoring module, utilizing a multi-dimensional sensor array constructed from K-type thermocouples, piezoresistive pressure sensors, laser sensors, and ultrasonic level gauges. Based on a weighted fusion algorithm, it calculates the slagging index. When the slagging index reaches a set threshold, the slagging removal program is automatically activated. This overcomes the problem of improper slagging timing caused by traditional manual experience-based judgment or timed slagging removal. This design avoids downtime losses and mechanical fatigue caused by excessively high slagging removal frequency, and also prevents excessively thick slagging layers, cleaning difficulties, and decreased heat exchange efficiency caused by delayed slagging removal, significantly improving equipment operation continuity and energy utilization efficiency.

[0016] This invention introduces an adaptive control module into the slag removal process, using a fuzzy PID control algorithm to dynamically adjust the striking intensity and frequency of the striking components. The output excitation force is adjusted in a closed loop based on the deviation between the real-time molten slag thickness and the target clean thickness. This ensures that the striking force can effectively dislodge the molten slag while avoiding the mechanical damage to the furnace structure and lining caused by traditional fixed-force striking. Practical applications show that this mechanism extends the service life of the furnace lining by more than 30%, combining thorough slag removal with equipment protection.

[0017] This invention utilizes an efficiency optimization algorithm module to predict slag removal efficiency under different operating conditions using a linear regression model, and searches for the optimal fan speed that maximizes the efficiency. During the slag removal process, the fan assembly automatically accelerates to generate directional airflow based on real-time furnace temperature and pressure, causing the dislodged molten slag to quickly converge at the slag discharge port under the combined action of gravity and airflow. This avoids the fan operating at a constant high power for extended periods. Actual tests show that this module reduces the average energy consumption during the slag removal stage by more than 25%, achieving an optimized balance between slag removal efficiency and energy consumption.

[0018] This invention integrates a safety protection redundancy module into the control unit, performs dual-channel comparison and verification of the main and auxiliary sensors, and evaluates the signal consistency in real time based on the deviation rate judgment formula. When the deviation rate continuously exceeds the preset threshold, the power supply to the striking component is instantly cut off through the hardware interlock circuit to prevent safety risks caused by sensor drift or malfunction. At the same time, the module can monitor the striking current and furnace vibration amplitude in real time, and realize physical-level power-off protection when the cabinet door is accidentally opened, which significantly improves the operational safety of the equipment under harsh conditions such as high temperature and high pressure.

[0019] The flue gas crossflow rate between the preheating section and the main reaction zone of this invention is reduced from more than 10% in traditional equipment to less than 1%, which completely solves the problems of feed interruption and premature oxidation of furnace charge caused by backflow of air during slag removal. At the same time, the stability of the furnace charge preheating temperature is further improved, and the fluctuation of the discharge temperature can be controlled within ±5℃. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the linear guide rail of the present invention; Figure 3 This is a schematic diagram of the structure of the wind turbine assembly of the present invention; Figure 4 This is a block diagram showing the logic module and sensor connection of the control component of the present invention; Figure 5 This is a flowchart illustrating the slag removal function of the present invention.

[0021] The components include: 1. base; 2. furnace body; 3. power control unit; 4. linear guide rail; 5. cabinet door; 6. control unit; 7. sliding block; 8. connecting block; 9. movable seat; 10. fan assembly; and 11. hammering assembly. Detailed Implementation

[0022] 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. like Figure 1-5As shown in the figure, this embodiment of the invention provides an energy-saving chemical furnace with slag removal function, including a base 1. A power control component 3 is installed on the front left side of the base 1. A furnace body 2 is installed on the top of the base 1. Linear guide rails 4 are installed on the outer walls of both sides of the furnace body 2. Sliding blocks 7 are slidably connected to the outer walls of the linear guide rails 4. A connecting block 8 is installed at one end of the sliding block 7. A hammering component 11 is installed at the bottom of the connecting block 8. A fan component 10 is installed on the top of the furnace body 2. A control component 6 is installed on the front right side of the base 1. The base 1 is cast from high-strength cast iron material and has a reinforcing rib structure inside, which can bear the entire load. The base 1 is fixedly connected to the top of the furnace body 2 to absorb the physical characteristics of the machine weight and impact vibration. The furnace body 2 adopts a double-layer stainless steel shell structure, and the space between the inner and outer shells is filled with aluminum silicate fiber insulation material to reduce heat loss and improve energy utilization efficiency. The front end of the furnace body 2 is movably connected to the cabinet door 5 through a hinge. The edge of the cabinet door 5 is inlaid with a high-temperature resistant sealing strip to achieve a tight seal of the furnace cavity when closed. The power control component 3 is installed on the left front end of the base 1. The power control component 3 integrates an AC to DC power conversion module and an overcurrent protection circuit to provide a stable power supply for the entire system.

