Horizontal pusher furnace and gas-char co-production treatment method thereof

Abstract

The present application belongs to the technical field of biomass pyrolysis gasification, and particularly relates to a horizontal pusher furnace and a gas-char co-production treatment method thereof, which comprises a furnace body and a feeding assembly. The furnace body is divided into a reaction chamber and a combustion chamber from top to bottom, and the feeding assembly is in communication with the reaction chamber. A baffle passage is arranged in the combustion chamber, and the baffle passage is communicated with a plurality of oxygen supplement openings, each of which is equipped with an electric regulating valve. An axleless spiral blade is arranged in the reaction chamber, and a movable baffle is arranged between adjacent blades in a staggered manner. One end of the movable baffle is fixedly connected with the blade, and the other end is slidably connected with the blade. The two ends of the axleless spiral blade are fixedly connected with connecting discs, and distance measuring baffle assemblies are arranged between the connecting discs and the adjacent blades. The displacement signals collected by the non-contact displacement sensor can not only be combined with the thermal expansion law to inverse the temperature distribution of the furnace body, but also can synchronously identify the mechanical deformation and axial load state of the axleless spiral blade, so that temperature + mechanical state dual monitoring is realized, and the limitation that the existing equipment can only measure temperature is improved.

Description

Technical Field

[0001] This invention belongs to the field of biomass pyrolysis gasification technology, specifically relating to a horizontal pusher furnace and its gas-carbon co-production treatment method. Background Technology

[0002] Biomass pyrolysis gas-char co-production technology is a clean energy technology that uses biomass raw materials such as straw, sawdust, and nutshells to undergo thermochemical conversion in a high-temperature environment under oxygen-deficient or oxygen-controlled conditions, simultaneously producing combustible gas and biochar. Horizontal spiral propeller pyrolysis furnaces, with their advantages of compact structure, continuous feeding and discharging, and adjustable material residence time, have become one of the mainstream equipment forms in this field.

[0003] Existing technologies (such as CN105542812A) disclose a biomass continuous pyrolysis device and its temperature monitoring and control method, which uses direct temperature measurement data inside the furnace as the only feedback source and constructs a closed-loop control loop of "temperature measurement, PID, and regulation execution".

[0004] Current technology relies solely on temperature sensor readings for control, failing to distinguish between the actual pyrolysis state within the furnace (temperature field distribution, heat absorption process) and the mechanical state of the equipment (spiral axial bending, material bridging, bearing wear, sliding pair jamming). When mechanical failures occur, the simple temperature feedback signal cannot effectively identify the fault type. The controller will still interpret the temperature deviation as a change in pyrolysis conditions and continue to execute adjustment actions, potentially exacerbating the fault or even damaging the equipment.

[0005] Existing oxygen supply or supplemental heating regulation methods typically involve overall regulation of the entire furnace, which cannot provide precise segmented oxygen supply control based on the differences in pyrolysis levels in different furnace sections. Biomass pyrolysis exhibits significant stage differences along the furnace axis (preheating and drying section, main pyrolysis section, and char stabilization section), and each section requires different atmospheric conditions. Overall regulation methods can lead to localized over- or under-oxygenation, affecting the quality and yield of gaseous char products. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention provides a horizontal pusher furnace and its gas-coke co-production treatment method, which can simultaneously acquire temperature field distribution and equipment mechanical status in a non-contact manner, and achieve segmented and refined oxygen supply control.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A horizontal pusher furnace includes a furnace body and a feeding assembly. The furnace body is divided into a reaction chamber and a combustion chamber from top to bottom. The feeding assembly is connected to the reaction chamber. The combustion chamber is provided with a baffle channel, which is connected to multiple oxygen supply ports. Each oxygen supply port is equipped with an electric regulating valve. The reaction chamber is connected to a gas collection port and a discharge device. The feeding assembly includes a hopper and a discharger. The hopper is connected to the reaction chamber through the discharger. The reaction chamber is equipped with shaftless spiral blades, and there are staggered movable baffles between adjacent blades. One end of the movable baffle is fixed to the blade, and the other end is slidably connected to the blade. Both ends of the shaftless spiral blade are fixed with connecting plates, and distance measuring baffle assemblies are respectively provided between the connecting plates and the adjacent blades. The connecting plates are equipped with connecting shafts, one of which is connected to the drive motor, and the other connecting shaft is rotatably connected to the furnace body. Both sets of ranging baffle assemblies include a ranging baffle and a connecting sleeve. The ranging baffle and the connecting sleeve are slidably connected. Each ranging baffle is equipped with a non-contact displacement sensor 1. The sensor circuit passes through the connecting shaft and is connected to the conductive slip ring on the connecting shaft. A non-contact displacement sensor 2 is provided on the outside of the connecting plate on the side not connected to the drive motor. It also includes a controller, which analyzes the furnace operating status based on the signals collected by one of the three non-contact displacement sensors, calculates the temperature deviation of the corresponding axial furnace section of each oxygen supply port, drives the electric regulating valve to realize segmented oxygen supply, synchronously adjusts the operating parameters of the feeding component and the drive motor, and performs fault-level control according to the equipment operating status.

[0008] The controller incorporates a built-in thermodynamic bidirectional coupling and decoupling module. This module is designed to take into account the thermal expansion characteristics of the stainless steel used in the shaftless spiral blades, the overall structural rigidity of the spiral, and the structural features of the ranging baffle assembly subjected to compressive stress. It includes two functional parts: forward decoupling and reverse decoupling. The forward decoupling part determines the overall temperature gradient of the furnace body based on signals collected by the non-contact displacement sensors on both sides of the ranging baffle assembly, and extracts the axial load from the signals collected by the second non-contact displacement sensor on the outside. The reverse decoupling part uses the axial load to correct the deformation error caused by material compression in the signal from the first non-contact displacement sensor.

[0009] The controller has a built-in displacement gradient to segmented temperature field dynamic mapping module, which is set in combination with the furnace body segment length, the heat dissipation characteristics of the baffle channel and the axial heat absorption law of biomass material pyrolysis. It includes two functional parts: gradient decomposition and heat absorption compensation. The gradient decomposition part breaks down the overall displacement gradient of the furnace body into the local temperature deviation corresponding to each axial furnace segment, and the heat absorption compensation part corrects the local temperature deviation for material heat absorption in combination with the axial load state.

[0010] The controller has a built-in four-dimensional feature fusion working condition recognition module, which extracts four types of features: the time-domain average state of the displacement signal, the frequency-domain fluctuation state synchronized with the drive motor speed, the real-time change rate of the signal, and the displacement difference between the two non-contact displacement sensors, and sets corresponding judgment rules. If the time-domain average state deviates from the normal baseline and the frequency domain shows synchronous fluctuation, it is judged as shaftless spiral tilting and deflection; if the instantaneous change amplitude of the signal suddenly increases, it is judged as material bridging; if the displacement difference between the two sides exceeds the normal range, it is judged as abnormal furnace temperature; if the displacement on both sides remains constant and the axial load continues to rise, it is judged as jamming of the ranging baffle assembly.

[0011] The controller is equipped with an online self-calibration function. It works based on the normal range of the furnace body axial displacement gradient. During operation, it extracts the average value of the low-frequency component of the displacement signal to calculate the zero-point offset, corrects the sensor output data in different temperature ranges, and completes the calibration operation during continuous operation of the equipment.

[0012] The controller has a built-in multi-segment oxygen supply cross-decoupling and zoned collaborative control module. It sets inter-segment compensation logic in combination with the airflow direction of the baffle channel and sets the displacement gradient of the furnace body as an adjustment limit constraint. The module divides the furnace body into three functional furnace areas: main pyrolysis zone, preheating zone and discharge zone for zoned management. Different functional furnace areas are matched with control parameters with different response speeds to weaken the cross-segment interference caused by independent oxygen supply of multiple axial furnace sections.

[0013] The controller is equipped with a cross-section flue gas hysteresis compensation function, which adjusts the compensation amplitude according to the real-time displacement gradient change; when the electric regulating valve of the front axial furnace section is activated, the regulating valve of the adjacent axial furnace section at the rear end performs a pre-adjustment action synchronously to offset the temperature control deviation caused by the cross-section transmission of flue gas and heat.

[0014] The controller is configured with a hierarchical linkage logic for segmented oxygen supply, feeding, and drive motor speed, with priority ordering as follows: mechanical fault handling, segmented temperature field adjustment, and overall material load adjustment. When the temperature of a single axial furnace segment is abnormal, only the regulating valve of the corresponding axial furnace segment is adjusted. When the overall temperature gradient exceeds the standard, the regulating valves of multiple axial furnace segments are adjusted in concert to balance the heat absorption with the feed rate. The controller has a built-in fault section location logic: by finely adjusting the electric regulating valves of each oxygen supply port segment by segment, the response degree of the change in displacement gradient at both ends is observed to locate the abnormal temperature location; the location of the local deformation of the spiral is calculated by the time delay difference of the fluctuation signal reaching the non-contact displacement sensor at both ends; the stuck position of the single-sided ranging baffle assembly is determined by the stroke values ​​of each non-contact displacement sensor at both ends; after identifying the equipment fault, the electric regulating valve corresponding to the fault section is locked at the current opening, and the feed rate and motor speed are reduced simultaneously. The fault status is divided into three levels: warning, alarm, and emergency shutdown, and corresponding audible and visual prompts, load reduction, and overall machine shutdown are executed.

