Data processing system for a fluidized bed reactor and fluidized bed reactor

Abstract

The application provides a data processing system and fluidized bed reactor, comprising: a data acquisition module, a data processing module and a man-machine interaction module; the data acquisition module is used for collecting process parameters of the fluidized bed reactor; the data processing module is used for filtering and engineering unit conversion of the collected process parameters, and real-time control according to a preset process logic; the man-machine interaction module is used for determining a process flow chart, parameter values and alarm information based on the process parameters, and displaying the process flow chart, parameter values and alarm information. In this way, full-link accurate tracing can be realized, the system supports multi-dimensional data association, the root cause can be quickly locked and the problem can be prevented from recurring; data deep value mining can also be realized, and intuitive trend curves, flexible data export and advanced analysis tools are provided.

Description

Technical Field

[0001] This invention relates to the field of fluidized bed reactor technology, and in particular to a data processing system for a fluidized bed reactor and a fluidized bed reactor. Background Technology

[0002] Currently, existing fluidized bed reactor control systems focus on real-time data display and basic control, but lack the function of systematic recording and analysis of historical data. Operators need to rely on instrument readings or simple notebooks for process monitoring.

[0003] Existing fluidized bed reactor control systems mainly suffer from the following defects: 1. Poor traceability: When product quality fluctuates or abnormal operating conditions occur, it is impossible to effectively trace back the process, making it difficult to locate the root cause and causing the problem to recur.

[0004] 2. Low data utilization efficiency: Even if some systems have data recording functions, they are often stored in simple text or table form, lacking intuitive curve display, data export and secondary analysis tools, which makes it difficult to meet the needs of R&D and production departments for in-depth data mining. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a data processing system and a fluidized bed reactor for recording and analyzing multi-parameter historical data of the fluidized bed reactor. It is applicable to data acquisition, storage, analysis and traceability in complex processes such as silicon-carbon anode material preparation, carbon coating, and catalyst activation, which are carried out under high temperature, multiple atmospheres and multiple stages.

[0006] In a first aspect, embodiments of the present invention provide a data processing system for a fluidized bed reactor. The data processing system for the fluidized bed reactor includes: a data acquisition module, a data processing module, and a human-machine interaction module. The data acquisition module is used to acquire process parameters of the fluidized bed reactor. The data processing module is used to filter and convert the acquired process parameters into engineering units, and to perform real-time control according to preset process logic. The human-machine interaction module is used to determine the process flow diagram, parameter values, and alarm information based on the process parameters, and to display the process flow diagram, parameter values, and alarm information.

[0007] In optional embodiments of this application, the above process parameters include: multi-point temperature inside the reactor, reactor pressure, water-cooled tank pressure, reactor inner and outer wall temperature, carrier gas flow rate, reaction gas flow rate, protective gas flow rate, heating module current and voltage, stirring motor speed and current, water-cooled tank weight, oxygen content, and valve on / off status feedback.

[0008] In optional embodiments of this application, the aforementioned data acquisition module is used to acquire multiple temperatures inside the reactor and the temperatures of the inner and outer walls of the reactor through temperature sensors deployed inside the reactor; the data acquisition module is used to acquire reactor pressure and water-cooled tank pressure through a pressure transmitter; the data acquisition module is used to acquire carrier gas flow rate, reaction gas flow rate, and protective gas flow rate through a mass flow controller; the data acquisition module is used to acquire heating module current and voltage through a current transformer connected in series in the heating element; the data acquisition module is used to acquire the weight of the water-cooled tank through a weighing sensor installed at the bottom of the water-cooled tank; the data acquisition module is used to acquire oxygen content through a zirconia oxygen sensor inserted into the tail gas pipe; and the data acquisition module is used to acquire valve opening and closing status feedback through a dual redundant magnetic limit switch installed on the valve.

[0009] In an optional embodiment of this application, the data acquisition module includes: a K-type thermocouple, which is arranged at different axial positions of the reactor and inside the heating module; each heating module is equipped with an independent temperature control thermocouple and a temperature measuring thermocouple.