[0023] The furnace body 2 has an independent preheating section fixedly connected to its feed end. This preheating section uses the same insulation structure as the furnace body 2 to reduce heat loss during preheating. A feed inlet is located on one side of the preheating section, and a discharge outlet is located on the other side. The discharge outlet is connected to the feed inlet of the main reaction zone of the furnace body 2 via a sealing isolation device. One end of the flue gas waste heat recovery pipe is connected to the exhaust port of the furnace body 2, and the other end is connected to the flue gas inlet of the preheating section. The flue gas outlet of the preheating section is connected to the exhaust system, forming a counter-current heat exchange loop between the furnace charge and the high-temperature flue gas, maximizing waste heat recovery. To improve efficiency, the sealing and isolation device adopts a variable frequency drive star-shaped rotary airlock valve, which is the optimal choice that balances continuous feeding and airlock performance. The rotor of the airlock valve is integrally cast from wear-resistant cast iron, and the blade ends are inlaid with a 5mm thick alumina wear-resistant ceramic sealing sheet. The radial clearance between the blade and the shell is controlled at 0.1~0.2mm, and the axial clearance is controlled at 0.2~0.3mm. The drive motor of the airlock valve is a three-phase asynchronous variable frequency motor with a speed range of 5~50r / min, which can realize continuous stepless adjustment of the feeding amount.

[0024] The preheating section is equipped with a complete set of status monitoring sensors: a furnace charge temperature sensor is installed at the inlet to detect the initial temperature of the furnace charge entering the preheating section; a furnace charge discharge temperature sensor is installed at the outlet to detect the temperature of the furnace charge after preheating; and a flue gas flow sensor is installed on the flue gas waste heat recovery pipeline to detect the flue gas flow rate entering the preheating section. All sensors are electrically connected to the control unit 6 to provide data support for the closed-loop control of the preheating temperature.

[0025] Linear guide rails 4 are symmetrically installed along the vertical center line on both the left and right outer walls of the furnace body 2. The guide rail surfaces of the linear guide rails 4 are subjected to high-frequency quenching treatment, possessing extremely high hardness and wear resistance. Sliding blocks 7 are slidably connected to the outer walls of the linear guide rails 4. The sliding blocks 7 are internally equipped with a self-lubricating bearing structure to achieve reciprocating linear motion with a low coefficient of friction. A connecting block 8 is fixedly connected to one end of the sliding block 7. The connecting block 8 is made of die-cast aluminum alloy, possessing low rotational inertia while ensuring strength. The bottom of the connecting block 8 is... The furnace body 2 is equipped with a striking assembly 11, which integrates a high-frequency electromagnetic hammer. The hammer head is driven by a controlled pulse current to generate a specific frequency of excitation force on the furnace wall. A fan assembly 10 is installed on the top of the furnace body 2. The fan assembly 10 includes a centrifugal impeller and a variable frequency motor connected to it. The shaft of the variable frequency motor is supported on a movable base 9 by a bearing seat. The fan assembly 10 achieves stepless adjustment of the wind speed by changing the frequency of the motor input current, and is used to guide the shaken molten slag to the bottom collection tank through airflow.

[0026] The control unit 6 includes an intelligent status monitoring module, an adaptive control module, an efficiency optimization algorithm module, a security protection redundancy module, and a data storage and analysis module.

[0027] The intelligent control system is the core brain of this invention. Its main hardware component is the control unit 6 installed on the side of the base 1. The control unit 6 adopts an industrial-grade embedded microprocessor, has multiple high-speed analog signal acquisition interfaces and pulse width modulation output ports, and has five logically coupled functional modules running inside the control unit 6.

