A rotary anode furnace natural gas combustion control system

Abstract

This invention discloses a natural gas combustion control system for a rotary anode furnace, relating to the field of anode furnace combustion control technology. It includes: a data acquisition unit for acquiring operational data, including fuel-side disturbance parameters and combustion process feedback variables, and marking the operational data with a unified time-series reference; and a feedforward control unit for generating feedforward compensation and pre-control trigger signals in response to the disturbance parameters. This invention, through advanced identification and coordinated pre-control of fuel-side disturbances, completes precise compensation on the fuel side and synchronous adaptation and adjustment on the combustion aid side before changes in gas supply caused by natural gas pipeline pressure fluctuations are transmitted to the furnace combustion conditions. This shortens the disturbance response cycle, eliminates the lag in adjustment actions, continuously maintains the air-fuel ratio within a reasonable range in the furnace, and avoids increased fluctuations in combustion conditions and temperature field inhomogeneity.

Description

Technical Field

[0001] This invention relates to the field of anode furnace combustion control technology, specifically to a rotary anode furnace natural gas combustion control system. Background Technology

[0002] The rotary anode furnace is a core piece of equipment in the copper electrolytic refining process. Its combustion system, primarily fueled by natural gas, performs the crucial function of smelting and shaping crude copper. The stability of the combustion system directly determines the quality of the finished anode plates and is also directly related to the energy consumption and pollutant emissions of the entire smelting process. In actual production, the industry generally controls the combustion conditions within the furnace by adjusting the supply of fuel gas and combustion air to maintain the stable temperature environment required for the smelting process and ensure continuous and stable production.

[0003] However, when the pressure in the natural gas pipeline fluctuates, the actual gas supply changes instantaneously. Existing control logic relies solely on furnace temperature as feedback; adjustments are only triggered when the pressure fluctuation causes a change in gas supply that is transmitted to the furnace, resulting in a detectable deviation in furnace temperature. In this adjustment mode, the pressure disturbance has a long transmission path, and the adjustment action exhibits significant lag. During the interval between the disturbance's occurrence and the adjustment's effectiveness, the air-fuel ratio in the furnace continuously deviates from the optimal range. This not only directly causes continuous fluctuations in combustion conditions but also exacerbates the non-uniformity of the furnace temperature field, affecting the stability of the anode plate melting process and leading to unnecessary fuel consumption and increased pollutant emissions. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a natural gas combustion control system for a rotary anode furnace, which solves the problems of lagging combustion control regulation, easy air-fuel ratio mismatch caused by pipeline pressure disturbances, furnace temperature fluctuations, and high energy consumption in existing technologies.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a natural gas combustion control system for a rotary anode furnace, comprising: The data acquisition unit is used to acquire operational data, which includes perturbation parameters on the fuel side and feedback variables of the combustion process, and to mark the operational data with a unified time series reference. The feedforward control unit is used to generate a feedforward compensation amount and a pre-control trigger signal in response to the disturbance parameters, and to synchronously send the pre-control trigger signal to the adaptive correction unit and the temperature closed-loop control unit. A temperature closed-loop control unit is used to generate a basic temperature regulation amount based on the closed-loop control logic of the operating temperature, and adjust the regulation characteristics in response to the pre-control trigger signal. An adaptive correction unit is used to respond to the pre-control trigger signal, activate the pre-adjustment logic on the combustion-supporting agent side, generate the combustion-supporting agent pre-adjustment amount, and adaptively adjust the control parameters based on the feedback variable to correct the control command on the combustion-supporting agent side. The instruction generation unit is used to generate fuel-side control instructions based on the feedforward compensation amount and the basic temperature adjustment amount, and to generate combustion-supporting side control instructions based on the combustion-supporting pre-adjustment amount. The command output unit is used to perform timing synchronization calibration of the fuel-side control command and the combustion-supporting agent-side control command, and output the calibrated control command to the corresponding actuator.