[0015] A method for cogeneration of gas and carbon includes the following steps: S1. Load the biomass raw materials into the silo and send the biomass raw materials into the reaction chamber through the unloader; S2. Start the drive motor to drive the shaftless spiral blade and its movable baffle to operate, lift, scatter and push the biomass raw material backward; at the same time, high-temperature flue gas is introduced into the combustion chamber, and the flue gas flows along the baffle channel to heat the biomass raw material to the pyrolysis temperature through indirect heat exchange. S3. Biomass raw materials are heated in the reaction chamber and undergo gasification and carbonization reactions. The generated pyrolysis combustible gas rises and gathers and is discharged through the gas collection port. The generated biomass char is transported to the discharge device and discharged through the discharge device. S4. The equipment performs signal acquisition synchronously throughout the process. The two non-contact displacement sensors on the two sets of ranging baffle assemblies collect the relative sliding displacement between the ranging baffle and the connecting sleeve. The two non-contact displacement sensors on the outside collect the axial displacement of the connecting plate on the non-drive motor side, and obtain the displacement monitoring signal. S5. Parallel data processing and status determination: Based on the thermo-mechanical bidirectional coupling decoupling module, the three types of state quantities of the furnace body temperature gradient, axial load and mechanical deformation are analyzed. Based on the displacement gradient to segmented temperature field dynamic mapping module, the local temperature deviation of each axial furnace section is calculated. At the same time, based on the four-dimensional feature fusion working condition identification module, the current operating status and fault type of the equipment are determined. S6. Drive the corresponding independent electric regulating valve to complete the segmented oxygen supply according to the local temperature deviation of each axial furnace section, synchronously adjust the feed rate, feed speed and drive motor speed, and perform graded fault handling in combination with the fault judgment results and fault section location results.

[0016] During the entire operation of the equipment, two auxiliary operations are performed in parallel. The first is to correct the zero-point offset of the sensor in real time based on the normal range of the axial displacement gradient of the furnace body and the average value of the low-frequency component of the displacement signal, without any downtime. The second is to continuously collect the operating data of the entire furnace. For various biomass raw materials and different production loads, the control parameters of each electric regulating valve are corrected according to the long-term statistical characteristics of the displacement signal and the preset rule table, so that the control parameters can be smoothly transitioned when switching raw materials and adjusting the load. During the operation, the specific fault section is determined by observing the displacement gradient response and analyzing the time delay difference of the fluctuation signal through segmented fine-tuning of the valve.

[0017] Compared with the prior art, the beneficial effects of this invention are: The displacement signal acquired by the non-contact displacement sensor can not only be combined with the thermal expansion law to invert the temperature distribution of the furnace body, but also simultaneously identify the mechanical deformation and axial load status of the shaftless screw, realizing dual monitoring of temperature and mechanical status. This improves the limitation of existing equipment that can only measure temperature, and significantly enhances the comprehensiveness of monitoring.

[0018] The thermodynamic bidirectional coupling and decoupling module effectively separates the thermal expansion deformation component from the mechanical deformation component generated by material extrusion in the displacement signal, and corrects detection errors caused by load. Simultaneously, through a displacement gradient to segmented temperature field dynamic mapping mechanism, relying on the inherent structure and heat transfer laws of the equipment, it accurately converts the furnace's overall state data into local temperature deviations for each axial furnace segment. Compared to single-point temperature measurement in comparative documents and traditional equipment relying on pipe wall temperature estimation, this solution eliminates the need for numerous additional temperature measurement points within the furnace to achieve full-domain segmented temperature analysis. This results in higher data traceability and calculation accuracy, providing a reliable basis for segmented and refined oxygen supply control.

[0019] To address the axial transfer characteristics of flue gas and heat in the combustion chamber baffle channel, this invention incorporates a multi-segment oxygen supply cross-decoupling and flue gas lag dynamic compensation mechanism. This effectively reduces cross-segment interference caused by independent oxygen supply in multiple axial furnace sections and dynamically adjusts the compensation amplitude according to the overall furnace operating conditions, solving the problem of poor compensation effect with fixed parameters. Simultaneously, functional furnace zones are divided into preheating, main pyrolysis, and discharge zones, and differentiated response parameters are matched to ensure that the temperature control logic of different process zones adapts to their own pyrolysis requirements, effectively stabilizing the furnace reaction environment and improving the product quality of combustible gas and biochar. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the present invention; Figure 2 yes Figure 1 A magnified view of a section at point A in the middle; Figure 3 This is a schematic diagram of the structure of the shaftless spiral blade of the present invention; Figure 4 This is a partial cross-sectional view of the ranging baffle assembly of the present invention; Wherein: 1 is furnace body, 10 is reaction chamber, 11 is combustion chamber, 12 is electric regulating valve, 13 is gas collection port, 14 is flue gas inlet, 15 is flue gas outlet, 16 is discharge device, 2 is feeding assembly, 20 is hopper, 21 is unloader, 3 is shaftless spiral blade, 30 is blade, 31 is movable baffle, 32 is connecting plate, 33 is distance measuring baffle assembly, 330 is distance measuring baffle, 331 is non-contact displacement sensor one, 33 is connecting sleeve, 34 is connecting shaft, 35 is non-contact displacement sensor two, 36 is conductive slip ring, and 4 is drive motor. Detailed Implementation

[0021] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0022] Example 1

[0023] like Figures 1 to 4 As shown, this embodiment provides a horizontal pusher furnace, including a furnace body 1, a feeding assembly 2, an axial pusher conveying structure (shaftless spiral blade 3), three sets of non-contact displacement sensors, a segmented oxygen supply actuator, and a controller (not shown in the figure).

[0024] The furnace body 1 is vertically divided into a reaction chamber 10 and a combustion chamber 11 arranged vertically. The two chambers together form a closed heat exchange cavity, which adopts an indirect heat exchange mode. High-temperature flue gas is introduced into the combustion chamber 11 to heat the outer wall, and the heat is transferred to the internal reaction chamber 10 to provide heat for biomass pyrolysis. The combustion chamber 11 is connected to a flue gas inlet 14 and a flue gas outlet 15.

[0025] The combustion chamber 11 has an axially extending baffle channel inside. Several oxygen supply ports are opened at intervals along the axial direction on the side wall of the baffle channel. Each oxygen supply port is independently equipped with an electric regulating valve 12. The opening degree of each electric regulating valve 12 is independently adjustable, which can control the oxygen supply of the corresponding axial furnace section and achieve precise oxygen supply in different areas.

[0026] The upper part of the reaction chamber 10 is reserved with a gas collection port 13 for exporting the combustible gas generated by pyrolysis; the discharge end of the reaction chamber 10 is connected to the discharge device 16 to continuously discharge the solidified biochar product.

[0027] The feeding assembly 2 consists of a hopper 20 and a discharger 21. The hopper 20 serves as a raw material buffer hopper, and the discharger 21 is installed at the bottom outlet of the hopper 20. The discharge end of the discharger 21 is sealed and connected to the feed end of the reaction chamber 10. Specifically, the discharger 21 is a star-shaped discharger 21.

[0028] Inside the reaction chamber 10, shaftless spiral blades 3 are horizontally arranged. The blades 30 are arranged along the entire axial direction of the furnace body 1, serving as the core component for material conveying. The shaftless spiral blade 3 is composed of multiple blade segments 30 units, with movable baffles 31 installed between adjacent blade segments 30 units. All movable baffles 31 are staggered along the circumference of the blades 30. One end of the movable baffle 31 is welded and fixed to the corresponding blade 30, and the other end is slidably connected to the adjacent blade 30. Specifically, the corresponding blade 30 is provided with a sliding hole, and the movable baffle 31 is slidably connected to the sliding hole and can extend out.

[0029] When the shaftless spiral blade 3 rotates, the movable baffle 31 moves in a synchronous circular motion to lift, scatter, and turn the accumulated material, increasing the heat exchange contact area between the material and the inner wall of the reaction chamber 10. At the same time, it continuously pushes the material to move axially towards the discharge end, ensuring that the material is heated evenly and that the conveying is continuous and does not block the material.

[0030] The shaftless spiral blade 3 has connecting discs 32 fixedly connected to both ends of its axial direction. The two connecting discs 32 rotate synchronously with the spiral blade 30. A distance measuring baffle assembly 33 is provided between each connecting disc 32 and the adjacent blade unit 30. A connecting shaft 34 is fixed coaxially at the center of each connecting disc 32. One connecting shaft 34 extends outward and is rigidly connected to the output shaft of the drive motor 4, which provides the rotational power for the entire shaftless spiral blade 3. The other connecting shaft 34 extends outward and is rotatably mounted on the side wall of the furnace body 1 through a bearing seat.

[0031] The ranging baffle assembly 33 includes a ranging baffle 330 and a connecting sleeve 33. The ranging baffle 330 is fixed to the connecting disc 32 on the same side, and the connecting sleeve 33 is fixed to the adjacent blade 30 unit. When the blade 30 is heated and elongated, or when the material is squeezed and causes axial deformation, the ranging baffle 330 and the connecting sleeve 33 slide relative to each other axially. Each ranging baffle 330 of the ranging baffle assembly 33 is fixed with a non-contact displacement sensor 331. The sensor detection end faces the inner bottom of the connecting sleeve 33, and the relative sliding displacement between the two is collected in real time. The signal cable led out by the sensor runs along the inside of the hollow connecting shaft 34 and finally connects to the conductive slip ring 36 fitted on the shaft body of the connecting shaft 34. The conductive slip ring 36 rotates synchronously with the shaft and can stably transmit the sensing signal outward under uninterrupted rotation conditions.

