Coal gas temperature-based spray tower water quantity control method and system

Abstract

This invention discloses a method and system for controlling the water volume of a spray tower based on gas temperature, belonging to the field of gas purification technology. It aims to solve the problems of water waste and poor temperature control caused by fixed water volume spraying in traditional spray towers. This invention collects the inlet and outlet temperatures of the gas at the TRT outlet in real time, sets the first set of normally open spray guns to a baseline water volume of 25 cubic meters per hour, and uses a gas outlet temperature of 55°C as the control threshold. When the temperature reaches the threshold, the second set of spray guns automatically opens, increasing the total water volume to 80 cubic meters per hour. When the temperature drops below the threshold, the second set of spray guns closes, restoring the baseline water volume. The control parameters can be continuously optimized according to operating conditions. The system includes a temperature monitoring module, a control module, a spraying execution module, and a data storage module, achieving automatic linkage control of temperature and water volume. This invention, while ensuring that gas cooling meets grid connection requirements, offers significant water savings and economic benefits. It is simple to modify, operates stably, and is suitable for gas spraying cooling at the outlet of a metallurgical blast furnace TRT. It can also be extended to other industrial gas cooling scenarios, possessing good promotional value.

Description

Technical Field

[0001] This invention belongs to the field of coal gas purification and treatment technology, specifically relating to a method and system for controlling the water volume of a spray tower based on coal gas temperature. Background Technology

[0002] In the blast furnace production process of the metallurgical industry, the gas outlet of the blast furnace top gas pressure recovery turbine (TRT) unit needs to be cooled by a spray tower to ensure that its temperature meets the requirements for grid connection and transmission. Spray cooling is a key link in ensuring the safe and stable operation of the gas system. Currently, the blast furnace TRT outlet gas spray tower generally adopts a fixed water volume control method, relying solely on simple adjustments based on manual experience.

[0003] This traditional control method has obvious drawbacks: On the one hand, the gas temperature fluctuates dynamically with the blast furnace production load and furnace conditions. Under most operating conditions, the gas temperature is stable at around 40℃, which is far below the safety threshold of 55℃. Fixed large-volume water spraying results in a large amount of water resources being ineffectively consumed, leading to serious water waste and high production costs for enterprises. On the other hand, the water volume cannot be matched and adjusted in real time according to the actual gas temperature. When the temperature is low, large-volume water spraying continues, which not only increases the energy consumption of equipment such as water pumps, but also increases the load on the subsequent water treatment system, which does not meet the requirements of energy conservation, emission reduction and green production policies.

[0004] Furthermore, existing spray tower systems lack automatic control logic that links temperature and water volume. The second set of spray guns is mostly manually started and stopped, resulting in a delayed response. When the gas temperature suddenly rises, there is a risk of untimely cooling and temperature exceeding limits. Conversely, when the temperature drops, the extra spray guns cannot be quickly shut down, further exacerbating water waste. Currently, the industry lacks a control method that can automatically and accurately adjust the spray water volume based on real-time changes in gas temperature, balancing cooling effect and water conservation goals. This makes it difficult to simultaneously improve the economic efficiency and stability of spray tower operation. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a spray tower water volume control method and system based on gas temperature. By monitoring the gas temperature and dynamically adjusting the water volume of the spray gun, the water consumption is reduced to the minimum while ensuring the gas cooling effect, so as to achieve the goals of energy saving, water saving and production cost reduction.

[0006] To solve the above technical problems, the technical solution of the present invention is as follows: A method for controlling the water volume of a spray tower based on gas temperature includes the following steps: (1) Real-time collection of inlet and outlet temperatures of TRT outlet gas, establishment of temperature monitoring ledger, and continuous tracking of gas temperature change trends; (2) Based on the long-term monitoring data of gas temperature and the stable range of gas temperature after optimization of blast furnace production conditions, the reference water volume of the first set of normally open spray guns is set to 25 cubic meters / hour. The water inlet valve of the first set of spray guns is adjusted to the minimum opening to stabilize the water volume at the reference value. (3) Set the gas outlet temperature alarm threshold to 55℃. When the gas outlet temperature is detected to reach 55℃, the second set of spray guns will be automatically turned on to increase the total water consumption of the spray tower to 80 cubic meters / hour. When the gas outlet temperature is detected to be lower than 55℃, the second set of spray guns will be automatically turned off and the reference water consumption of the first set of spray guns will be restored to 25 cubic meters / hour. (4) Regularly summarize the gas temperature monitoring data and water consumption data, and finely adjust the reference water volume of the first group of spray guns and the start-stop response parameters of the second group of spray guns according to the changes in the blast furnace production conditions, so as to balance the cooling effect and the water saving effect.

[0007] The present invention further defines the technical solution as follows: Preferably, in step (1), temperature sensors are installed at the inlet and outlet of the TRT outlet gas pipeline to achieve real-time temperature acquisition. The temperature sampling frequency is once every 5 minutes. The acquired temperature data is transmitted to the control terminal and a ledger is established.