[0006] Preferably, the feedforward control unit includes: The deviation calculation subunit is used to calculate the deviation between the real-time data of the disturbance parameter and the process set value; The disturbance determination subunit is used to determine that the absolute value of the deviation exceeds the preset dead zone threshold as a valid disturbance and generate the pre-control trigger signal. The compensation calculation subunit is used to calculate and generate the feedforward compensation amount based on the deviation and the feedforward gain coefficient.

[0007] Preferably, the adaptive correction unit includes: The trend prediction subunit is used to predict the direction and magnitude of changes in fuel-side flow rate based on the changing trend of the effective disturbance. The pre-adjustment execution subunit is used to synchronously adjust the flow rate setpoint of the combustion-supporting agent based on the prediction result to generate the pre-adjustment amount of the combustion-supporting agent, rather than triggering the adjustment based on the deviation of the feedback variables of the combustion process.

[0008] Preferably, the instruction output unit includes: The timing matching subunit is used to match and calibrate the triggering time and change rate of the fuel-side control command and the combustion-supporting agent-side control command. The output execution subunit is used to synchronously output calibrated control commands to the corresponding actuators based on the calibration results.

[0009] Preferably, the timing matching subunit is further configured to: Acquire response characteristic data of fuel-side actuators and combustion-supporting actuators, wherein the response characteristic data reflects the response delay of each actuator from receiving a command to completing an action; Based on the response characteristic data, the output delay time of the fuel-side control command and the combustion-supporting agent-side control command is adjusted to eliminate the time difference of the actuator action.

[0010] Preferably, the adaptive correction unit further includes: The deviation analysis subunit is used to calculate the deviation and the rate of change of the feedback variables in order to analyze the degree of matching between the combustion state and the air-fuel ratio in real time. The parameter adjustment subunit is used to adaptively adjust the control parameters based on the deviation and the rate of change of the deviation; The instruction correction subunit is used to correct the combustion-supporting control instruction based on the adjusted control parameters.

[0011] Preferably, the temperature closed-loop control unit includes: The temperature deviation calculation subunit is used to calculate the temperature deviation between the real-time operating temperature data and the process set value. The adjustment amount generation subunit is used to generate the basic temperature adjustment amount based on continuous time-series temperature deviation data and employs a closed-loop control algorithm. The characteristic adjustment subunit is used to dynamically adjust the adjustment parameters and response characteristics of the temperature closed-loop control unit in response to the pre-control trigger signal, so as to smoothly inherit the adjustment effect of the feedforward compensation.

[0012] Preferably, the instruction generation unit further includes: A basic adjustment acquisition subunit is used to acquire the basic temperature adjustment amount; The instruction superposition subunit is used to linearly superimpose the feedforward compensation amount and the basic temperature adjustment amount to generate the fuel-side control instruction.

[0013] Preferably, the parameter adjustment subunit includes: The fuzzification processing subunit is used to perform fuzzification processing on the input variables, using the deviation and the rate of change of deviation as input variables and employing multi-level linguistic variables, mapping the deviation to a deviation linguistic variable and the rate of change of deviation to a rate of change of deviation linguistic variable. The inference subunit is used to construct a fuzzy inference engine through preset fuzzy inference rules, perform fuzzy inference based on the deviation linguistic variable and the deviation change rate linguistic variable, and output the real-time correction amount of the control parameters. The parameter update subunit is used to adaptively adjust the control parameters based on the real-time correction amount.

[0014] Preferably, the data acquisition unit is further configured to: The operational data is digitally filtered to remove transient interference signals during the acquisition process, thereby obtaining valid operational data. The effective operating data is synchronously distributed to the feedforward control unit, the temperature closed-loop control unit, the adaptive correction unit, the instruction generation unit, and the instruction output unit; The system receives feedback data on the actual actions of the actuator from the instruction output unit, thus completing the closed-loop acquisition and real-time updating of operational data.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention, through advanced identification and coordinated pre-control of fuel-side disturbances, completes precise compensation on the fuel side and synchronous adaptation and adjustment on the combustion-supporting agent side before the gas supply changes caused by natural gas pipeline pressure fluctuations are transmitted to the combustion conditions in the furnace. This shortens the disturbance response cycle, eliminates the lag in adjustment actions, and continuously maintains the air-fuel ratio in the furnace within a reasonable range, avoiding the aggravation of combustion condition fluctuations and temperature field inhomogeneity. At the same time, it performs time-synchronized calibration of control commands for fuel and combustion-supporting agents to ensure consistent action of the actuators on both sides. Combined with real-time analysis of combustion status and adaptive correction of control parameters, it stably maintains the optimal combustion state, ensuring continuous and stable anode furnace smelting process, reducing fuel consumption in the smelting process, and lowering pollutant emission levels. Attached Figure Description