[0032] A third non-contact displacement sensor 331 is fixedly installed on the outside of the connecting plate 32 on the side away from the drive motor 4 and on the furnace body 1. This sensor does not make physical contact with the rotating parts and collects the overall axial absolute displacement of the connecting plate 32 on this side in a non-contact manner, so as to fully capture the total axial elongation and overall axial load deformation of the entire spiral blade 30.

[0033] All displacement detection signals output by the three non-contact displacement sensors 331 are individually wired and connected to the signal acquisition port of the controller. The controller has a built-in signal acquisition module, a processing module, and a multi-channel drive output module, which are electrically connected to each non-contact displacement sensor 331, the electric regulating valve 12 of each oxygen supply port, the drive motor 4, and the feed assembly 2 and unloader 21.

[0034] The controller receives displacement values ​​from three non-contact displacement sensors (331) in real time. Based on the predetermined thermal expansion coefficient of the stainless steel material of the shaftless spiral blade (3) and the overall structural stiffness parameters, combined with the fixed axial heat transfer law of the flue gas in the baffle channel, the controller breaks down and calculates the collected global displacement data, converting the overall displacement gradient into the actual temperature deviation value of the axial furnace section corresponding to each oxygen supply port. This conversion is achieved based on the determined physical laws of mechanical thermal expansion and a fixed flow field distribution.

[0035] Based on the temperature deviation value of each axial furnace section, the controller independently issues opening adjustment commands to the electric regulating valve 12 of the corresponding oxygen supply port, and adjusts the oxygen supply air volume of a single section separately, so as to realize independent oxygen control and zoned temperature control of each axial furnace section, avoiding the local over-oxygenation and under-oxygenation problems caused by unified oxygen supply throughout the entire area.

[0036] The controller synchronously outputs control signals to adjust the start / stop and conveying rate of the feed assembly 2 and the unloader 21, while also adjusting the working speed of the drive motor 4; changing the speed can adjust the rotation speed of the shaftless spiral blade 3, thereby controlling the residence time of the material in the reaction chamber 10 for pyrolysis, and matching it with the segmented oxygen supply strategy to stabilize the pyrolysis process parameters.

[0037] The controller continuously analyzes the long-term detection data of the three displacement sensors in real time, automatically identifies various abnormal operating conditions of the equipment such as material bridging, spiral tilting and deflection, sliding pair jamming, and abnormal furnace temperature distribution, and executes corresponding protection actions such as early warning prompts, load reduction operation, and emergency shutdown in sequence according to the preset classification strategy to prevent the fault from expanding and damaging the entire set of equipment.

[0038] The specific workflow is as follows: Biomass raw materials are loaded into the silo 20, and the unloader 21 feeds the materials quantitatively at a set speed, continuously feeding the raw materials into the feed end of the reaction chamber 10; the drive motor 4 drives the shaftless spiral blade 3 to rotate continuously, and the staggered movable baffles 31 simultaneously flip and scatter the materials, pushing them uniformly towards the discharge end. High-temperature flue gas enters the baffle channel of the combustion chamber 11, flows along the predetermined baffle path, and continuously heats the reaction chamber 10 through indirect heat exchange, causing the raw materials to gradually undergo gasification and carbonization reactions. Throughout the operation, three non-contact displacement sensors 331 continuously collect axial displacement data at various points and upload it to the controller in real time.

[0039] The controller calculates the temperature deviation of each axial furnace section and adjusts the opening of the corresponding electric regulating valve 12 to achieve segmented oxygen supply, and synchronously matches and adjusts the feed speed and screw speed; once abnormal operating conditions of the equipment are identified, it automatically performs graded fault handling. The combustible gas generated by pyrolysis is collected and discharged through the gas collection port 13, and the carbonized solid biomass char is continuously transported to the discharge device 16 and discharged out continuously. The whole set of equipment is in continuous cycle production.

[0040] Example 2

[0041] This embodiment specifically discloses the controller settings based on embodiment 1.

[0042] Furthermore, the controller incorporates a built-in thermodynamic bidirectional coupling and decoupling module. This module is the core functional unit of the controller, designed based on the material characteristics and overall structural rigidity of the shaftless spiral blade 3 of the horizontal pusher furnace, as well as the actual working conditions of the ranging baffle assembly 33 under long-term material extrusion stress. It consists of two collaborative functional parts: forward decoupling and reverse decoupling. The module performs calculations based on the raw displacement signals collected by three non-contact displacement sensors 331, effectively separating and correcting the error between the thermal expansion component and the mechanical load deformation component in the displacement signal. This provides accurate basic data for subsequent temperature judgment, working condition identification, and control actions of the equipment. The module is deeply integrated with the equipment hardware and is an indispensable component of the entire control system.

[0043] During actual operation of the equipment, the shaftless spiral blade 3 will simultaneously generate two types of axial deformation: one is thermal expansion deformation caused by the high temperature environment inside the furnace, which is directly related to the overall temperature distribution of the furnace body 1; the other is mechanical compression deformation caused by the axial compression of the conveyed material and the operating load of the equipment, which is directly related to the axial load state of the equipment. The two types of deformation will be reflected in the relative displacement of the ranging baffle assembly 33 and the overall axial displacement of the connecting plate 32, making the original output signal of the sensor a composite signal.

[0044] The shaftless spiral blade 3 of this equipment is made of a fixed grade of stainless steel with a defined coefficient of thermal expansion. The overall structure of the blade 30 has undergone mechanical design to ensure stable structural rigidity. Meanwhile, the sliding fit structure formed by the ranging baffle 330 and the connecting sleeve 33 continuously withstands axial compressive stress during material conveying, which further causes additional deformation of the sliding pair. Based on the inherent material properties, structural characteristics, and operating conditions of the equipment, this module specifically incorporates bidirectional decoupling logic to decompose and correct the composite displacement signal.

[0045] The thermal bidirectional coupling decoupling module is integrated inside the controller. The signal input terminal of the module is connected to two non-contact displacement sensors 331 on the two end ranging baffle assemblies 33 and a third non-contact displacement sensor 331 on the side away from the drive motor 4, respectively, to receive three channels of raw displacement data in real time. After the module completes the calculation, it outputs the decoupled global temperature gradient, pure axial load and corrected displacement signal to other functional modules of the controller.

[0046] The module is internally divided into a forward decoupling part and a reverse decoupling part that cooperate with each other. The two parts run continuously according to a preset logical sequence. The forward decoupling completes the component splitting first, and the reverse decoupling performs error compensation based on the result of the forward decoupling. The two form a closed-loop operation logic.

[0047] The forward decoupling section uses the relative displacement signals collected by two non-contact displacement sensors 331 on the two side ranging baffle assemblies 33 as the core input. Combining the thermal expansion coefficient of the stainless steel material of the shaftless spiral blade 3, the total axial length of the furnace body 1, and the overall structural stiffness of the blade 30, the forward decoupling section performs comprehensive calculations on the two sets of relative displacement signals. Based on the physical law of the correspondence between thermal expansion deformation and temperature, the global temperature gradient of the entire furnace body 1 is derived. This gradient can objectively reflect the overall axial temperature distribution of the furnace body 1.

[0048] Meanwhile, the forward decoupling part connects to the non-contact displacement sensor 35 to collect the overall axial displacement signal of the connecting disk 32. This displacement signal includes the deformation caused by the thermal elongation of the blade 30 and the overall axial load of the equipment. During the calculation process, the previously calculated thermal elongation component is removed from the overall axial displacement, and finally the pure axial load of the equipment is extracted separately. This load data accurately characterizes the mechanical operating state such as the extrusion of materials in the furnace and the force on the transmission components.

[0049] When the equipment is running, the axial compressive stress generated by the material in the furnace will act on the ranging baffle assembly 33, causing additional deformation error caused by the compressive stress to be mixed into the relative displacement signal collected by the non-contact displacement sensors 331 on both sides. If the original signal is used directly, the accuracy of the temperature gradient calculation will be reduced. Therefore, a reverse decoupling part is set up to complete the error correction.

[0050] The reverse decoupling section uses the pure axial load obtained from the forward decoupling as the core calculation basis. Combining the structural dimensions of the ranging baffle assembly 33 and the deformation law of the sliding pair, it calculates the deformation caused by the current axial load at the sliding fit position between the ranging baffle 330 and the connecting sleeve 33. Subsequently, this deformation is used to correct the original relative displacement signals output by the non-contact displacement sensors 331 on both sides, offsetting the deformation error caused by material extrusion, and finally obtaining a pure displacement signal that only reflects the thermal expansion state.

[0051] The corrected displacement signal will be fed back to the forward decoupling part to participate in the next round of global temperature gradient calculation, forming a continuously iterative closed-loop correction mechanism to ensure the stability of the decoupling results under long-term continuous operation.

[0052] During normal equipment production, the thermodynamic bidirectional coupling decoupling module operates synchronously and continuously with the displacement signal acquisition, completing signal decoupling and error correction in real time. The two core data continuously output by the module—the global temperature gradient and the pure axial load—are synchronously transmitted to the displacement gradient-to-segmented temperature field dynamic mapping module and the four-dimensional feature fusion condition identification module inside the controller. These serve as the basic data source for segmented temperature deviation calculation and equipment fault condition determination, indirectly guiding the coordinated adjustment actions of the electric regulating valve 12 at each oxygen supply port, the feeding assembly 2, and the drive motor 4, achieving integrated control of mechanical and thermal states.