[0008] Preferably, in step (4), the gas temperature monitoring data and water consumption data are summarized on a monthly basis, the gas temperature fluctuation pattern is analyzed, the valve opening of the first group of spray guns is finely adjusted according to the changes in blast furnace production load, and the start-stop response speed of the second group of spray guns is checked.

[0009] A spray tower water volume control system based on gas temperature, characterized in that it includes a temperature monitoring module, a control module, a spray execution module, and a data storage module, wherein: The temperature monitoring module is used to collect the inlet and outlet temperatures of the TRT outlet gas in real time and transmit the temperature data to the control module. The control module is electrically connected to the temperature monitoring module and the spray execution module. It receives temperature data transmitted by the temperature monitoring module and sends start / stop and water volume adjustment commands to the spray execution module according to the preset 55℃ temperature threshold and water volume control logic. The spray execution module includes two sets of spray guns and corresponding inlet valve groups. The first set of spray guns is normally open, and its inlet valve is a regulating valve that can adjust the opening to control the reference water volume of 25 cubic meters / hour. The inlet valve of the second set of spray guns is a start / stop valve that can automatically start and stop according to the instructions of the control module. When both sets of spray guns are turned on at the same time, the total water consumption is 80 cubic meters / hour. The data storage module is used to store temperature monitoring data, water consumption data, and control parameters, providing data support for subsequent parameter optimization. Preferably, the temperature monitoring module includes at least two temperature sensors, respectively installed at the inlet and outlet of the TRT outlet gas pipeline.

[0010] Preferably, the control module is a PLC controller with a built-in preset temperature threshold and water volume control logic program, which can realize the automated control of the spray execution module.

[0011] Preferably, the data storage module can store temperature, water consumption, and control parameter data periodically, supporting data retrieval, aggregation, and analysis, providing a data foundation for continuous optimization of system parameters.

[0012] The beneficial effects of this invention are: This invention breaks away from the existing control mode of fixed water volume in the first group of spray guns of the spray tower. By combining the dynamic changes in gas temperature and the actual needs after optimizing the blast furnace production conditions, a reasonable benchmark water volume is set, realizing dynamic and precise control of water volume and solving the core problem of water waste in traditional control methods.

[0013] This invention optimizes the standard water volume of the first set of spray guns from 60 cubic meters / hour to 25 cubic meters / hour, thereby reducing water consumption by 35 cubic meters per hour while ensuring the cooling needs of the gas, thus lowering production costs.

[0014] This invention uses a gas outlet temperature of 55℃ as the automatic control threshold to achieve intelligent linkage and regulation of two sets of spray guns. The gas temperature is stably controlled within the range of 40–55℃, fully meeting the gas grid connection standards and completely solving the problems of lag and high risk of overheating in traditional methods. Simultaneously, the system achieves fully automatic closed-loop control of temperature monitoring and water volume adjustment, replacing manual operation and improving operational stability and response speed. Detailed Implementation

[0015] To make the content of this invention easier to understand, the invention will be further described in detail below based on specific embodiments. Example 1

[0016] This embodiment provides a method for controlling the water volume of a spray tower based on gas temperature, including the following steps: (1) Temperature sensors are installed at the inlet and outlet of the TRT outlet gas pipeline to collect gas temperature data in real time. The sampling frequency is once every 5 minutes. The collected temperature data is transmitted to the control terminal to establish a temperature monitoring ledger and continuously track the gas temperature change. After confirming that the blast furnace operating conditions are optimized, the TRT outlet gas temperature is stable at 40℃. (2) Based on the temperature monitoring data and the gas grid connection temperature requirements, the water inlet valve of the first set of normally open spray guns was manually adjusted to the minimum opening. The flow rate was confirmed by flow metering. At this time, the water volume of the first set of spray guns was stable at 25 cubic meters / hour, which was used as the benchmark spray water volume. (3) Set the gas outlet temperature alarm threshold to 55℃. The control module receives the outlet temperature data transmitted by the temperature sensor in real time. When the outlet temperature reaches 55℃, the control module automatically sends an instruction to turn on the second set of spray guns. At this time, the total water consumption of the spray tower increases to 80 cubic meters / hour to quickly cool the gas. When the outlet temperature drops below 55℃, the control module automatically sends an instruction to turn off the second set of spray guns and restore the reference water consumption of 25 cubic meters / hour of the first set of spray guns. (4) Summarize temperature monitoring data and water consumption data every month, analyze the gas temperature fluctuation pattern, and fine-tune the valve opening of the first set of spray guns according to the changes in blast furnace production load to ensure that the reference water volume can meet the cooling requirements and save water to the maximum extent; at the same time, check the start-stop response speed of the second set of spray guns to ensure that they can be started in time when the temperature is abnormal, so as to avoid the gas temperature from exceeding the standard.