[0016] Figure 1 This is a system structure diagram of the present invention; Figure 2 This is a flowchart of the pipeline pressure disturbance feedforward-adaptive collaborative pre-control process of the present invention. Detailed Implementation

[0017] 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.

[0018] Please see Figures 1-2 This embodiment provides a natural gas combustion control system for a rotary anode furnace, and the specific implementation is as follows: The data acquisition unit is used to acquire operational data, which includes perturbation parameters on the fuel side and feedback variables of the combustion process, and to mark the operational data with a unified time series reference. The feedforward control unit is used to generate a feedforward compensation amount and a pre-control trigger signal in response to the disturbance parameters, and to synchronously send the pre-control trigger signal to the adaptive correction unit and the temperature closed-loop control unit. A temperature closed-loop control unit is used to generate a basic temperature regulation amount based on the closed-loop control logic of the operating temperature, and adjust the regulation characteristics in response to the pre-control trigger signal. An adaptive correction unit is used to respond to the pre-control trigger signal, activate the pre-adjustment logic on the combustion-supporting agent side, generate the combustion-supporting agent pre-adjustment amount, and adaptively adjust the control parameters based on the feedback variable to correct the control command on the combustion-supporting agent side. The instruction generation unit is used to generate fuel-side control instructions based on the feedforward compensation amount and the basic temperature adjustment amount, and to generate combustion-supporting side control instructions based on the combustion-supporting pre-adjustment amount. The command output unit is used to perform timing synchronization calibration of the fuel-side control command and the combustion-supporting agent-side control command, and output the calibrated control command to the corresponding actuator.

[0019] This solution utilizes a multi-unit collaborative control architecture to deeply integrate the advanced identification and pre-control of fuel-side disturbances, closed-loop adjustment of combustion conditions, and adaptive matching of the combustion aid side. This changes the lagging control mode in existing technologies that relies solely on furnace temperature feedback to trigger adjustment. The collaborative pre-control action can be initiated before fuel-side disturbances are transmitted to the combustion conditions in the furnace, effectively avoiding deviations in the air-fuel ratio and temperature fluctuations caused by disturbances, ensuring the stable operation of the anode furnace smelting process, and reducing fuel consumption and pollutant emissions during the smelting process.

[0020] In one specific embodiment, the feedforward control unit includes: The deviation calculation subunit is used to calculate the deviation between the real-time data of the disturbance parameter and the process set value; The disturbance determination subunit is used to determine that the absolute value of the deviation exceeds the preset dead zone threshold as a valid disturbance and generate the pre-control trigger signal. The compensation calculation subunit is used to calculate and generate the feedforward compensation amount based on the deviation and the feedforward gain coefficient.