[0053] Furthermore, the controller incorporates a displacement gradient to segmented temperature field dynamic mapping module. This module serves as the functional unit connecting signal decoupling and segmented oxygen supply control. Designed based on the inherent segmented dimensions of furnace body 1, the heat dissipation characteristics of the baffle channel, and the axial pyrolysis endothermic law of biomass materials, it is divided into two collaborative functional parts: gradient decomposition and endothermic compensation. This module receives the global displacement gradient and axial load data output from the thermodynamic bidirectional coupling decoupling module, transforming the global parameters characterizing the overall state of furnace body 1 into the corresponding local temperature deviations of each axial furnace segment, providing a precise basis for the independent adjustment of the electric regulating valves 12 at each oxygen supply port.

[0054] The core input data for this module all come from the calculation results of the thermodynamic bidirectional coupling and decoupling module: firstly, the global displacement gradient characterizing the overall thermal state of furnace body 1, which is obtained by decoupling the raw signals from three non-contact displacement sensors 331 and directly corresponds to the overall axial temperature distribution of furnace body 1; secondly, the pure axial load characterizing the material accumulation and compression state inside the furnace, used for subsequent temperature deviation compensation and correction. Both sets of data are transmitted to this module in real time and continuously as the equipment operates.

[0055] The module's operations rely on fixed physical parameters and process rules determined by factory calibration and actual measurements of the equipment, specifically including: Furnace body 1 segment dimensional parameters: Furnace body 1 is divided into several axial furnace segments along the axial direction. Each axial furnace segment corresponds to an oxygen supply port and a matching electric regulating valve 12. The length of each axial furnace segment is a fixed geometric dimension, which is the basis for gradient decomposition. Heat dissipation characteristics of the baffle channel: The flue gas flow direction, flow cross-sectional area, and wall heat dissipation coefficient of the baffle channel inside the combustion chamber 11 are fixed parameters determined by the equipment structure. The heat exchange law between the flue gas and the wall of the furnace body 1 is stably distributed along the axial direction. Biomass pyrolysis endothermic law: Biomass raw materials gradually complete the entire process of preheating, pyrolysis and carbonization along the axial direction in the furnace. The heat absorption intensity and heat absorption rate of the material in different axial furnace sections have stable distribution characteristics. This law is determined by the material characteristics and the process structure of the furnace body 1.

[0056] The displacement gradient to segmented temperature field dynamic mapping module is integrated inside the controller. The signal input end is connected to the thermodynamic bidirectional coupling decoupling module, and the calculation output end is connected to the multi-segment oxygen supplementation cross-decoupling control module and the four-dimensional feature fusion working condition recognition module, respectively.

[0057] The module is divided into a gradient decomposition section and a heat absorption compensation section. The data is processed step by step in the order of "inputting global displacement gradient → obtaining initial local temperature deviation through gradient decomposition → completing heat absorption compensation by combining axial load → outputting final local temperature deviation". The two functional parts are connected in time and run continuously, which is suitable for the working mode of long-term continuous production of equipment.

[0058] The gradient decomposition part is the first-level computing unit of the module. Its core function is to decompose the overall displacement gradient of the furnace body 1 into the initial local temperature deviations corresponding to each axial furnace section.

[0059] Based on the fixed lengths of each axial furnace section of furnace body 1 and the heat dissipation coefficients of each segment of the baffle channel, and according to the physical correspondence between metal thermal expansion and heat conduction, a dynamic mapping relationship between the global displacement gradient and the temperature of each segment is established. Since the shaftless spiral blade 3 is made of uniform material and the axial heat transfer path of furnace body 1 is fixed, the overall displacement gradient of furnace body 1 is a comprehensive reflection of the thermal expansion effect of all axial furnace sections. The gradient decomposition part decomposes the global displacement gradient according to the length proportion of each axial furnace section and the heat dissipation loss of each segment, calculating the initial local temperature deviation corresponding to each axial furnace section.

[0060] This process is based on the objective physical laws of equipment geometry, fluid heat transfer, and solid thermal expansion. The decomposition logic and mapping coefficients are calibrated through actual thermal measurements of the entire equipment and can be stably reproduced.

[0061] The initial local temperature deviation obtained by gradient decomposition only considers the effects of thermal expansion of furnace body 1 and heat dissipation from the wall. However, in actual production, the filling amount and stacking and compression state of biomass materials in the furnace will change the total local heat absorption, thus causing temperature calculation deviation. Therefore, a heat absorption compensation part is set to complete the error correction.

[0062] The heat absorption compensation section uses the pure axial load output by the thermodynamic bidirectional coupling decoupling module as the core correction basis: the axial load value directly reflects the amount of material accumulation and the degree of compression in each axial furnace section. The more material there is, the greater the axial load, and the higher the heat absorption of the corresponding furnace section.

[0063] The module combines the heat absorption distribution law of biomass material along the axial direction of the furnace body, converts the axial load data into the heat absorption correction amount of each axial furnace section, and compensates and corrects the initial local temperature deviation obtained by gradient decomposition one by one, finally obtaining the final local temperature deviation that can truly reflect the actual working conditions of each furnace section.

[0064] The local temperature deviations of each axial furnace section obtained after gradient decomposition and endothermic compensation will be transmitted to the subsequent functional modules of the controller in real time: on the one hand, they will be sent to the multi-segment oxygen supply cross-decoupling and zone collaborative control module as the direct control basis for the independent adjustment of the opening of each oxygen supply port electric regulating valve 12 to realize segmented oxygen supply; on the other hand, they will be shared synchronously with the four-dimensional feature fusion working condition identification module to assist in the comprehensive judgment of equipment operating conditions and fault types.

[0065] Throughout the entire operating cycle of the equipment, this module performs synchronous and cyclical calculations with other components such as displacement signal acquisition, thermal decoupling, and oxygen supply regulation to ensure real-time updates of segmented temperature data and match dynamically changing production conditions.

[0066] Furthermore, the controller incorporates a built-in four-dimensional feature fusion operating condition recognition module. This module is the core functional unit for determining the equipment's operating status and fault type. Its input interface connects to the real-time acquisition signals of three non-contact displacement sensors (331). By extracting four typical features of the displacement signals and combining them with judgment rules specifically designed for the equipment's operating conditions, it accurately distinguishes four operating states: abnormal furnace temperature, material bridging, shaftless spiral tilting and deflection, and jamming of the distance measuring baffle assembly (33). This module works in deep collaboration with the sensing components, the front-end thermal decoupling module, and the back-end linkage control and fault protection unit. Its computational logic is designed based on the physical signals generated during actual equipment operation.

[0067] During normal operation of the equipment, the three non-contact displacement sensors 331 continuously output real-time displacement signals. Affected by factors such as changes in furnace temperature, material conveying status, deformation of moving parts, and jamming of sliding pairs, the displacement signals will exhibit different time-domain, frequency-domain, and dynamic change characteristics. These characteristics have a fixed correspondence with the actual operating conditions of the equipment.

[0068] The original input signal of this module is the real-time displacement data of all three non-contact displacement sensors 331. At the same time, it can also call the axial load data output by the thermo-mechanical bidirectional coupling decoupling module as an auxiliary judgment basis. The module runs continuously in real time along with the equipment production process, continuously extracting features and judging working conditions of the displacement signal to match the long-term continuous operation mode of the equipment.

[0069] The module extracts four core features from displacement signals. All feature extraction is based on real physical signals collected by the sensors, and the feature definitions are set in accordance with the structure and operating characteristics of this equipment. The average displacement values ​​over a continuous period of time are calculated to characterize the overall steady-state displacement level of the shaftless helical blade 3 and the ranging baffle assembly 33, mainly reflecting the overall thermal expansion and static deformation of the furnace body 1. Under steady-state conditions, the time-domain average value will remain stable within the preset normal baseline range of the equipment. When the overall temperature of the furnace body 1 fluctuates significantly, the average value will deviate from the normal baseline synchronously.

[0070] When the drive motor 4 drives the shaftless helical blade 3 to rotate at a constant speed, if the blade 30 undergoes deformation such as eccentricity or tilting, it will generate periodic vibration, which will be reflected in the displacement signal. The module performs frequency domain analysis on the displacement signal and extracts the fundamental amplitude value that is consistent with the rated speed frequency of the motor, thereby characterizing the intensity of the periodic vibration of the moving parts.

[0071] This characterizes the magnitude of displacement change per unit time, corresponding to the instantaneous rate of change of the signal. When material suddenly accumulates or becomes blocked inside the furnace, the displacement will change abruptly in a short time, and this characteristic quantity will increase significantly; when the equipment is running in steady state, the rate of change of the signal remains stable.

[0072] The difference calculation is performed on the data collected by the two non-contact displacement sensors 331 on the two-end ranging baffle assembly 33 to characterize the uniformity of the axial displacement on both sides of the furnace body 1, and directly reflects the axial temperature distribution of the furnace body 1 and the consistency of the operation of the sliding pairs on both sides.