[0010] In an optional embodiment of this application, the data processing module includes: a data preprocessing unit, an engineering unit conversion unit, and a real-time process control unit; the data preprocessing unit is used to perform sliding window mid-value filtering and abnormal data interpolation replacement processing on the collected process parameters; the engineering unit conversion unit is used to convert the process parameters into engineering units by table lookup interpolation; and the real-time process control unit is used to construct a variable control matrix from the process parameters through a pre-written process logic control program.

[0011] In an optional embodiment of this application, the data processing module described above is also used to upload process parameters.

[0012] In an optional embodiment of this application, the data processing module further includes: an upper-layer interface service unit; the upper-layer interface service unit is used to upload process parameters through an open user communication interface and an open platform communication unified architecture interface.

[0013] In an optional embodiment of this application, the aforementioned human-computer interaction module includes: a historical curve unit, a data export unit, an alarm history unit, and a statistical analysis unit; the historical curve unit is used to display the changing trend of process parameters within a selected time period as a process flow diagram in the form of a curve graph; the data export unit is used to export the historical data of the selected process parameters into a general format file; the alarm history unit is used to query and statistically analyze alarm information by time, type, and process segment; wherein, the alarm information includes: alarm occurrence time, alarm content, alarm value, and recovery time; the statistical analysis unit is used to perform statistical analysis on the historical data of process parameters and generate statistical analysis reports.

[0014] In optional embodiments of this application, the human-computer interaction module described above is also used to provide a user operation interface.

[0015] Secondly, embodiments of the present invention also provide a fluidized bed reactor, the fluidized bed reactor including: the data processing system of the above-mentioned fluidized bed reactor.

[0016] The embodiments of the present invention bring the following beneficial effects: This invention provides a data processing system and a fluidized bed reactor for a fluidized bed reactor. The system includes a data acquisition module for collecting process parameters of the fluidized bed reactor; a data processing module for filtering and converting the collected process parameters to engineering units, and performing real-time control according to preset process logic; and a human-machine interaction module for determining the process flow diagram, parameter values, and alarm information based on the process parameters, and displaying these information. This approach enables precise end-to-end traceability, supports multi-dimensional data correlation, quickly identifies the root cause, and prevents problem recurrence. It also allows for in-depth data value mining, providing intuitive trend curves, flexible data export, and advanced analysis tools.

[0017] Other features and advantages of this disclosure will be set forth in the following description, or some features and advantages may be inferred from the description or determined without doubt, or may be learned by practicing the techniques described above.

[0018] To make the above-mentioned objects, features and advantages of this disclosure more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0019] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of a data processing system for a fluidized bed reactor provided in an embodiment of the present invention; Figure 2 A schematic diagram illustrating the display content of a historical curve unit provided in an embodiment of the present invention; Figure 3 A schematic diagram illustrating the display content of an alarm history unit provided in an embodiment of the present invention; Figure 4 A schematic diagram illustrating the display content of a data export unit provided in an embodiment of the present invention; Figure 5A schematic diagram illustrating the display content of a statistical analysis unit provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of the arrangement of a temperature sensor on a reactor according to an embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of a fluidized bed reactor provided in an embodiment of the present invention. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Currently, existing fluidized bed reactor control systems mainly suffer from the following defects: 1. Poor traceability: When product quality fluctuates or abnormal operating conditions occur, it is impossible to effectively trace back the process, making it difficult to locate the root cause and causing the problem to recur.

[0023] 2. Low data utilization efficiency: Even if some systems have data recording functions, they are often stored in simple text or table form, lacking intuitive curve display, data export and secondary analysis tools, which makes it difficult to meet the needs of R&D and production departments for in-depth data mining.

[0024] Based on this, the present invention provides a data processing system and a fluidized bed reactor, specifically a multi-parameter historical data recording and analysis system for fluidized bed reactors, which can solve the problems of insufficient traceability of process data and lack of visualization and in-depth analysis capabilities of production data, realize complete traceability and root cause localization of production process data, and meet the data mining needs of R&D and production departments.

[0025] To facilitate understanding of this embodiment, a detailed description of a data processing system for a fluidized bed reactor disclosed in this embodiment of the invention will be provided first.