[0021] Specifically, this unit uses the natural gas pipeline pressure on the fuel side as the core disturbance parameter to complete the identification, judgment, and advance compensation calculation of the disturbance. The deviation calculation subunit synchronously receives real-time pipeline pressure data with a unified time-series reference from the data acquisition unit, performs difference calculations with the preset process setpoints, and obtains the real-time pressure deviation. The corresponding calculation formula is as follows: ; In the formula, The pressure deviation at time t. Let be the real-time monitored value of the natural gas pipeline pressure at time t. The pipeline pressure setpoints for the smelting process are all measured in pressure units to maintain dimensional consistency. The disturbance determination subunit identifies effective disturbances based on real-time pressure deviations. A preset dead-zone threshold filters out minute instantaneous fluctuations during normal pipeline operation, preventing frequent triggering of ineffective adjustments. The dead-zone threshold is determined based on the daily operating fluctuation range of the natural gas pipeline network in the anode furnace plant area and the disturbance rejection requirements of the smelting process. For example, a corresponding dead-zone threshold can be set based on more than 95% of the fluctuation range during normal pipeline operation. Only when the absolute value of the pressure deviation exceeds this threshold is it considered an effective disturbance that will substantially affect the combustion conditions inside the furnace, and a pre-control trigger signal is generated simultaneously. The compensation calculation subunit calculates the feedforward compensation amount based on the effective pressure deviation and the feedforward gain coefficient. The corresponding calculation formula is: ; In the formula, The feedforward compensation amount generated at time t. The feedforward gain coefficient is determined based on the flow characteristics of the natural gas regulating valve and the correspondence between natural gas pipeline pressure and gas flow. It can be tuned through on-site step response testing to ensure that the feedforward compensation can accurately offset the gas flow changes caused by pressure disturbances, thus achieving proactive suppression of disturbances. The generation of the feedforward compensation does not require waiting for pressure fluctuations to be transmitted to the gas flow or furnace temperature changes; the compensation calculation and output can be completed before the disturbance is transmitted to the controlled object in the furnace, effectively shortening the disturbance response cycle.

[0022] In one specific embodiment, the adaptive correction unit includes: The trend prediction subunit is used to predict the direction and magnitude of changes in fuel-side flow rate based on the changing trend of the effective disturbance. The pre-adjustment execution subunit is used to synchronously adjust the flow rate setpoint of the combustion-supporting agent based on the prediction result to generate the pre-adjustment amount of the combustion-supporting agent, rather than triggering the adjustment based on the deviation of the feedback variables of the combustion process.

[0023] Specifically, the trend prediction subunit receives continuous time-series pressure deviation data corresponding to effective disturbances output by the feedforward control unit. Based on the pressure deviation changes over multiple consecutive sampling periods, it analyzes the development direction and rate of change of the disturbance. Combining the corresponding characteristics of natural gas pipeline pressure and gas flow, it predicts the direction and magnitude of change in fuel-side gas flow in subsequent sampling periods, providing a predictive basis for pre-adjustment on the combustion-supporting agent side. The pre-adjustment execution subunit, based on the predicted gas flow change information, synchronously adjusts the flow setpoint on the combustion-supporting agent side, generating a corresponding pre-adjustment amount. This pre-adjustment action is triggered synchronously with the feedforward compensation action on the fuel side, eliminating the need to wait for detectable deviations in the combustion process's feedback variables before initiating adjustment. This enables synchronous adaptation and adjustment of the combustion-supporting agent supply and gas supply, avoiding instantaneous deviations in the air-fuel ratio caused by the time difference between fuel-side flow changes and combustion-supporting agent adjustment actions after a disturbance occurs, ensuring that the air-fuel ratio remains within a reasonable range during disturbance events.

[0024] In one specific embodiment, the instruction output unit includes: The timing matching subunit is used to match and calibrate the triggering time and change rate of the fuel-side control command and the combustion-supporting agent-side control command. The output execution subunit is used to synchronously output calibrated control commands to the corresponding actuators based on the calibration results.

[0025] Specifically, the timing matching subunit receives the fuel-side control commands and oxidizer-side control commands output by the command generation unit, and performs precise matching and calibration on the execution timing of the two commands to ensure that the actuators corresponding to the two commands can respond synchronously, avoiding the problem of asynchronous fuel and oxidizer supply caused by mismatch in command triggering time or change rate. Based on the calibrated timing parameters, the output execution subunit synchronously outputs the two control commands to the corresponding fuel-side actuators and oxidizer-side actuators, driving the actuators to complete the corresponding adjustment actions, ensuring that the adjustment process of fuel supply and oxidizer supply is completely synchronized.

[0026] In one specific embodiment, the timing matching subunit is further configured to: Acquire response characteristic data of fuel-side actuators and combustion-supporting actuators, wherein the response characteristic data reflects the response delay of each actuator from receiving a command to completing an action; Based on the response characteristic data, the output delay time of the fuel-side control command and the combustion-supporting agent-side control command is adjusted to eliminate the time difference of the actuator action.