[0073] The module combines the above four types of characteristics with the physical laws summarized from long-term equipment operation to set one-to-one judgment rules to distinguish four typical operating conditions. Each rule is based on the actual operating phenomena of the equipment. When the shaftless helical blade 3 tilts or eccentrically deflects, the rotation of blade 30 will generate continuous periodic vibration. The corresponding signal manifestations are: the average displacement in the time domain deviates from the normal baseline, while a significant fundamental amplitude value appears in the frequency domain, synchronized with the speed of the drive motor 4, although the instantaneous rate of change of the signal and the difference in displacement between the two sides are not significantly abnormal. When the module detects this combination of characteristics, it determines that the equipment has experienced shaftless helical tilting and deflection.

[0074] When biomass material accumulates locally or becomes bridging and blocked inside the furnace, it will instantly impact and compress the shaftless spiral blade 3 and the ranging baffle assembly 33, causing a short-term abrupt change in displacement. The corresponding signal is characterized by a sudden increase in the real-time amplitude of the signal change, without periodic fluctuations at a fixed frequency, while the displacement difference between the two sides remains within the normal range. Based on this combination of characteristics, the module determines that material bridging has occurred inside the furnace.

[0075] When the temperature of the furnace body 1 as a whole or over a large area deviates from the rated range, the overall thermal expansion of the shaftless spiral blade 3 changes, and the axial displacement of both sides of the furnace body 1 simultaneously shifts. The corresponding signal is that the displacement difference of the two non-contact displacement sensors 331 exceeds the normal range, while other frequency domain fluctuations and signal change rates remain normal. Based on this, the module determines that the furnace body 1 has an abnormal temperature.

[0076] When the sliding pair consisting of the ranging baffle 330 and the connecting sleeve 33 becomes stuck, their relative movement stops, and the values ​​of the non-contact displacement sensors 331 on both sides remain constant for a long time; at the same time, the squeezing effect caused by the continuous material conveying will cause the overall axial load of the equipment to continuously increase. Based on the combination of the characteristics of "constant displacement on both sides + continuous increase in axial load", the module determines that the ranging baffle assembly 33 is stuck.

[0077] After the module completes the determination of the operating condition and fault type, it will output the identification results to the hierarchical linkage logic unit and fault classification control unit inside the controller in real time. Under normal operating conditions, the identification results serve as an auxiliary reference, in conjunction with the routine adjustment of segmented oxygen supply, feed, and speed. Once a fault condition is identified, the controller immediately initiates the corresponding graded handling actions, including adjusting the opening of the oxygen supply port, limiting the stroke of the regulating valve in the fault area, adjusting the feed rate and motor speed, or triggering audible and visual alarms, load reduction, emergency shutdown, and other protective operations, realizing the full-process linkage of status identification, equipment control, and fault protection.

[0078] Furthermore, the controller is equipped with an online self-calibration function. This function compensates for the zero-point drift error generated by the non-contact displacement sensor 331 during long-term continuous operation, ensuring the long-term accuracy of the displacement acquisition data. The function relies on the inherent conventional range of the axial displacement gradient of the furnace body 1 during steady-state operation as a judgment benchmark. It calculates the zero-point offset by extracting the average of the low-frequency components of the displacement signal and uses corresponding strategies to correct the sensor output data in combination with different temperature ranges of the furnace body 1. The entire calibration process is carried out in parallel with the equipment production process, without requiring machine shutdown or external calibration equipment. It is a crucial functional unit for ensuring the accuracy of the entire detection and control system and is deeply integrated with the equipment hardware and main control logic.

[0079] The horizontal pusher furnace has a fixed structure and uses a uniform material for its shaftless spiral blades. Under rated process conditions and continuous steady-state operation, the axial displacement gradient of the furnace body 1 will stably fall within a predetermined range. This range is determined by the equipment's geometric dimensions, the thermal expansion characteristics of the stainless steel material, and the conventional biomass pyrolysis process temperature. It is determined through multiple rounds of hot-state calibration measurements during the equipment's factory manufacturing phase and represents an objective physical parameter of the equipment's operation, not a subjectively set parameter. This predetermined range serves as a benchmark for comparing the sensor's zero-point offset throughout the entire self-calibration process.

[0080] The raw signal output by the three-non-contact displacement sensor 331 contains two types of components: one is a low-frequency steady-state component, which mainly reflects the sensor's zero-point drift and the overall steady-state displacement of the equipment, and its changes are gradual and continuous; the other is a high-frequency disturbance component, which is generated by short-term factors such as instantaneous impact of materials in the furnace, mechanical vibration of the equipment, and dust interference, and does not represent the sensor's reference offset. Therefore, this function selects the average value of the low-frequency component as the core data for calculating the zero-point offset, which can effectively shield instantaneous interference and ensure the accuracy and reliability of the calibration results.

[0081] The internal ambient temperature of furnace body 1 varies significantly during different stages, including preheating, normal pyrolysis, and high-load operation. The electrical characteristics of the non-contact displacement sensor 331 change slightly with ambient temperature, resulting in different zero-point drift patterns. Therefore, the equipment is divided into multiple temperature ranges based on the actual operating temperature, with each range equipped with independent correction parameters, achieving precise calibration within each range and further improving data correction effectiveness.

[0082] The function input end directly connects to the three non-contact displacement sensors 331 to receive three raw displacement signals in real time; internally, it sequentially completes signal component extraction, zero-point offset calculation, and temperature zone data correction; finally, it outputs the calibrated standard displacement signal, which is synchronously transmitted to downstream units such as the thermo-mechanical bidirectional coupling decoupling module, the displacement gradient to segmented temperature field dynamic mapping module, and the four-dimensional feature fusion working condition recognition module.

[0083] Throughout the entire operating cycle of the equipment, the functional unit continuously samples the raw signals from the three non-contact displacement sensors 331. High-frequency disturbance components in the signals are filtered out using a digital filtering algorithm, and the low-frequency signals reflecting the steady-state of the equipment and the reference state of the sensors are extracted separately. The real-time average value of the low-frequency components is then calculated. This average value represents the reference value output by the sensors under the current state.

[0084] The calculated average of the low-frequency components is compared with the conventional range of the axial displacement gradient of furnace body 1 as specified by the equipment manufacturer. Using the standard reference value under steady-state conditions as a reference, the difference between the two is the current zero-point offset generated by the sensor. The offset is calculated independently for each of the three sensors, achieving individual calibration of each signal.

[0085] The controller calls upon the global temperature gradient data output by the thermal bidirectional coupling and decoupling module to determine the current temperature range of the device and matches it with the preset correction coefficient and correction rules corresponding to that temperature range. Different correction logic is used for different temperature ranges to adapt to the drift characteristics of the sensor under different high-temperature environments.

[0086] By combining the calculated zero-point offset with the correction parameters for the current temperature range, the three original displacement data are dynamically compensated and corrected to offset the error caused by the sensor's zero-point drift and output a standard displacement signal with the required accuracy.

[0087] The above sampling, extraction, calculation, and correction process is executed in a fixed cycle to track the slow changes in the zero-point drift of the sensor in real time, so as to achieve dynamic and continuous calibration and adapt to the operation requirements of the equipment for long-term uninterrupted production.

[0088] The standard displacement signal, after online self-calibration, serves as the fundamental data source for all subsequent calculations, status determinations, and control adjustments by the controller. Accurate displacement data ensures the computational precision of processes such as thermal decoupling, segmented temperature field conversion, and fault condition identification, thereby guaranteeing the accurate and reliable adjustment actions of the electric regulating valves 12 at each oxygen supply port, the feed assembly 2, and the drive motor 4. Without this self-calibration function, long-term sensor drift will gradually cause deviations in temperature calculations and operating condition determinations, ultimately affecting the stability of the gas-coal cogeneration process and the safety of equipment operation.

[0089] Furthermore, the controller incorporates a multi-segment oxygen supply cross-decoupling and zoned collaborative control module. This module primarily addresses cross-segment interference issues arising from the flow of flue gas and heat along the baffle channels when multiple axial furnace sections independently adjust their oxygen supply. The module incorporates inter-segment compensation logic based on the inherent airflow direction of the baffle channels within furnace body 1, while using the overall displacement gradient of furnace body 1 as an adjustment limit constraint. Moreover, the entire furnace is divided into three functional zones according to process function: the main pyrolysis zone, the preheating zone, and the discharge zone. Differentiated control parameters with varying response speeds are matched to each functional zone to achieve coordinated control of oxygen supply actions across multiple axial furnace sections.

[0090] Combustion chamber 11 is equipped with a continuous, through-flow channel, where flue gas and heat are transferred along fixed paths between the axial furnace sections. When the oxygen supply flow rate of a single axial furnace section changes, the airflow and heat will flow downstream, affecting adjacent axial furnace sections and causing cross-section interference, which in turn leads to local temperature fluctuations. Simultaneously, the entire furnace body 1 is naturally divided into three functional furnace zones according to the biomass pyrolysis process: a preheating zone, a main pyrolysis zone, and a discharge zone. Each functional furnace zone contains several axial furnace sections, and the process objectives and temperature control requirements of different functional furnace zones vary significantly.

[0091] The real-time input data for this module comes from the displacement gradient to segmented temperature field dynamic mapping module and the thermodynamic bidirectional coupling decoupling module: firstly, the local temperature deviation corresponding to each axial furnace segment, which serves as the direct basis for single-segment oxygen supply adjustment; secondly, the global displacement gradient of furnace body 1, which reflects the overall temperature level of the entire furnace and is used as a global adjustment constraint. Both types of data are continuously updated as the equipment operates, ensuring dynamic control of the module.