[0026] Example 1: This invention provides a data processing system for a fluidized bed reactor. See [link to relevant documentation]. Figure 1The diagram shows a structural schematic of a data processing system for a fluidized bed reactor. This system includes: a data acquisition module, a data processing module, and a human-machine interface module. The data acquisition module is used to acquire the process parameters of the fluidized bed reactor. The data processing module is used to filter and convert the acquired process parameters to engineering units, and to perform real-time control according to preset process logic. The human-machine interface module is used to determine the process flow diagram, parameter values, and alarm information based on the process parameters, and to display the process flow diagram, parameter values, and alarm information.

[0027] I. Data Acquisition Module: The data acquisition module in this embodiment may include multiple sensors for real-time acquisition of process parameters of the fluidized bed reactor.

[0028] The process parameters include: multi-point temperature inside the reactor, reactor pressure, water-cooled tank pressure, reactor inner and outer wall temperature, carrier gas flow rate, reaction gas flow rate (such as silane, acetylene, etc.), protective gas flow rate, heating module current and voltage, stirring motor speed and current, water-cooled tank weight, oxygen content, and feedback on the on / off status of key valves.

[0029] In some embodiments, the data acquisition module is used to acquire multiple temperatures inside the reactor and the temperatures of the inner and outer walls of the reactor via temperature sensors deployed inside the reactor; the data acquisition module is used to acquire reactor pressure and water-cooled tank pressure via a pressure transmitter; the data acquisition module is used to acquire carrier gas flow rate, reactant gas flow rate, and protective gas flow rate via a mass flow controller; the data acquisition module is used to acquire heating module current and voltage via a current transformer connected in series in the heating element; the data acquisition module is used to acquire the weight of the water-cooled tank via a weighing sensor installed at the bottom of the water-cooled tank; the data acquisition module is used to acquire oxygen content via a zirconia oxygen sensor inserted into the exhaust gas pipe; and the data acquisition module is used to acquire valve opening / closing status feedback via a dual redundant magnetic limit switch installed on the valve.

[0030] The specific implementation steps of the data acquisition module in this embodiment may include: 1. Multi-point temperature acquisition: K-type or S-type armored thermocouples (accuracy ±0.5℃) are deployed at key locations such as the reactor inner wall, central area, and upper part of the bed. Each point is independently wired to avoid electromagnetic interference. After signal conditioning by an isolated differential amplifier, it is acquired by a 24-bit high-resolution Σ-Δ ADC (Sigma-Delta ADC) with a sampling frequency ≥10Hz. The data is uploaded to the PLC (Programmable Logic Controller) via RS-485 (a physical layer electrical standard for serial communication) bus to realize dynamic modeling of the multi-point temperature field.

[0031] 2. Pressure and Flow Parameter Acquisition: Equipped with a ceramic capacitive pressure transmitter featuring temperature compensation and self-diagnostic functions. Utilizing a thermal mass flow controller, it directly outputs a 4–20mA or Modbus RTU (a serial communication protocol widely used in industrial automation) signal, supporting accurate metering of corrosive gases such as silane and acetylene, with a response time of <50ms.

[0032] 3. Heating Module and Motor Status Monitoring: A high-precision current transformer is connected in series with the heating element SCR (Silicon Controlled Rectifier). The PLC synchronously collects voltage and current data, calculates real-time power and energy consumption, and the SCR maintains the set temperature curve through PID (Proportional-Integral-Derivative) closed-loop control. A 1000-line incremental encoder is installed at the motor shaft end, and combined with the feedback signal from the servo driver, the rotational speed (±0.1 rpm accuracy) and load current are acquired in real time. Abnormal torque fluctuations can trigger anti-caking protection logic.

[0033] 4. Weight acquisition of water-cooled tank: Install a 3-point S-type load cell (range 500kg, accuracy ±0.1%) at the bottom of the water-cooled tank. The output signal is converted into a 4–20mA or Modbus RTU signal by an instrumentation amplifier.

[0034] 5. Oxygen content monitoring: Install a zirconia oxygen sensor with an operating temperature ≥700℃. It can be directly inserted into the exhaust gas pipe with a response time <3s and an accuracy of ±0.1%O2. It is used for explosion-proof safety interlocking.