[0027] Specifically, the timing matching subunit pre-acquires the response characteristic data of the fuel-side natural gas regulating valve and the combustion-supporting air regulating valve. This data can be obtained by conducting on-site step response tests on the actuators. During the test, a step command of fixed amplitude is sent to the actuator, and the response delay time and action response rate of the actuator from receiving the command to completing the valve position action are collected to characterize the response characteristics of the actuator. Based on the difference in response delay between the two actuators, the timing matching subunit adjusts the output delay time of the two control commands accordingly. For the actuator with a longer response delay, the corresponding control command is sent earlier; for the actuator with a shorter response delay, the control command is sent later. This offsets the action time difference caused by the difference in the response characteristics of the two actuators, ensuring that the actual start time and completion time of the action of the two actuators are completely synchronized, further ensuring the instantaneous stability of the air-fuel ratio.

[0028] In one specific embodiment, the adaptive correction unit further includes: The deviation analysis subunit is used to calculate the deviation and the rate of change of the feedback variables in order to analyze the degree of matching between the combustion state and the air-fuel ratio in real time. The parameter adjustment subunit is used to adaptively adjust the control parameters based on the deviation and the rate of change of the deviation; The instruction correction subunit is used to correct the combustion-supporting control instruction based on the adjusted control parameters.

[0029] Specifically, the deviation analysis subunit receives combustion process feedback variables with a unified time-series reference from the data acquisition unit. Using flue gas oxygen content as the core feedback variable, it calculates the oxygen deviation between real-time flue gas oxygen content data and the process setpoint. Simultaneously, it calculates the rate of change of the oxygen deviation over a continuous sampling period, thereby analyzing the real-time combustion completeness and the actual air-fuel ratio matching within the furnace. The corresponding formulas for calculating oxygen deviation and its rate of change are as follows: ; ; In the formula, Let be the oxygen deviation at time t. Let t be the real-time detected value of the oxygen content in the flue gas. The preset oxygen content value for flue gas in the smelting process. Let be the rate of change of oxygen deviation at time t. The data acquisition unit uses a fixed sampling period, all parameters are dimensionally matched, and the computational logic conforms to physical meaning. The parameter adjustment subunit adaptively adjusts the control parameters of the combustion-supporting side closed-loop control based on real-time calculated oxygen deviation and its rate of change, ensuring that the control parameters can adapt to changes in the furnace combustion conditions in real time, guaranteeing the stability and response speed of the air-fuel ratio control. The command correction subunit, based on the adjusted control parameters and combined with real-time oxygen deviation data, performs correction calculations for the combustion-supporting side control commands, ensuring that the combustion-supporting side control commands can accurately adapt to the current combustion characteristics in the furnace, guaranteeing that the air-fuel ratio is always maintained within the optimal range.

[0030] In one specific embodiment, the temperature closed-loop control unit includes: The temperature deviation calculation subunit is used to calculate the temperature deviation between the real-time operating temperature data and the process set value. The adjustment amount generation subunit is used to generate the basic temperature adjustment amount based on continuous time-series temperature deviation data and employs a closed-loop control algorithm. The characteristic adjustment subunit is used to dynamically adjust the adjustment parameters and response characteristics of the temperature closed-loop control unit in response to the pre-control trigger signal, so as to smoothly inherit the adjustment effect of the feedforward compensation.