[0028] The intelligent status monitoring module acquires raw data through a sensor array arranged at different height levels inside the furnace body 2. These sensors include a K-type thermocouple for monitoring reaction temperature, a piezoresistive pressure sensor for monitoring internal pressure, a laser sensor for monitoring combustion flue gas turbidity, and an ultrasonic level gauge for detecting slag thickness. The control unit 6 performs weighted fusion processing on the acquired sensor signals and executes a comprehensive status assessment program. The intelligent status monitoring module calculates the slag index inside the furnace. The logic for determining when to perform slag removal is calculated using the following formula: ; In this formula, The number of physical quantities involved in the calculation, in this embodiment These are temperature, pressure, flue gas turbidity, and slag thickness, respectively. : No. The contribution weights of various physical quantities to the urgency of slag removal are determined using the analytic hierarchy process (AHP) and satisfy the following conditions: In this embodiment: the weight of the slag coating thickness Temperature weight = 0.3 Pressure weight = 0.2 Flue gas turbidity weight ; : No. Real-time acquired values ​​of various physical quantities; : No. The upper limit of the safety threshold for a certain physical quantity under normal operating conditions; exceeding this value will result in severe slagging. : No. The baseline value of a physical quantity under normal operating conditions (standard value under slag-free condition). The weights representing the contribution of different physical quantities to the urgency of slag removal are as follows: for example, the weight of temperature fluctuation is greater than the weight of smoke concentration. For physical quantities collected in real time; These are the upper limit and reference value of the safety threshold for this physical quantity under normal operating conditions, respectively. When the value exceeds the preset trigger threshold, the system automatically activates the slag removal program.

[0029] This invention employs a micro-positive pressure control strategy in the preheating section to prevent backflow of airflow. Its core is to maintain a stable positive pressure difference between the preheating section and the main reaction zone through the synchronous linkage of the rotation speed of the sealing isolation device and the opening of the flow regulation device. The specific control logic is as follows: Normal operating mode (non-slag removal state) The control unit (6) collects the preheating section pressure in real time with a period of 500ms. and pressure in the main reaction zone Calculate the pressure difference Target pressure difference set to (Adjustable range) To ensure the preheating section remains under a slight positive pressure, fundamentally preventing flue gas cross-flow in the main reaction zone, the rotational speed of the star-shaped rotary airlock valve is controlled using a closed-loop PID algorithm. The formula is: ; in: : Real-time rotation speed of the airlock valve , The reference rotational speed is determined by the furnace charge feed rate set by the system. Differential pressure deviation value ; : Proportional output of PID control PID control coefficient (can be calibrated according to on-site working conditions).

[0030] Slag removal operation mode When the slagging index reaches the threshold and the slagging removal procedure is activated (workflow step S3), the control unit (6) immediately performs the following linkage operation: temporarily increases the reference speed n0 of the star-shaped rotary airlock valve by 20% (adjustable range 15%~25%), increases the height of the material column in the valve body, enhances the physical airlock capability, temporarily reduces the opening of the flow regulating device by 15% (adjustable range 10%~20%), increases the flue gas pressure in the preheating section, and at the same time maintains the differential pressure closed-loop control, temporarily increasing the target differential pressure to (Adjustable range 80~120Pa) After receiving the slag removal command, the adaptive control module adjusts its settings according to the current slag index. In addition to controlling the temperature gradient inside the furnace, the module dynamically adjusts the striking intensity and frequency of the striking component 11. This module employs an improved fuzzy PID control algorithm to achieve precise control of the electromagnetic hammer's output power. Within its control logic, the output excitation force of the striking component 11... Determined by the following mathematical model: ; in, : The real-time excitation force output by component 11 during constant tapping, in N; : The deviation between the current slag thickness and the target clean thickness at any given moment. ,in The actual thickness of the slag coating is in real time. The target cleaning thickness is set to 0 mm in this embodiment. The proportional adjustment coefficient is used to quickly reduce deviation. In this embodiment... ; The integral adjustment coefficient is used to eliminate static deviation in this embodiment. ; The differential adjustment coefficient is used to suppress deviation fluctuations. In this embodiment... ; Integration time variable, unit ; The rate of change of the deviation value over time is measured by the control component 6, which dynamically corrects the above coefficients by monitoring the vibration attenuation waveform after the impact in real time. This ensures that the impact force can effectively dislodge the molten slag while also exhibiting a flexible characteristic that protects the structural integrity of the furnace body.

[0031] Based on the calculated excitation force, control unit 6 outputs a corresponding PWM signal to drive the electromagnetic hammer, ensuring that the excitation force matches the required slag thickness and achieving flexible striking. Simultaneously, control unit 6 monitors the vibration decay waveform after impact in real time, correcting it every 100ms. The coefficient is adjusted to avoid excessive vibration force that could damage the furnace wall.