[0035] 6. Valve Status Acquisition: All critical valves (such as inlet valves, exhaust valves, and bypass valves) are equipped with dual redundant magnetic limit switches (normally open + normally closed contacts). The signals are input to the PLC digital input module, and the actual opening and closing status of the valves is determined by a status consistency verification algorithm (such as "AND gate logic") to prevent process accidents caused by signal misjudgment.

[0036] In some embodiments, the data acquisition module includes: a type K thermocouple, which is arranged at different axial positions of the reactor and inside the heating module; each heating module is equipped with an independent temperature control thermocouple and a temperature measurement thermocouple.

[0037] As a further improvement of the present invention, the data acquisition module can use K-type thermocouples and be arranged at different axial positions of the reactor (such as the conical section, straight section, and enlarged section) and inside the heating module to obtain the temperature distribution inside the reactor; each heating module is equipped with an independent temperature control thermocouple and a temperature measuring thermocouple, with a total of no less than 16 temperature measuring points.

[0038] II. Data Processing Module: In some embodiments, the data processing module described above is also used to upload process parameters.

[0039] The data processing module in this embodiment mainly includes a PLC central processing unit, which is responsible for preprocessing, filtering, and converting the collected data into engineering units, and performing real-time control according to the preset process logic; at the same time, this layer is also responsible for packaging the processed data and uploading it to the data storage layer, and providing a data interface for upper-layer applications.

[0040] In some embodiments, the data processing module includes: a data preprocessing unit, an engineering unit conversion unit, and a real-time process control unit; the data preprocessing unit is used to perform sliding window mid-value filtering and abnormal data interpolation substitution processing on the collected process parameters; the engineering unit conversion unit is used to convert the process parameters into engineering units by table lookup interpolation; the real-time process control unit is used to construct the process parameters into a variable control matrix through a pre-written process logic control program.

[0041] In some embodiments, the data processing module further includes: an upper-layer interface service unit; the upper-layer interface service unit is used to upload process parameters through an open user communication interface and an open platform communication unified architecture interface.

[0042] The data processing module in this embodiment may include: 1. Data Preprocessing Unit: After receiving raw sensor data (such as temperature fluctuations of ±0.5℃, pressure noise of ±0.1%FS), the PLC immediately activates a sliding window mid-range filter (window length = 5, sampling period = 100ms) to effectively suppress pulse interference. Simultaneously, a 3σ (σ is the standard deviation) dynamic threshold method is introduced: based on 200 historical data sets, the mean and standard deviation are calculated. Data points exceeding ±3σ are marked as abnormal and interpolated, ensuring that the control logic is not falsely triggered by momentary glitches, improving signal stability to 98.7%.

[0043] 2. Engineering Unit Conversion Unit: For different sensor outputs (such as 4–20mA, 0–10V, Modbus (an open communication protocol widely used in industrial automation) register values), the PLC has a built-in multi-channel engineering unit conversion table. For example: pressure transmitter (0–10bar→4–20mA); thermocouple (K-type, mV→℃): a lookup table interpolation algorithm is used, achieving an accuracy of ±0.3℃, avoiding linear approximation errors. All conversion logic is stored in a non-volatile EEPROM (Electrically Erasable Programmable Read-Only Memory), supporting automatic loading after power failure, ensuring that recalibration is not required after system restart.

[0044] 3. Real-time process control unit: The PLC runs a pre-written logic control program, selects equipment status according to process steps, and monitors various feedback data (temperature, pressure, flow rate, valve status, etc.) to complete the construction of a multivariable control matrix. For example: when the pressure rises above the limit, heating is automatically stopped and the exhaust valve is opened to prevent explosion; when the weight of the water-cooled tank is lower than the set value, the interlock logic of "closing the water-cooled tank backflush valve + allowing furnace discharge" is triggered.

[0045] 4. Upper-level interface service unit: The PLC simultaneously provides two interfaces to deliver data: OUC (Open User Communication) interface: including TCP (Transmission Control Protocol), ISO on TCP (International Organization for Standardization Transmission Protocol), and UDP (User Datagram Protocol), used for data communication with equipment or systems; OPCUA (Open Platform Communication Unified Architecture) interface: can act as an OPCUA server to provide data to upper-level systems such as SCADA (Supervisory Control and Data Acquisition) and MES (Manufacturing Execution System) in a secure and cross-platform manner.