[0031] Specifically, the temperature deviation calculation subunit receives real-time furnace temperature data with a unified time-series reference from the data acquisition unit, calculates the temperature deviation between the real-time furnace temperature data and the smelting process setpoint, and provides a calculation basis for closed-loop regulation. The regulation quantity generation subunit, based on continuous time-series temperature deviation data, uses an incremental PID closed-loop control algorithm to calculate the basic temperature regulation quantity. The corresponding incremental PID algorithm formula is as follows: ; In the formula, The temperature adjustment increment at time t. The temperature deviation at time t. This is the proportionality coefficient. The integral coefficient is... These are the differential coefficients. With a fixed sampling period, the base temperature regulation is generated by accumulating continuous temperature regulation increments. All parameters are dimensionally matched, and the operational logic conforms to the basic principles of closed-loop control. The characteristic adjustment subunit receives the pre-control trigger signal sent by the feedforward control unit. When a valid disturbance is detected, it dynamically adjusts the proportional, integral, and derivative coefficients of the temperature closed-loop control algorithm based on the intensity and trend of the disturbance, changing the unit's regulation parameters and response characteristics. In the initial stage of the disturbance, it reduces the gain of the closed-loop regulation to avoid control overshoot caused by superposition with the feedforward compensation. As the disturbance gradually subsides, it gradually restores the normal regulation characteristics, smoothly inheriting the regulation effect of the feedforward compensation, ensuring that the furnace temperature remains stable throughout the entire disturbance cycle. Under normal operating conditions without valid disturbances, the temperature closed-loop control unit maintains stable closed-loop regulation logic, ensuring the continuous stability of the furnace melting temperature.

[0032] In one specific embodiment, the instruction generation unit further includes: A basic adjustment acquisition subunit is used to acquire the basic temperature adjustment amount; The instruction superposition subunit is used to linearly superimpose the feedforward compensation amount and the basic temperature adjustment amount to generate the fuel-side control instruction.

[0033] Specifically, the basic regulation acquisition subunit synchronously receives the basic temperature regulation output from the temperature closed-loop control unit, providing a basic regulation basis for the generation of fuel-side control commands. The command superposition subunit linearly superimposes the feedforward compensation output from the feedforward control unit with the basic temperature regulation to generate the final fuel-side control command. This command corresponds to the valve position control command of the natural gas regulating valve and can be directly used to drive the actuator to regulate the gas supply. The linear superposition operation deeply integrates disturbance advance compensation with furnace temperature closed-loop regulation. It can achieve rapid disturbance suppression through feedforward compensation and ensure long-term furnace temperature stability through closed-loop regulation, thus balancing the response speed and stability of the control process.

[0034] In one specific embodiment, the parameter adjustment subunit includes: The fuzzification processing subunit is used to perform fuzzification processing on the input variables, using the deviation and the rate of change of deviation as input variables and employing multi-level linguistic variables, mapping the deviation to a deviation linguistic variable and the rate of change of deviation to a rate of change of deviation linguistic variable. The inference subunit is used to construct a fuzzy inference engine through preset fuzzy inference rules, perform fuzzy inference based on the deviation linguistic variable and the deviation change rate linguistic variable, and output the real-time correction amount of the control parameters. The parameter update subunit is used to adaptively adjust the control parameters based on the real-time correction amount.

[0035] Specifically, the fuzzification processing subunit uses oxygen deviation and its rate of change as input variables. It employs seven levels of linguistic variables to fuzzify the input variables: negative large, negative medium, negative small, zero, positive small, positive medium, and positive large. Based on a preset membership function, it maps the precise values ​​of the real-time input oxygen deviation and its rate of change to the corresponding linguistic variables, completing the fuzzification transformation of the input variables. The inference subunit constructs a fuzzy inference engine using preset fuzzy inference rules. These rules are based on on-site operational experience with anode furnace combustion control and the tuning rules of closed-loop control parameters, covering parameter adjustment strategies corresponding to different combinations of oxygen deviation and its rate of change. Fuzzy inference is performed based on the fuzzified deviation and rate of change linguistic variables, and after defuzzification, the real-time correction values ​​of the control parameters are output. The parameter update subunit, based on the real-time correction amount obtained through inference, completes the adaptive adjustment of the closed-loop control parameters on the combustion-supporting side, enabling the control parameters to adapt to the dynamic changes in the combustion conditions inside the furnace in real time, and to adapt to the periodic temperature field changes caused by the continuous rotation of the rotary anode furnace body, thus ensuring the stability and adaptability of the air-fuel ratio control.