[0092] The multi-stage oxygen supplementation cross-decoupling and zoned collaborative control module is integrated inside the controller, which is internally divided into three collaborative sub-units: inter-stage compensation logic unit, adjustment and limiting constraint unit, and functional furnace zoned control unit.

[0093] The module input receives local temperature deviations in each axial furnace section and global displacement gradients of furnace body 1; internally, it sequentially performs cross-section interference compensation, global amplitude limiting, and zone parameter matching; finally, it outputs adjustment commands to the electric regulating valve 12 corresponding to each oxygen supply port. The module operates synchronously and continuously with the equipment's oxygen supply actuator, adapting to long-term continuous production modes.

[0094] The direction and propagation rate of flue gas flow in the baffle channel are determined by the equipment cavity structure and the cross-sectional shape of the channel. These are fixed flow field characteristics of the equipment, and the relevant laws are calibrated through hot-state measurements before the equipment leaves the factory.

[0095] When the electric regulating valve 12 corresponding to any axial furnace section performs an opening adjustment action, the module identifies the affected adjacent axial furnace sections based on the predetermined airflow direction and heat transfer law of the baffle channel, and simultaneously calculates the corresponding compensation adjustment amount. By making corresponding fine adjustments to the oxygen supply flow of adjacent axial furnace sections, the airflow disturbance and heat crosstalk generated by the main regulating furnace section are offset, the cross-section interference caused by independent oxygen supply of multiple axial furnace sections is weakened, and the temperature of each furnace section is ensured to be stable. The entire compensation logic is built based on the measured flow field data of the equipment, and the adjustment relationship can be stably reproduced over a long period of time.

[0096] The global displacement gradient of furnace body 1 directly represents the overall temperature status of the entire equipment. In order to avoid excessive adjustment of oxygen supply in a single axial furnace section, which could cause local oxygen supply abnormalities and a significant deviation of the furnace temperature from the process range, the module sets the global displacement gradient as an adjustment hard constraint.

[0097] The module presets upper and lower limits for the opening of the regulating valve and threshold values ​​for the regulating rate to match the global displacement gradient. During each oxygen supply adjustment, the current global displacement gradient value is compared in real time. If the adjustment range of a single segment is about to exceed the allowable range of the global temperature, the module will automatically limit the maximum adjustment amount and action speed of the electric regulating valve 12. This achieves local adjustment conforming to global steady state, optimizing single-segment operating conditions while ensuring that the overall pyrolysis process does not experience significant fluctuations.

[0098] The module divides furnace body 1 into three functional zones according to process attributes: preheating zone, main pyrolysis zone, and discharge zone. Different functional zones are matched with control parameters that have different response speeds. Preheating zone: Its main function is to gradually heat up the biomass feedstock. The process allows for gradual temperature changes, so it is matched with control parameters with low response speed and the regulating valve operates smoothly to avoid frequent fluctuations in oxygen supply. Main pyrolysis zone: This is the core reaction area for biomass gasification and carbonization. It has high requirements for the accuracy of temperature and oxygen supply, and needs to respond quickly to changes in operating conditions. Therefore, it is matched with control parameters with high response speed, and the regulating valve is sensitive to correct temperature deviations in a timely manner. Discharge area: mainly for heat preservation of carbonized products. The process conditions are relatively stable, and control parameters with low response speed are matched to maintain stable operating conditions in the area.

[0099] The module first determines the functional furnace zone to which a single axial furnace section belongs, and then calls the corresponding control parameters to perform adjustments, so that the oxygen supply control logic can adapt to the process requirements of different zones.

[0100] The final adjustment command generated by this module is directly sent to the electric regulating valve 12 of each axial furnace section to complete the segmented oxygen supply adjustment; at the same time, the module's operating data will be shared synchronously with the cross-section flue gas lag compensation function unit to provide a basis for subsequent timing compensation.

[0101] In the entire control system, this module receives the segmented temperature calculation results from the front end and directly drives the core execution components. It also takes into account local optimization and global constraints, single-segment adjustment and cross-segment coordination, and is a key intermediate unit connecting signal processing and process execution.

[0102] Furthermore, the controller is equipped with a cross-section flue gas lag compensation function. This function is different from the conventional fixed parameter compensation mode. It can dynamically adjust the compensation amplitude according to the real-time global displacement gradient of the furnace body 1. When the electric regulating valve 12 of the front axial furnace section performs the opening adjustment action, it can pre-adjust the regulating valve of the adjacent axial furnace section at the rear end in advance to eliminate the temperature control deviation caused by the lag in the cross-section transmission of flue gas and heat.

[0103] Combustion chamber 11 has an integrated baffle channel inside, where flue gas and heat are gradually transferred from the front axial furnace section to the adjacent rear axial furnace section according to a fixed flow direction. This transfer process has an inherent time difference. When the oxygen supply flow rate of a certain front axial furnace section changes, the corresponding temperature change cannot be instantly transferred to the rear region. If only the current furnace section is adjusted, the rear furnace section will experience problems such as temperature response lag and operating condition fluctuations, affecting the overall stability of the pyrolysis process. Therefore, a lag compensation mechanism is required.

[0104] Before the equipment leaves the factory, multiple rounds of hot-state tests are conducted to calibrate the standard transmission sequence of flue gas and heat between adjacent axial furnace sections. This sequence is determined by the structural dimensions, flow cross-section, and conventional flue gas velocity of the baffle channel, providing a fixed basis for controlling the timing of compensation actions.

[0105] The core inputs to this function include two types of real-time data: first, the action signals and opening changes of the front-end axial furnace section regulating valves from the multi-segment oxygen supplementation cross-decoupling and zone collaborative control module; second, the global displacement gradient of the furnace body 1 obtained by the front-end module through calculations by three non-contact displacement sensors 331. Both types of data are updated in real time as the equipment operates, serving as the core basis for dynamically adjusting the compensation amplitude.

[0106] The cross-section flue gas lag compensation function is integrated as a sub-unit within the multi-section oxygen supplementation cross-decoupling and zoned collaborative control module, sharing controller hardware resources and signal interfaces. The function input synchronously acquires the front-end regulating valve action commands and real-time global displacement gradients; internally, it sequentially completes the compensation amplitude calculation, pre-adjustment timing matching, and pre-adjustment command generation; finally, it sends the pre-adjustment command to the electric regulating valve 12 of the adjacent axial furnace section at the back end.

[0107] During equipment operation, the functional unit monitors the working status of all axial furnace section electric regulating valves 12 in real time. When any electric regulating valve 12 in the front axial furnace section receives a regulating command and changes its opening, the functional unit immediately captures the action signal and the specific increase or decrease in opening, as the activation condition for triggering the compensation logic. The global displacement gradient of the furnace body 1 can intuitively reflect the current overall temperature level, flue gas velocity, and heat transfer intensity of the entire furnace, while the degree of lag in flue gas transmission and the range of heat influence will change with the overall temperature and flue gas velocity.

[0108] The functional unit compares the real-time global displacement gradient with the factory-calibrated correspondence table, and dynamically calculates the compensation range required for this pre-adjustment based on the changes in the gradient value. When the overall temperature is high and the flue gas velocity is fast, the compensation range is increased accordingly; when the overall temperature is low and the flue gas velocity is slow, the compensation range is decreased accordingly, so as to achieve adaptive adjustment of the compensation amount according to the furnace condition.

[0109] Based on the flue gas transmission sequence of adjacent axial furnace sections obtained from factory testing, the execution time of pre-conditioning for the downstream adjacent furnace sections is determined. The initiation point of the pre-conditioning action is controlled according to the transmission duration of flue gas and heat, ensuring precise matching between the pre-conditioning action and the delayed temperature effects.

[0110] Based on the calculated compensation range and preset timing, a pre-adjustment command is sent to the electric regulating valve 12 of the adjacent axial furnace section at the rear end to adjust the oxygen supply flow in that area in advance. By intervening in advance, the temperature deviation caused by the lag in the cross-section transmission of flue gas and heat is offset, and abnormal operating conditions such as sudden temperature rises or drops in the rear furnace section are avoided.

[0111] After each round of compensation, the functional unit continuously collects the temperature deviation and global displacement gradient changes of each axial furnace section, and iteratively optimizes the compensation parameters based on the actual temperature control effect. This ensures the adaptability of the compensation logic under different biomass raw materials such as straw, sawdust, and nutshells, as well as under varying production loads.

[0112] This function interfaces upwards with the multi-segment oxygen supplementation cross-decoupling and zoned collaborative control module to obtain main control commands and overall status data; downwards, it directly drives the physical actuator, electric regulating valve 12, in the adjacent axial furnace section. The operational data generated by the compensation action is simultaneously shared with the four-dimensional feature fusion operating condition identification module and the fault classification control unit to assist in the overall equipment operating condition judgment. This entire function is embedded in the complete equipment control chain, not as an independent logical unit, forming a complete closed loop with the mechanical structure, sensing system, and actuators.

[0113] Furthermore, the controller is configured with a layered linkage logic for segmented oxygen supply, feeding, and four-speed drive motors, with priorities in the following order: mechanical fault handling, segmented temperature field adjustment, and overall material load adjustment. During equipment operation, the controller receives real-time data from three non-contact displacement sensors (331) and automatically performs condition judgment, parameter adjustment, fault location, and safety actions according to preset logic.