[0046] III. Human-Computer Interaction Module: In some embodiments, the human-computer interaction module is also used to provide a user operation interface.

[0047] The human-machine interaction module in this embodiment may include a touch screen human-machine interface (HMI) or a host computer monitoring system, used to display process flow diagrams, parameter values, alarm information in real time, and provide a user operation interface.

[0048] In some embodiments, the human-computer interaction module includes: a historical curve unit, a data export unit, an alarm history unit, and a statistical analysis unit; the historical curve unit is used to display the changing trend of process parameters within a selected time period as a process flow diagram in the form of a curve graph; the data export unit is used to export the historical data of the selected process parameters into a general format file; the alarm history unit is used to query and statistically analyze alarm information by time, type, and process segment; wherein, the alarm information includes: alarm occurrence time, alarm content, alarm value, and recovery time; the statistical analysis unit is used to perform statistical analysis on the historical data of process parameters and generate statistical analysis reports.

[0049] The human-computer interaction module in this embodiment includes: 1. Historical Curve Unit: This unit displays the changing trends of multiple process parameters within a selected time period in the form of a curve graph. It supports curve scaling, translation, cursor reading of values, and multi-curve overlay comparison functions.

[0050] In this embodiment, a "historical trend" screen can be created on the touchscreen using the MCGS (Monitor and Control Generated System) embedded configuration software. It reads 15 types of process parameters (such as temperature, pressure, and flow rate) from the PLC in real time via TCP protocol and calls the built-in Trend control (a software component for real-time or historical data visualization). It supports: custom time ranges (1h / 24h / 7d / 30d); multiple curve overlays (up to 8 curves, distinguished by different colors and line types); mouse wheel zooming, dragging and panning, and cursor hovering to read precise values ​​(accuracy ±0.1%FS). Simultaneously, the WinCC (Windows Control Center) host computer synchronously reads the same data stream via TCO / IP, enabling the real-time curve function of the WINCConline TrendControl (the core control for real-time and historical data visualization), and storing the data permanently in the WinCC database in .hda format.

[0051] 2. Data export unit, used to export selected historical data into common format files (such as CSV, Excel, TXT) for users to perform offline analysis or generate reports.

[0052] In this embodiment, a "Data Export" button can be set in the HMI interface to trigger the export function of the local SQLite database (a lightweight, embedded, zero-configuration relational database engine) (with built-in storage of ≥30 days of sampled data). It supports parameter selection and time range selection, and outputs in CSV / TXT format. The file naming rule is [Device ID]_[Parameter Name]_[YYYYMMDD-HHMMSS].csv, and it is automatically saved to a USB drive. On the WinCC side, a VBScript script (a lightweight, interpreted scripting language) calls a pre-formatted Excel template with all formats, charts, and signature bars. It retrieves the required data from WinCC's historical database (e.g., through SQL queries) and then accurately fills the data into the specified cells of the template. Historical data can be exported in batches as Excel (.xlsx) files. The export task supports scheduled processing (e.g., automatically generating the previous day's daily report at 2 AM) and is automatically uploaded to the enterprise FTP (Text Transfer Protocol) server.

[0053] 3. Alarm history unit, used to record information such as alarm occurrence time, alarm content, alarm value, and recovery time, and supports querying and statistics by time, type, and work section.

[0054] In this embodiment, an alarm event buffer (capacity ≥ 5000 entries) can be configured in the HMI to record the occurrence time, alarm ID, alarm value, current work section, and operator confirmation status of each alarm. Upon alarm triggering, an audible and visual alert immediately pops up in the HMI, and the data is written to the local database. WinCC activates the alarm record in the project manager and selects appropriate controls: the Alarm Control displays currently occurring alarms that have not yet been cleared; the Alarm Archive Control is specifically used to query and display historical alarm records. Alarms are clearly categorized into different levels and distinguished by color. Hard faults causing downtime or posing safety risks (such as motor overload or emergency stop button pressed) are highlighted in red; abnormal states requiring attention but not immediate shutdown (such as low liquid level or temperature approaching the upper limit) are indicated in yellow; normal equipment state transitions or production events can be displayed in white or gray. Through the configured Alarm Archive Control, operators can set a time range (such as "past 8 hours" or a custom start and end time) to query all historical alarms within that time period.