[0017] To implement the above method, this embodiment provides a spray tower water volume control system based on gas temperature, including a temperature monitoring module, a control module, a spray execution module, and a data storage module, wherein: Temperature monitoring modules are installed at the inlet and outlet of the TRT outlet gas pipeline to collect the inlet and outlet temperatures of the TRT outlet gas in real time and transmit the temperature data to the control module. The control module is electrically connected to the temperature monitoring module and the spray execution module. It receives temperature data transmitted by the temperature monitoring module and sends start / stop and water volume adjustment commands to the spray execution module according to the preset 55℃ temperature threshold and water volume control logic. The spray execution module includes two sets of spray guns and corresponding inlet valve groups. The first set of spray guns is normally open, and its inlet valve is a regulating valve that can adjust the opening to control the reference water volume of 25 cubic meters / hour. The inlet valve of the second set of spray guns is a start / stop valve that can automatically start and stop according to the instructions of the control module. When both sets of spray guns are turned on at the same time, the total water consumption is 80 cubic meters / hour. The data storage module stores temperature monitoring data, water consumption data, and control parameters, providing data support for subsequent parameter optimization. The control module is a PLC controller with built-in preset temperature thresholds and water consumption control logic programs, enabling automated control of the sprinkler system.

[0018] The aforementioned data storage module can store temperature, water consumption, and control parameter data periodically, supporting data retrieval, aggregation, and analysis, providing a data foundation for continuous optimization of system parameters.

[0019] In addition to the above embodiments, the present invention may have other implementation methods; all technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by the present invention.

Claims

1. A coal gas temperature-based spray tower water quantity control method, characterized by, Includes the following steps: (1) Real-time collection of inlet and outlet temperatures of TRT outlet gas, establishment of temperature monitoring ledger, and continuous tracking of gas temperature change trends; (2) Based on the long-term monitoring data of gas temperature and the stable range of gas temperature after optimization of blast furnace production conditions, the reference water volume of the first set of normally open spray guns is set to 25 cubic meters / hour. The water inlet valve of the first set of spray guns is adjusted to the minimum opening to stabilize the water volume at the reference value. (3) Set the gas outlet temperature alarm threshold to 55℃. When the gas outlet temperature is detected to reach 55℃, the second set of spray guns will be automatically turned on to increase the total water consumption of the spray tower to 80 cubic meters / hour. When the gas outlet temperature is detected to be lower than 55℃, the second set of spray guns will be automatically turned off and the reference water consumption of the first set of spray guns will be restored to 25 cubic meters / hour. (4) Regularly summarize the gas temperature monitoring data and water consumption data, and finely adjust the reference water volume of the first group of spray guns and the start-stop response parameters of the second group of spray guns according to the changes in the blast furnace production conditions, so as to balance the cooling effect and the water saving effect.

2. The coal gas temperature-based spray tower water quantity control method of claim 1, wherein: In step (1), temperature sensors are installed at the inlet and outlet of the TRT outlet gas pipeline to achieve real-time temperature acquisition. The temperature sampling frequency is once every 5 minutes. The acquired temperature data is transmitted to the control terminal and a ledger is established.

3. The coal gas temperature-based spray tower water volume control method of claim 1, wherein: In step (4), gas temperature monitoring data and water consumption data are summarized on a monthly basis, the gas temperature fluctuation pattern is analyzed, the valve opening of the first group of spray guns is finely adjusted according to the changes in blast furnace production load, and the start-stop response speed of the second group of spray guns is checked.

4. A coal gas temperature based spray tower water control system implementing the method of any one of claims 1-3, characterized by, It includes a temperature monitoring module, a control module, a spray execution module, and a data storage module, among which: The temperature monitoring module is used to collect the inlet and outlet temperatures of the TRT outlet gas in real time and transmit the temperature data to the control module. The control module is electrically connected to the temperature monitoring module and the spray execution module. It receives temperature data transmitted by the temperature monitoring module and sends start / stop and water volume adjustment commands to the spray execution module according to the preset 55℃ temperature threshold and water volume control logic. The spray execution module includes two sets of spray guns and corresponding inlet valve groups. The first set of spray guns is normally open, and its inlet valve is a regulating valve that can adjust the opening to control the reference water volume of 25 cubic meters / hour. The inlet valve of the second set of spray guns is a start / stop valve that can automatically start and stop according to the instructions of the control module. When both sets of spray guns are turned on at the same time, the total water consumption is 80 cubic meters / hour. The data storage module is used to store temperature monitoring data, water consumption data, and control parameters, providing data support for subsequent parameter optimization.

5. The coal gas temperature based spray tower water volume control system of claim 4, wherein, The temperature monitoring module includes at least two temperature sensors, which are respectively installed at the inlet and outlet of the TRT outlet gas pipeline.

6. The coal gas temperature based spray tower water volume control system of claim 4, wherein, The control module is a PLC controller with built-in preset temperature thresholds and water volume control logic programs, which can realize automated control of the spray execution module.

7. The coal gas temperature based spray tower water volume control system of claim 4, wherein, The data storage module can store temperature, water consumption, and control parameter data periodically, and supports data retrieval, aggregation, and analysis, providing a data foundation for continuous optimization of system parameters.