[0036] In one specific embodiment, the data acquisition unit is further configured to: The operational data is digitally filtered to remove transient interference signals during the acquisition process, thereby obtaining valid operational data. The effective operating data is synchronously distributed to the feedforward control unit, the temperature closed-loop control unit, the adaptive correction unit, the instruction generation unit, and the instruction output unit; The system receives feedback data on the actual actions of the actuator from the instruction output unit, thus completing the closed-loop acquisition and real-time updating of operational data.

[0037] Specifically, the data acquisition unit synchronously acquires multi-source operating data throughout the entire operation cycle of the anode furnace according to a fixed high-frequency sampling period. The acquired raw operating data undergoes digital filtering using a moving average filter to remove instantaneous spike interference signals generated during the acquisition process, resulting in effective operating data that can be directly used for control calculations, thus avoiding malfunctions in the control logic caused by interference signals. The data acquisition unit marks all synchronously acquired operating data with a unified timing reference, ensuring that operating data from different sources and detection points are completely aligned in the time dimension, eliminating timing deviations caused by transmission delays in different detection links, and providing a unified timing reference for subsequent multi-unit collaborative control. According to the computational needs of each downstream unit, the data acquisition unit synchronously distributes the processed effective operating data to the corresponding units. Simultaneously, it receives action feedback data such as the actual valve position status and actual medium flow rate of the actuators from the command output unit, completing the closed-loop acquisition and real-time update of operating data for the entire control process. This ensures the real-time performance and accuracy of the data used in the control process, providing reliable data support for control calculations.

[0038] In summary, this invention, through advanced identification and coordinated pre-control of fuel-side disturbances, achieves precise compensation on the fuel side and synchronous adaptation and adjustment on the combustion-supporting agent side before changes in gas supply caused by fluctuations in natural gas pipeline pressure are transmitted to the combustion conditions in the furnace. This shortens the disturbance response cycle, eliminates the lag in adjustment actions, and continuously maintains the air-fuel ratio in the furnace within a reasonable range, avoiding increased fluctuations in combustion conditions and temperature field inhomogeneity. Simultaneously, it performs time-synchronized calibration of control commands for fuel and combustion-supporting agents, ensuring consistent and coordinated actions of the actuators on both sides. Combined with real-time analysis of combustion status and adaptive correction of control parameters, it stably maintains the optimal combustion state, ensuring a continuous and stable anode furnace smelting process, reducing fuel consumption in the smelting process, and lowering pollutant emission levels.

[0039] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0040] 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. A natural gas combustion control system for a rotary anode furnace, characterized in that, include: The data acquisition unit is used to acquire operational data, which includes perturbation parameters on the fuel side and feedback variables of the combustion process, and to mark the operational data with a unified time series reference. The feedforward control unit is used to generate a feedforward compensation amount and a pre-control trigger signal in response to the disturbance parameters, and to synchronously send the pre-control trigger signal to the adaptive correction unit and the temperature closed-loop control unit. A temperature closed-loop control unit is used to generate a basic temperature regulation amount based on the closed-loop control logic of the operating temperature, and adjust the regulation characteristics in response to the pre-control trigger signal. An adaptive correction unit is used to respond to the pre-control trigger signal, activate the pre-adjustment logic on the combustion-supporting agent side, generate the combustion-supporting agent pre-adjustment amount, and adaptively adjust the control parameters based on the feedback variable to correct the control command on the combustion-supporting agent side. The instruction generation unit is used to generate fuel-side control instructions based on the feedforward compensation amount and the basic temperature adjustment amount, and to generate combustion-supporting side control instructions based on the combustion-supporting pre-adjustment amount. The command output unit is used to perform timing synchronization calibration of the fuel-side control command and the combustion-supporting agent-side control command, and output the calibrated control command to the corresponding actuator.

2. The natural gas combustion control system for a rotary anode furnace according to claim 1, characterized in that, The feedforward control unit includes: The deviation calculation subunit is used to calculate the deviation between the real-time data of the disturbance parameter and the process set value; The disturbance determination subunit is used to determine that the absolute value of the deviation exceeds the preset dead zone threshold as a valid disturbance and generate the pre-control trigger signal. The compensation calculation subunit is used to calculate and generate the feedforward compensation amount based on the deviation and the feedforward gain coefficient.