[0055] 4. Statistical analysis unit, used to perform simple statistical analysis on historical data, such as average, maximum, minimum, standard deviation, cumulative amount, etc., and supports report generation.

[0056] In this embodiment, statistical analysis of historical data (average, maximum, minimum, standard deviation, cumulative amount) and report generation can be achieved through WinCC Advanced Reporting. Open the WinCC OLE DB Provider for Archives control in the WinCC graphical editor. In the control properties, select WinCC process archive (Tag Logging) or user archive as the data source and check the variables that need to be statistically analyzed. In the "Statistics" or "Calculation" tab of the control, check the required functions (such as average, maximum, minimum, standard deviation, cumulative amount), associate with the Excel template, and export the data.

[0057] This invention provides a data processing system for a fluidized bed reactor. The system includes a data acquisition module for collecting process parameters of the fluidized bed reactor; a data processing module for filtering and converting the acquired process parameters to engineering units, and performing real-time control according to preset process logic; and a human-machine interaction module for determining the process flow diagram, parameter values, and alarm information based on the process parameters, and displaying these information. This approach enables precise end-to-end traceability, supports multi-dimensional data correlation, quickly identifies root causes, and prevents problem recurrence. It also allows for in-depth data value mining, providing intuitive trend curves, flexible data export, and advanced analysis tools.

[0058] Example 2: This invention provides an overall architecture for a data processing system for a fluidized bed reactor, which includes a data acquisition module, a data processing module, and a human-computer interaction module.

[0059] I. The data acquisition layer comprises multiple sensors and actuators. Specifically, it includes: (1) Temperature sensor: K-type thermocouples are used, a total of 16, which are installed on the six heating modules of the reactor. Each module contains two thermocouples (one for temperature control and one for temperature measurement). In addition, there are also preheating thermocouples for the reactor inlet gas and temperature measuring thermocouples for the upper and lower parts of the water-cooled tank.

[0060] (2) Pressure sensors: including reactor pressure sensor (range -0.1~0.1MPa), water-cooled tank pressure sensor (range -0.1~0.1MPa), and gas source pressure gauge (used to monitor the pressure of gas sources such as nitrogen and silane).

[0061] (3) Flow sensors: including mass flow meters, used to accurately control the flow of gases such as nitrogen, silane, and acetylene; and rotor flow meters, used to monitor the flow of auxiliary gas paths such as protective gas.

[0062] (4) Current / voltage sensor: used to monitor the power supply current and voltage of each heating module, as well as the current of the stirring motor.

[0063] (5) Weight sensor: installed at the bottom of the water-cooled tank to weigh the material inside the water-cooled tank and determine whether the discharge is complete.

[0064] (6) Switching sensor: used to monitor the switching status feedback of various pneumatic valves, piston valves, sampling valves, etc.

[0065] (7) Other sensors: such as oxygen content analyzer (optional), exhaust emission parameter sensors (temperature, pressure), etc.

[0066] All of the above sensors are connected to the distributed I / O (input / output) module or directly to the input module of the PLC via shielded cables to ensure the stability and anti-interference of signal transmission.

[0067] II. The core of the data processing module is the PLC. This PLC performs the following functions: real-time scanning and acquisition of analog and digital signals from various sensors; filtering the acquired raw data (e.g., using first-order hysteresis filtering or median filtering) to remove high-frequency noise; converting the acquired electrical signals (e.g., 4-20mA, thermocouple millivolt signals) into actual engineering unit values ​​(e.g., ℃, kPa, L / min, kg); executing preset control logic, such as heating PID control, flow PID control, valve interlock control, safety protection logic, etc.; packaging the processed real-time data at fixed time intervals (e.g., 1 second, 5 seconds, or dynamically adjusted according to the parameter change rate), and transmitting it via industrial Ethernet 205 to the human-machine interface module 300. III. The human-machine interface module uses one industrial touchscreen and one engineering workstation computer. The touchscreen is mainly used for on-site operation and monitoring, while the engineering workstation is used for advanced data analysis, report generation, and system configuration. The human-machine interface mainly includes the following core modules: 1. Real-time monitoring screen: Dynamically displays the equipment operating status in the form of a flowchart, including temperature, pressure, flow rate, valve status, motor status, etc., and supports real-time curve display of parameters.