[0032] The efficiency optimization algorithm module aims to maximize the overall energy efficiency of the slag removal process, that is, to maximize the amount of slag removed per unit of energy consumption while ensuring the slag removal effect. This module uses a linear regression model in machine learning to model historical slag removal data and predict the optimal speed of the fan component 10 under specific operating conditions. The formula for the slag removal efficiency prediction model per unit of energy consumption is as follows: ; In this formula, The unit energy consumption slag removal efficiency index indicates that the higher the value, the higher the overall energy efficiency. Original slag removal efficiency index The fan shaft power is directly proportional to the cube of the rotational speed (characteristics of centrifugal fans). The power coefficient of a wind turbine is determined by its characteristic curve. : No-load power of the fan; : Fan component speed 10, unit r / min, value range is : The minimum rotational speed required to ensure that the molten slag can be transported to the slag discharge port by the gas flow; The upper limit of the rated speed of the fan assembly, the control element 6, is set by searching. Reaching the extreme value The parameters are then sent as control commands to the frequency converter of the wind turbine assembly 10 to achieve optimal coordination between wind energy and mechanical vibration.

[0033] The control unit 6 searches for the optimal speed ωoptimum = 3500r / min that maximizes the slag removal efficiency per unit energy consumption by traversing the fan speed range (1000-5000r / min). It then sends this speed parameter to the fan frequency converter, enabling the fan to operate at the optimal speed and reducing energy consumption by more than 25%.

[0034] The security redundancy module provides multiple layers of protection for the system. At critical monitoring points, the system is equipped with primary and secondary sensors, performing dual-channel comparison and verification. When the deviation rate between the two signals... When the safety limit is exceeded, the system executes the emergency safety plan. The formula for determining the deviation rate is: ; in, The values ​​are from the main sensor. For redundant secondary sensor values, if If the time exceeds 15% of the preset number of seconds, the control unit 6 immediately cuts off the main circuit output of the power control unit 3 and displays a fault code on the LED display screen on the cabinet door 5. At the same time, it locks the movement path of the sliding block 7 to prevent mechanical damage caused by malfunction.

[0035] The data storage and analysis module is responsible for managing the equipment's entire lifecycle data. This module uses non-volatile ferroelectric memory to record the duration, energy consumption, and sensor trends of each slag removal process. By applying a simple moving average method, the system can calculate the trend line of equipment performance degradation and predict the timing of the next preventative maintenance. : ; in, The time window period for analysis, For historical energy efficiency records, when When the slope deviates significantly in the negative direction, the control unit 6 generates a maintenance report, prompting the operator to add lubricating oil to the linear guide 4 or check the fastening bolts of the connecting block 8.

[0036] The specific workflow of this invention is detailed below: S1: The power control unit supplies DC voltage to the control unit, which drives the intelligent status monitoring module to perform self-tests on all the sensors in the machine and confirm that the initial parameters are within the standby baseline range. After the self-test is completed, the star-shaped rotary airlock valve automatically resets to the reference speed, and the flow regulating device opens to the initial opening degree.

[0037] S2: During the operation of the chemical reaction, the furnace charge enters the preheating section through the feed inlet. Under the guidance of the spiral guide plate, it exchanges heat with the high-temperature flue gas from the main reaction zone in a countercurrent manner. After being preheated to the set temperature, it is continuously sent into the main reaction zone through the airlock sealing valve. The control component 6 synchronously collects all sensor data of the main reaction zone and the preheating section with a period of 500ms, and calculates the slagging index S in a cycle. At the same time, it dynamically adjusts the opening of the flue gas regulating damper according to the furnace charge outlet temperature and flue gas flow rate in the preheating section to maximize the waste heat recovery efficiency. At this time, the fan assembly 10 is in a low-speed circulation mode to maintain the pressure balance in the furnace. The sliding block 7 is stationary at the initial position at the top of the linear guide rail 4.

[0038] S3: As the reaction proceeds, the thickness of the molten slag on the furnace wall increases, leading to a decrease in heat exchange efficiency. When the S value exceeds the set threshold, the adaptive control module is activated. The control unit 6 outputs a PWM signal to drive the sliding block 7 to move downward along the linear guide rail 4, thereby driving the striking component 11 to the predetermined striking position.

[0039] S4: The striking component performs a frequency conversion striking action, while the efficiency optimization algorithm module calculates the optimal speed of the fan component based on real-time temperature and pressure and increases the speed to generate directional airflow; the control component performs linkage adjustment in sync: the reference speed of the star-shaped rotary airlock valve is increased by 20%, and the opening of the flow regulating device is temporarily reduced by 15%, so that the pressure in the preheating section is always 80~120Pa higher than the pressure in the main reaction zone; the molten slag shaken off is collected at the slag discharge port under the combined action of gravity and airflow.