3. The natural gas combustion control system for a rotary anode furnace according to claim 1, characterized in that, The adaptive correction unit includes: The trend prediction subunit is used to predict the direction and magnitude of changes in fuel-side flow rate based on the changing trend of the effective disturbance. The pre-adjustment execution subunit is used to synchronously adjust the flow rate setpoint of the combustion-supporting agent based on the prediction result to generate the pre-adjustment amount of the combustion-supporting agent, rather than triggering the adjustment based on the deviation of the feedback variables of the combustion process.

4. The natural gas combustion control system for a rotary anode furnace according to claim 1, characterized in that, The instruction output unit includes: The timing matching subunit is used to match and calibrate the triggering time and change rate of the fuel-side control command and the combustion-supporting agent-side control command. The output execution subunit is used to synchronously output calibrated control commands to the corresponding actuators based on the calibration results.

5. A natural gas combustion control system for a rotary anode furnace according to claim 4, characterized in that, The timing matching subunit is also used for: Acquire response characteristic data of fuel-side actuators and combustion-supporting actuators, wherein the response characteristic data reflects the response delay of each actuator from receiving a command to completing an action; Based on the response characteristic data, the output delay time of the fuel-side control command and the combustion-supporting agent-side control command is adjusted to eliminate the time difference of the actuator action.

6. The natural gas combustion control system for a rotary anode furnace according to claim 1, characterized in that, The adaptive correction unit further includes: The deviation analysis subunit is used to calculate the deviation and the rate of change of the feedback variables in order to analyze the degree of matching between the combustion state and the air-fuel ratio in real time. The parameter adjustment subunit is used to adaptively adjust the control parameters based on the deviation and the rate of change of the deviation; The instruction correction subunit is used to correct the combustion-supporting control instruction based on the adjusted control parameters.

7. The natural gas combustion control system for a rotary anode furnace according to claim 1, characterized in that, The temperature closed-loop control unit includes: The temperature deviation calculation subunit is used to calculate the temperature deviation between the real-time operating temperature data and the process set value. The adjustment amount generation subunit is used to generate the basic temperature adjustment amount based on continuous time-series temperature deviation data and employs a closed-loop control algorithm. The characteristic adjustment subunit is used to dynamically adjust the adjustment parameters and response characteristics of the temperature closed-loop control unit in response to the pre-control trigger signal, so as to smoothly inherit the adjustment effect of the feedforward compensation.

8. The natural gas combustion control system for a rotary anode furnace according to claim 1, characterized in that, The instruction generation unit further includes: A basic adjustment acquisition subunit is used to acquire the basic temperature adjustment amount; The instruction superposition subunit is used to linearly superimpose the feedforward compensation amount and the basic temperature adjustment amount to generate the fuel-side control instruction.

9. A natural gas combustion control system for a rotary anode furnace according to claim 6, characterized in that, The parameter adjustment subunit includes: The fuzzification processing subunit is used to perform fuzzification processing on the input variables, using the deviation and the rate of change of deviation as input variables and employing multi-level linguistic variables, mapping the deviation to a deviation linguistic variable and the rate of change of deviation to a rate of change of deviation linguistic variable. The inference subunit is used to construct a fuzzy inference engine through preset fuzzy inference rules, perform fuzzy inference based on the deviation linguistic variable and the deviation change rate linguistic variable, and output the real-time correction amount of the control parameters. The parameter update subunit is used to adaptively adjust the control parameters based on the real-time correction amount.

10. A natural gas combustion control system for a rotary anode furnace according to claim 1, characterized in that, The data acquisition unit is also used for: The operational data is digitally filtered to remove transient interference signals during the acquisition process, thereby obtaining valid operational data. The effective operating data is synchronously distributed to the feedforward control unit, the temperature closed-loop control unit, the adaptive correction unit, the instruction generation unit, and the instruction output unit; The system receives feedback data on the actual actions of the actuator from the instruction output unit, thus completing the closed-loop acquisition and real-time updating of operational data.

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