[0114] The equipment is divided into several axial furnace sections along the axial direction, and each axial furnace section is equipped with an independent electric regulating valve 12; the whole machine is equipped with a drive motor 4, a feeding assembly 2, an audible and visual prompting device, and an emergency stop actuator; three non-contact displacement sensors 331 continuously output displacement data to provide the original physical signal for logical judgment.

[0115] Based on the priorities of industrial safety production and the requirements of biomass pyrolysis process, the preset logic priorities within the controller, from highest to lowest, are: mechanical fault handling, segmented temperature field adjustment, and overall material load adjustment. Mechanical faults directly threaten the structural safety of the equipment, therefore they have the highest priority; segmented temperature fields determine the quality of pyrolysis products, so they have the next highest priority; and overall material load is used for capacity matching, so it has the lowest priority.

[0116] This part of the logic is used for coordinated adjustment of process parameters when the equipment is fault-free. It is divided into two scenarios: uniaxial furnace section abnormality and global temperature gradient abnormality. The actions are executed strictly according to the preset priority.

[0117] When the controller determines that a temperature deviation occurs in a single axial furnace section, it issues an adjustment command only to the electric regulating valve 12 corresponding to that axial furnace section according to the segmented temperature field adjustment rules, and adjusts the local oxygen supply flow separately; the regulating valves, feeding assembly 2 conveying rate, and drive motor 4 speed of the other axial furnace sections all maintain their original operating status, so as to realize the individual correction of local operating conditions and avoid fluctuations in the entire process.

[0118] When the overall temperature gradient of the furnace body 1 deviates from the process range, the controller activates the overall coordinated adjustment rule, controlling the electric regulating valves 12 of multiple axial furnace sections to synchronously and collaboratively adjust the oxygen supply; at the same time, in conjunction with the feed rate of the fine-tuning feed assembly 2, by changing the total filling amount of materials in the furnace to balance the overall heat absorption state, the overall temperature gradient is gradually corrected to ensure the stability of the pyrolysis process of the whole furnace.

[0119] When the equipment malfunctions, the controller activates the fault section location rules. Combining the equipment's hardware characteristics and physical laws, it accurately determines the fault section in three ways, without adding any additional segment detection sensors.

[0120] The controller controls the electric regulating valves 12 corresponding to each axial furnace section to make small, incremental adjustments to their openings, while simultaneously monitoring the displacement gradient changes at both ends fed back by three non-contact displacement sensors 331. Based on the physical laws of axial heat transfer through the baffle channel of furnace body 1, if a significant change in the overall displacement gradient occurs after fine-tuning the valves in a certain axial furnace section, then that location is determined to be a fault section corresponding to an abnormal temperature; furnace sections without a significant response are considered to be operating normally.

[0121] The tilting and local deformation of the shaftless spiral will generate periodic fluctuation signals. These signals propagate along the spiral axis towards both ends and are collected by two end non-contact displacement sensors 331. The controller calculates the time delay difference between the arrival of the fluctuation signals at the two end non-contact displacement sensors 331, and, combined with the signal propagation speed calibrated at the factory and the total axial length of the furnace body 1, calculates the axial position of the local deformation of the spiral based on the time delay difference, thus determining the corresponding fault section.

[0122] The two end ranging baffle assemblies 33 correspond to two sets of non-contact displacement sensors 331 respectively. The controller reads the travel value of each set of sensors individually. If the travel value of a sensor on one side does not change for a long time, it can be directly determined that the ranging baffle assembly 33 on that side is stuck, and the fault section at the corresponding end is locked.

[0123] Once a faulty section of any type or location is identified, the controller prioritizes performing unified protective actions: locking the electric regulating valve 12 corresponding to the faulty section at its current opening degree and ceasing to adjust its opening degree; simultaneously reducing the feed rate of the feeding assembly 2 and lowering the speed of the drive motor 4 to reduce the amount of material conveyed in the furnace and the operating load of the equipment, thus preventing the fault from further escalating from the source.

[0124] Based on the scope and severity of the fault, equipment faults are classified into three levels: early warning, alarm, and emergency shutdown. The controller executes the corresponding action according to the fault level. Fault warning: If the equipment only shows a slight deviation in parameters and there is no substantial operational risk, the controller will trigger an audible and visual warning to remind on-site personnel to monitor the operating conditions, and the equipment will continue to operate under the original load. Fault alarm: The equipment has a moderate abnormality and there is a risk of component wear. The controller will implement load reduction operation to reduce equipment wear while maintaining basic production. Emergency shutdown: If the equipment malfunctions, causing structural damage or safety hazards, the controller will immediately trigger a shutdown action, cutting off the power to the equipment and achieving hard protection.

[0125] During normal equipment operation, the controller prioritizes the execution of layered linkage adjustment logic to ensure stable process parameters. Once abnormal characteristics are detected in the displacement signal, it automatically switches to the fault location logic to pinpoint the fault location. Subsequently, it executes unified handling and graded protection actions according to the fault level. After the fault is cleared, the logic automatically returns to the normal process adjustment mode, and the entire process operates in a closed loop.

[0126] Example 3

[0127] This embodiment provides a gas-coke co-production treatment method applied to the horizontal pusher furnace of Embodiment 1, specifically including the following steps: S1. Raw material loading and feeding operations Biomass raw materials are continuously loaded into the feed hopper 20 at the feed end of the equipment and the unloader 21 is started. The unloader 21 delivers the material quantitatively and in a sealed manner at a preset rate, and smoothly sends the biomass raw materials into the feed end of the reaction chamber 10.

[0128] S2, Material Pushing and Indirect Heat Exchange Operations Start the drive motor 4, which drives the shaftless spiral blade 3 to rotate as a whole. The movable baffles 31, which are arranged alternately between the blades 30, rotate synchronously. The movable baffles 31 lift and scatter along with the blades 30, pushing the biomass raw materials backward at a uniform speed along the axis of the furnace body 1, and increasing the contact area between the material and the wall of the reaction chamber 10, thereby improving the heat exchange efficiency.

[0129] High-temperature flue gas is simultaneously introduced into combustion chamber 11. The flue gas flows along a fixed path through the internal baffle channel of combustion chamber 11, and indirectly exchanges heat through the furnace wall, gradually heating the biomass raw materials in reaction chamber 10 to the pyrolysis temperature set by the process. The flue gas flow rate and baffle path are determined by the inherent structure of the equipment to ensure uniform heating of the entire furnace.

[0130] S3, Pyrolysis reaction and product discharge operations Biomass feedstock heated to the pyrolysis temperature undergoes continuous gasification and carbonization reactions within the reaction chamber 10. The pyrolysis combustible gas generated by the reaction has a relatively low density, and after rising upwards, it is collected and discharged through the gas collection port 13 at the top of the reaction chamber 10, entering the subsequent gas collection and utilization process; The carbonized solid biochar is continuously pushed to the end of the reaction chamber 10 by the shaftless spiral blade 3, and continuously discharged outward through the discharge device 16 to complete the collection of solid products.

[0131] This step is the core reaction process, which is carried out continuously during the material feeding process, realizing a continuous production mode of "conveying, reacting, and discharging at the same time".

[0132] S4, Equipment-wide signal acquisition operation Throughout the entire production cycle from S1 to S3, signal acquisition is carried out synchronously and continuously. The relative sliding displacement between the ranging baffle 330 and the connecting sleeve 33 is collected in real time by two non-contact displacement sensors 331 on the two sets of ranging baffle assemblies 33; the overall axial displacement of the connecting plate 32 on the non-drive motor 4 side is collected by a non-contact displacement sensor 35 arranged on the non-drive motor 4 side.

[0133] All displacement monitoring signals collected by the three sensors are transmitted to the controller in real time. The data acquisition work runs in parallel with the production process without interruption or downtime, reflecting the mechanical deformation, thermal expansion and overall operating status of the equipment in real time.

[0134] S5. Parallel Data Operations and State Determination After receiving the displacement monitoring signal, the controller performs multiple sets of data calculations and operating condition judgments in parallel, which is a processing procedure that runs synchronously in the background of the equipment: relying on the thermo-mechanical bidirectional coupling decoupling logic, the original displacement signal is decomposed and the three types of state variables of the furnace body 1 global temperature gradient, axial load, and mechanical deformation are analyzed; relying on the displacement gradient to segmented temperature field mapping logic, combined with the equipment structure and heat transfer law, the local temperature deviation corresponding to each axial furnace section is calculated.

[0135] Based on four-dimensional feature fusion operating condition recognition logic, multiple types of signal features are extracted to simultaneously determine the current operating status and fault type of the equipment. The three types of operations are executed independently and synchronously, and the operation results are output to the control execution stage in real time.

[0136] S6. Segmented oxygen supply regulation and graded fault handling Based on the calculated local temperature deviation of each axial furnace section, the controller sends adjustment commands to the corresponding electric regulating valve 12 to independently complete the segmented oxygen supply control; it also synchronously adjusts the feed rate of the unloader 21 and the speed of the drive motor 4 to match the process requirements of biomass pyrolysis.

[0137] Simultaneously, based on the fault determination results and fault section location results, graded fault handling actions are executed: maintaining stable process parameters under normal operating conditions; after identifying the fault, locking the valves in the fault section, reducing the load, and executing corresponding safety actions according to the three-level rules of early warning, alarm, and emergency shutdown to ensure equipment and production safety.