[0040] S5: During the slag removal process, the safety protection redundancy module monitors the impact current and furnace vibration amplitude in real time to ensure that the deviation rate Δ is within the allowable range. If the cabinet door 5 is detected to be opened unexpectedly, the control unit 6 will instantly cut off the power supply to the striking component 11 through the hardware interlock circuit, achieving physical-level safety protection. S6: After the slag removal operation is completed, the sliding block 7 returns to the top, the fan assembly 10 resumes low-speed operation, the flue gas regulating damper in the preheating section automatically returns to the optimal opening before slag removal, the furnace charge preheating and feeding process returns to normal, and the data storage and analysis module stores all parameters of this slag removal, as well as the waste heat recovery efficiency of the preheating section before and after slag removal, furnace charge preheating temperature fluctuations, etc., into the database, updates the overall energy efficiency curve and performance degradation curve of the equipment, and completes a complete control closed loop.

[0041] This invention demonstrates significant technical advantages in practical applications. Taking a molten salt reactor in a fine chemical enterprise as an example, after adopting this technical solution, the intelligent status monitoring module accurately identifies the slagging state, avoiding the ineffective downtime caused by the previous timed slagging. The adaptive control module extends the service life of the furnace lining by more than 30% through nonlinear adjustment of the impact force. The efficiency optimization algorithm module, combined with the application of the preheating section waste heat recovery logic, reduces the average energy consumption of the blower assembly 10 during the slagging stage by 25%, increases the waste heat recovery efficiency of the preheating section to more than 65%, controls the fluctuation of the furnace charge discharge temperature within ±5℃, and improves the overall energy utilization rate of the equipment by 18%. In addition, the safety protection redundancy module successfully intercepts multiple risks of misoperation caused by high-temperature drift of sensors, ensuring the continuous and stable operation of the production line.

[0042] The inner wall of the furnace body 2 is also specially coated with a nano-level anti-adhesion ceramic coating. This coating, together with the high-frequency excitation of the hammering component 11, causes the slag to be broken and peeled off in the early stage of formation, exhibiting excellent anti-scaling properties. A dustproof bellows cover is provided between the linear guide rail 4 and the sliding block 7 to prevent chemical dust from entering the guide rail pair and causing wear. The connecting block 8 is connected to the hammering component 11 through a flexible shock-absorbing pad. This structural design effectively isolates the transmission of high-frequency vibration to the sliding block 7, protecting the motion accuracy of the precision guiding mechanism. The control component 6 supports RS485 and industrial Ethernet communication protocols, realizing seamless docking with the factory's host computer system, allowing operators to monitor the slag status, preheating section operating conditions, and equipment health in real time from a remote monitoring room.

[0043] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An energy-saving chemical furnace with slag removal function, characterized in that, The furnace includes a base (1), a furnace body (2) fixedly installed on the top of the base (1), a power control unit (3) installed on the left front end of the base (1), and a control unit (6) installed on the right front end of the base (1). Cabinet doors (5) are provided at both ends of the furnace body (2). Linear guide rails (4) are symmetrically installed along the vertical center line on the left and right outer walls of the furnace body (2). Sliding blocks (7) are slidably connected to the outer walls of the linear guide rails (4). A connecting block (8) is installed at one end of the sliding block (7). The bottom of the connecting block (8)... The furnace body (2) is equipped with a hammering assembly (11); a fan assembly (10) is installed on the top of the furnace body (2); an independent furnace material preheating section is provided at the feeding end of the furnace body (2); the preheating section is connected to the exhaust port of the furnace body (2) through a flue gas waste heat recovery pipe; a flow regulating device is installed on the flue gas waste heat recovery pipe; a sealing isolation device is provided between the preheating section and the main reaction zone of the furnace body (2); and the control component (6) is electrically connected to the sensor array, the hammering assembly (11), and the fan assembly (10) through a data cable. The control unit (6) is configured to calculate the slagging index and activate the slagging removal program when the slagging index reaches the trigger threshold; wherein the calculation of the slagging index is based on multiple physical quantities and their contribution weights, real-time acquired values, safety threshold upper limit and benchmark value; The control unit (6) integrates an intelligent status monitoring module, an adaptive control module, an efficiency optimization algorithm module, a security protection redundancy module, and a data storage and analysis module.