[0068] 2. Historical Curve Unit: Users can select one or more parameters (such as reactor upper section temperature, reactor middle section temperature, reactor pressure, nitrogen flow rate, etc.) and set the start and end times. The system then retrieves data from the database and displays it as a curve. The curve supports zooming, panning, cursor reading, curve hiding / showing, etc. See [link to documentation]. Figure 2 The diagram shows the display content of a historical curve unit. The historical curve interface includes a timeline selector, a parameter selection box, a curve display area, a cursor value display area, and an export button.

[0069] 3. Alarm History Unit: Records all alarm events, including alarm time, alarm type, alarm value, limit, recovery time, and confirmation time. Users can filter and query by date, alarm level, device tag number, etc., and can also count alarm frequency. (See also...) Figure 3 The diagram shows the display content of an alarm history unit.

[0070] 4. Data Export Unit: After selecting parameters and time range, users can click the "Export" button. The system will save the data in CSV format to a USB drive or network path. Export options include whether to include a header row, timestamp format, data interval, etc. See [link to relevant documentation]. Figure 4 The diagram shows the display content of a data export unit.

[0071] 5. Statistical Analysis Module: Provides commonly used statistical functions, such as calculating the average, maximum, minimum, and standard deviation of a parameter within a specified time period, as well as cumulative traffic flow and cumulative electricity consumption. Statistical results can be displayed in tabular or bar chart format and support the generation of PDF reports. (See attached image.) Figure 5 The diagram shows the display content of a statistical analysis unit.

[0072] Example 3: This invention provides a specific method for implementing temperature acquisition and distribution monitoring in a data processing system for a fluidized bed reactor. In a fluidized bed reactor, the uniformity of temperature distribution is crucial to product quality. (See also...) Figure 6 The diagram shows the arrangement of a temperature sensor on a reactor.

[0073] like Figure 6 As shown, the reactor body is divided into a lower conical section, a straight section, and an upper enlarged section along its height. Eight sets of heating modules (each set consisting of two semicircles on the left and right) are evenly arranged externally, corresponding to different height regions of the reactor. Each heating module is equipped with two K-type thermocouples: one as a temperature-controlling thermocouple (inserted inside the reactor or close to the outer wall) for PID control; the other as a temperature-sensing thermocouple to monitor the actual temperature of that region. Therefore, there are a total of 8 temperature control points and 8 temperature sensing points, resulting in a total of 16 temperature signals.

[0074] In this embodiment, all temperature signals are input to the PLC's analog input module as thermocouple signals. The PLC internally converts the signals into actual temperature values ​​and stores them in the data area. The historical curve module allows users to select multiple temperature points simultaneously for comparison, such as comparing temperature change trends at different heights to determine if there is flow deviation or localized overheating. When the temperature in a certain area fluctuates abnormally, the operator can quickly locate the problem area and, in conjunction with the heating current curve, determine whether it is caused by heater malfunction or a change in the material fluidization state.

[0075] In summary, the data processing system for the fluidized bed reactor provided in the embodiments of the present invention can solve the following problems: 1. Problem of insufficient traceability of process data: Use the WinCC process value archiving module to collect key process parameters at the second level and store them with timestamps, and combine them with the alarm archiving system to record abnormal working conditions to achieve complete traceability and root cause location of production process data.

[0076] 2. Lack of production data visualization and in-depth analysis capabilities: The WinCC trend chart control is used to intuitively display the process parameter change curves. The Connectivity Pack (a functional control) provides an OLE-DB (Object Linking and Embedding, Database) interface to support Excel data export and secondary analysis, meeting the data mining needs of R&D and production departments.

[0077] Example 4: This invention provides a fluidized bed reactor, see [link to relevant documentation]. Figure 7 The diagram shows a structure of a fluidized bed reactor, which includes the data processing system for the fluidized bed reactor provided in the foregoing embodiments.

[0078] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the fluidized bed reactor described above can be referred to the corresponding process in the aforementioned embodiment of the data processing system for the fluidized bed reactor, and will not be repeated here.