[0138] The above description only illustrates preferred embodiments of the present invention, but the present invention is not limited to the above embodiments.

Claims

1. A horizontal pusher furnace, characterized in that: It includes a furnace body (1) and a feeding assembly (2). The furnace body (1) is divided into a reaction chamber (10) and a combustion chamber (11) from top to bottom. The feeding assembly (2) is connected to the reaction chamber (10). The combustion chamber (11) is provided with a baffle channel, which is connected to multiple oxygen supply ports. Each oxygen supply port is equipped with an electric regulating valve (12). The reaction chamber (10) is equipped with a shaftless spiral blade (3), and there are staggered movable baffles (31) between adjacent blades (30); both ends of the shaftless spiral blade (3) are fixed with connecting disks (32), and there are distance measuring baffle assemblies (33) between the connecting disks (32) at both ends and the adjacent blades (30); the connecting disks (32) are equipped with connecting shafts (34). Both sets of ranging baffle assemblies (33) include a ranging baffle (330) and a connecting sleeve (33). The ranging baffle (330) and the connecting sleeve (33) are slidably connected. Each ranging baffle (330) is provided with a non-contact displacement sensor (331). The sensor line passes through the connecting shaft (34) and is connected to the conductive slip ring (36) on the connecting shaft (34). A non-contact displacement sensor (35) is provided on the outside of the connecting plate (32) on the side not connected to the drive motor (4). It also includes a controller, which analyzes the operating status of the furnace body (1) based on the acquisition signals of the non-contact displacement sensor 1 (331) and the non-contact displacement sensor 2 (35), calculates the temperature deviation of the axial furnace section corresponding to each oxygen supply port, drives the electric regulating valve (12) to realize segmented oxygen supply, synchronously adjusts the operating parameters of the feeding component (2) and the drive motor (4), and performs fault classification control according to the equipment operating status.

2. The horizontal pusher furnace according to claim 1, characterized in that: The controller has a built-in thermodynamic bidirectional coupling and decoupling module. It is designed based on the thermal expansion characteristics of the stainless steel material used in the shaftless spiral blade (3), the overall structural rigidity of the spiral, and the structural characteristics of the measuring baffle assembly (33) which is subjected to compressive stress. It includes two functional parts: forward decoupling and reverse decoupling. The forward decoupling part judges the temperature gradient of the furnace body (1) based on the signals collected by the non-contact displacement sensor 1 (331) on both sides of the measuring baffle assembly (33), and extracts the axial load of the equipment from the signals collected by the non-contact displacement sensor 2 (35) on the outside. The reverse decoupling part uses the axial load to correct the deformation error caused by material extrusion in the signal of the non-contact displacement sensor 1 (331).

3. The horizontal pusher furnace according to claim 1, characterized in that: The controller has a built-in displacement gradient to segmented temperature field dynamic mapping module, which is set in combination with the segment length of the furnace body (1), the heat dissipation characteristics of the baffle channel, and the axial heat absorption law of biomass material pyrolysis. It includes two functional parts: gradient decomposition and heat absorption compensation. The gradient decomposition part divides the overall displacement gradient of the furnace body (1) into the local temperature deviation corresponding to each axial furnace segment. The heat absorption compensation part combines the axial load state to correct the local temperature deviation by material heat absorption.

4. The horizontal pusher furnace according to claim 1, characterized in that: The controller has a built-in four-dimensional feature fusion working condition recognition module, which extracts four types of features: the time-domain average state of the displacement signal, the frequency-domain fluctuation state synchronized with the speed of the drive motor (4), the real-time change rate of the signal, and the displacement difference between the two non-contact displacement sensors (331), and sets corresponding judgment rules. If the time-domain average state deviates from the normal baseline and the frequency domain shows synchronous fluctuation, it is judged as shaftless spiral tilting and deflection. If the instantaneous change amplitude of the signal suddenly increases, it is judged as material bridging. If the displacement difference between the two sides exceeds the normal range, it is judged as abnormal furnace temperature. If the displacement on both sides remains constant and the axial load continues to rise, it is judged as jamming of the distance measuring baffle assembly (33).

5. The horizontal pusher furnace according to claim 1, characterized in that: The controller is equipped with an online self-calibration function. It works based on the normal range of the axial displacement gradient of the furnace body (1). During operation, it extracts the average value of the low-frequency component of the displacement signal to calculate the zero-point offset, corrects the sensor output data in different temperature ranges, and completes the calibration operation during continuous operation of the equipment.

6. The horizontal pusher furnace according to claim 1, characterized in that: The controller has a built-in multi-segment oxygen supply cross-decoupling and zone collaborative control module. It combines the airflow direction of the baffle channel to set the inter-segment compensation logic and sets the displacement gradient of the furnace body (1) as the adjustment limit constraint. The module divides the furnace body (1) into three functional furnace areas: main pyrolysis zone, preheating zone and discharge zone for zoned management. Different functional furnace areas are matched with control parameters with different response speeds to weaken the cross-segment interference caused by independent oxygen supply of multiple axial furnace sections.

7. The horizontal pusher furnace according to claim 6, characterized in that: The controller is equipped with a cross-section flue gas hysteresis compensation function, which adjusts the compensation amplitude according to the real-time displacement gradient change; when the electric regulating valve (12) of the front axial furnace section is activated, the regulating valve of the adjacent axial furnace section at the rear end performs a pre-adjustment action synchronously to offset the temperature control deviation caused by the cross-section transmission of flue gas and heat.

8. The horizontal pusher furnace according to claim 1, characterized in that: The controller is set with a hierarchical linkage logic for segmented oxygen supply, feeding, and drive motor (4) speed, with priority order as follows: mechanical fault handling, segmented temperature field adjustment, and overall material load adjustment; when the temperature of a single axial furnace section is abnormal, only the regulating valve of the corresponding axial furnace section is adjusted; when the overall temperature gradient exceeds the standard, the regulating valves of multiple axial furnace sections are adjusted in coordination and the feeding amount is used to balance heat absorption; the controller has built-in fault section positioning logic: by adjusting the electric regulating valve (12) of each oxygen supply port segment by segment, the change response of the displacement gradient at both ends is observed to locate the abnormal temperature position; the position of the local deformation of the spiral is calculated by the time delay difference of the wave signal reaching the non-contact displacement sensor (331) at both ends; the position of the stuck single-sided ranging baffle assembly (33) is determined by the stroke value of each non-contact displacement sensor at both ends; after identifying the equipment fault, the electric regulating valve (12) corresponding to the fault section is locked at the current opening, and the feeding amount and motor speed are reduced simultaneously. The fault status is divided into three levels: warning, alarm, and emergency shutdown, and corresponding audio-visual prompts, load reduction, and overall machine shutdown are executed.

9. A method for cogeneration of gas and carbon in a horizontal pusher furnace as described in claim 1, characterized in that: Includes the following steps: S1. Load the biomass raw materials into the silo (20) and send the biomass raw materials into the reaction chamber (10) through the unloader (21); S2. Start the drive motor (4) to drive the shaftless spiral blade (3) and its movable baffle (31) to operate, lift and throw the biomass raw material and push it backward; at the same time, high temperature flue gas is introduced into the combustion chamber (11), and the flue gas flows along the baffle channel to heat the biomass raw material to the pyrolysis temperature through indirect heat exchange. S3. The biomass raw material is heated in the reaction chamber (10) and undergoes gasification and carbonization reaction. The generated pyrolysis combustible gas rises and converges and is discharged through the gas collection port (13). The generated biomass char is transported to the discharge device (16) and discharged through the discharge device (16). S4. The equipment synchronously carries out signal acquisition work throughout the process. The relative sliding displacement between the distance measuring baffle (330) and the connecting sleeve (33) is collected by the two non-contact displacement sensors (331) on the two sets of distance measuring baffle assemblies (33). The axial displacement of the connecting plate (32) on the non-drive motor (4) side is collected by the two non-contact displacement sensors (35) on the outside to obtain displacement monitoring signals. S5. Parallel data calculation and status determination: Based on the thermo-mechanical bidirectional coupling decoupling module, the three types of state quantities of the furnace body (1) global temperature gradient, axial load and mechanical deformation are analyzed. Based on the displacement gradient to segmented temperature field dynamic mapping module, the local temperature deviation of each axial furnace section is calculated. At the same time, based on the four-dimensional feature fusion working condition identification module, the current operating status and fault type of the equipment are determined. S6. Drive the corresponding independent electric regulating valve (12) according to the local temperature deviation of each axial furnace section to complete the segmented oxygen supply, synchronously adjust the feed rate, feed speed and drive motor (4) speed, and perform graded fault handling in combination with the fault judgment result and fault section location result.

10. The gas-coke co-production treatment method according to claim 9, characterized in that: During the entire operation of the equipment, two auxiliary operations are performed in parallel. One is to correct the sensor zero-point offset in real time based on the conventional range of the axial displacement gradient of the furnace body (1) and the average value of the low-frequency component of the displacement signal, without stopping the machine throughout the process. Second, continuously collect the whole furnace operation data. For various biomass raw materials and different production loads, based on the long-term statistical characteristics of displacement signals, correct the control parameters of each electric regulating valve (12) according to the preset rule table. The control parameters are smoothly transitioned when switching raw materials and adjusting load. During operation, the valve is finely adjusted segment by segment to observe the displacement gradient response and analyze the time delay difference of the fluctuation signal to reverse determine the specific fault section.

Images