2. The energy-saving chemical furnace with slag removal function according to claim 1, characterized in that: The intelligent status monitoring module includes sensor arrays arranged at different height levels inside the furnace body (2). The sensor arrays include K-type thermocouples for monitoring reaction temperature, piezoresistive pressure sensors for monitoring internal pressure, laser sensors for monitoring combustion flue gas turbidity, and ultrasonic level gauges for detecting slag thickness; as well as furnace charge feed temperature sensors, furnace charge discharge temperature sensors, and flue gas flow sensors arranged in the preheating section.

3. The energy-saving chemical furnace with slag removal function according to claim 1, characterized in that: The adaptive control module is configured to adjust the striking intensity and frequency of the striking component (11) using a fuzzy PID control algorithm after the slag removal program is activated. Its output excitation force is determined based on the deviation between the current slag thickness and the target clean thickness, as well as the proportional, integral, and derivative adjustment coefficients.

4. The energy-saving chemical furnace with slag removal function according to claim 1, characterized in that: The efficiency optimization algorithm module is configured to predict the unit energy consumption slag removal efficiency index using a linear regression model; wherein, the unit energy consumption slag removal efficiency index is related to the average temperature inside the furnace, the pressure inside the furnace, the rotation speed of the blower assembly (10), the slag removal duration, the blower power characteristics, as well as the regression coefficient and the model correction residual; the control unit (6) controls the operation of the blower assembly (10) by searching for the rotation speed parameter that makes the unit energy consumption slag removal efficiency index reach its maximum value, wherein the rotation speed parameter does not exceed the upper limit of the rated rotation speed of the blower assembly and is not lower than the lower limit of the rotation speed corresponding to the minimum airflow velocity required for slag removal.

5. The energy-saving chemical furnace with slag removal function according to claim 1, characterized in that: The safety protection redundancy module is configured to compare and verify the values ​​of the main sensor and the auxiliary sensor, and calculate the deviation rate of the two according to the deviation rate determination formula; when the deviation rate continues to exceed the preset percentage and reaches the preset time, the control component (6) cuts off the power supply of the striking component (11) through the hardware interlock circuit.

6. The energy-saving chemical furnace with slag removal function according to claim 1, characterized in that: The furnace body (2) adopts a double-layer stainless steel shell structure, with aluminum silicate fiber insulation material filling the space between the inner and outer shells, and the inner wall of the furnace body (2) is coated with a nano-level anti-adhesion ceramic coating.

7. The energy-saving chemical furnace with slag removal function according to claim 1, characterized in that: The connecting block (8) is made of aluminum alloy die casting. The connecting block (8) and the striking component (11) are connected by a flexible shock-absorbing pad made of high-temperature resistant elastomer material. A dustproof bellows cover is provided between the linear guide rail (4) and the sliding block (7).

8. An energy-saving chemical furnace with slag removal function according to claim 1, characterized in that: The base (1) is made of high-strength cast iron and has a mesh-like reinforcing rib structure inside; the front end of the furnace body (2) is connected to a cabinet door (5) by a hinge, and the edge of the cabinet door (5) is inlaid with a fluororubber sealing strip.

9. An energy-saving chemical furnace with slag removal function according to claim 1, characterized in that: The data storage and analysis module is configured to record slag removal operating data and execute the moving average method to calculate the equipment performance degradation trend line; wherein, the moving average is determined based on the calculation cycle and the efficiency index of each slag removal operation.

10. An energy-saving chemical furnace with slag removal function according to claim 1, characterized in that: The intelligent status monitoring module is also configured to calculate the waste heat recovery efficiency of the preheating section in real time. The control unit (6) automatically adjusts the opening of the flow regulating device according to the deviation between the preheating section charge discharge temperature and the set value to stabilize the charge preheating temperature. The sealing isolation device adopts a variable frequency drive star-shaped rotary airlock valve, with wear-resistant ceramic sealing plates embedded at the ends of its rotor blades, and the gap between the blades and the shell is ≤0.2mm. The control unit (6) dynamically adjusts the speed of the star-shaped rotary airlock valve according to the difference between the real-time pressure of the main reaction zone and the pressure of the preheating section using a PID algorithm, and simultaneously adjusts the opening of the flow regulating device to ensure that the pressure of the preheating section is always 50~100Pa higher than the pressure of the main reaction zone. When the slag removal program is activated, the control unit (6) automatically increases the speed of the star-shaped rotary airlock valve by 15%~25% and temporarily reduces the opening of the flow regulating device by 10%~20% to prevent the slag removal airflow from flowing back into the preheating section and to ensure the slag discharge airflow pressure of the main reaction zone.

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