[0079] Furthermore, in the description of the embodiments of the present invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention based on the specific circumstances.

[0080] If a function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0081] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0082] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A data processing system for a fluidized bed reactor, characterized in that, The data processing system of the fluidized bed reactor includes: a data acquisition module, a data processing module, and a human-computer interaction module; The data acquisition module is used to acquire the process parameters of the fluidized bed reactor; The data processing module is used to filter and convert the collected process parameters into engineering units, and to perform real-time control according to the preset process logic. The human-computer interaction module is used to determine the process flow diagram, parameter values ​​and alarm information based on the process parameters, and to display the process flow diagram, parameter values ​​and alarm information.

2. The data processing system for the fluidized bed reactor according to claim 1, characterized in that, The process parameters include: multi-point temperature inside the reactor, reactor pressure, water-cooled tank pressure, reactor inner and outer wall temperature, carrier gas flow rate, reaction gas flow rate, protective gas flow rate, heating module current and voltage, stirring motor speed and current, water-cooled tank weight, oxygen content, and valve on / off status feedback.

3. The data processing system for the fluidized bed reactor according to claim 2, characterized in that, The data acquisition module is used to collect the temperature at multiple points inside the reactor and the temperature of the inner and outer walls of the reactor by temperature sensors deployed inside the reactor. The data acquisition module is used to acquire the pressure of the reactor and the pressure of the water-cooled tank through a pressure transmitter; The data acquisition module is used to acquire the carrier gas flow rate, the reaction gas flow rate, and the protective gas flow rate through the mass flow controller; The data acquisition module is used to acquire the current and voltage of the heating module through a current transformer connected in series in the heating element; The data acquisition module is used to acquire the weight of the water-cooled tank by a weighing sensor installed at the bottom of the water-cooled tank. The data acquisition module is used to acquire the oxygen content through a zirconium oxide oxygen sensor inserted into the exhaust pipe. The data acquisition module is used to collect feedback on the valve's on / off status through a dual-redundant magnetic limit switch installed on the valve.

4. The data processing system for the fluidized bed reactor according to claim 3, characterized in that, The data acquisition module includes: a K-type thermocouple, which is arranged at different axial positions of the reactor and inside the heating module; each heating module is equipped with an independent temperature control thermocouple and a temperature measuring thermocouple.

5. The data processing system for the fluidized bed reactor according to claim 1, characterized in that, The data processing module includes: a data preprocessing unit, an engineering unit conversion unit, and a real-time process control unit; The data preprocessing unit is used to perform sliding window mid-range filtering and abnormal data interpolation and replacement processing on the collected process parameters. The engineering unit conversion unit is used to convert the process parameters into engineering units by table lookup and interpolation. The real-time process control unit is used to construct the process parameters into a variable control matrix through a pre-written process logic control program.

6. The data processing system for the fluidized bed reactor according to claim 1, characterized in that, The data processing module is also used to upload the process parameters.

7. The data processing system for the fluidized bed reactor according to claim 6, characterized in that, The data processing module further includes: an upper-layer interface service unit; The upper-layer interface service unit is used to upload the process parameters through the open user communication interface and the open platform communication unified architecture interface.

8. The data processing system for the fluidized bed reactor according to claim 1, characterized in that, The human-computer interaction module includes: a historical curve unit, a data export unit, an alarm history unit, and a statistical analysis unit; The historical curve unit is used to display the changing trend of the process parameters within a selected time period in the form of a curve graph as the process flow diagram. The data export unit is used to export the historical data of the selected process parameters into a general format file; The alarm history unit is used to query and statistically analyze the alarm information by time, type, and work section; wherein the alarm information includes: alarm occurrence time, alarm content, alarm value, and recovery time; The statistical analysis unit is used to perform statistical analysis on the historical data of the process parameters and generate statistical analysis reports.

9. The data processing system for a fluidized bed reactor according to claim 1, characterized in that, The human-computer interaction module is also used to provide a user operation interface.

10. A fluidized bed reactor, characterized in that, The fluidized bed reactor includes: a data processing system for the fluidized bed reactor according to any one of claims 1-9.

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