POE polymerization reaction stage multi-parameter coupling control method and device

Abstract

The present application relates to the technical field of polyolefin production safety control, and particularly relates to a POE polymerization stage multi-parameter coupling control method and device. The method obtains multi-point axial and radial temperature data, cooling medium thermodynamic parameters and pressure data in the reactor, calculates the axial temperature gradient, temperature rise rate and total heat transfer coefficient, and generates a comprehensive safety index through a weighted algorithm in combination with the pressure-temperature matching relationship. According to the preset interval of the index, a graded response operation including early warning, adjusting the cooling and catalyst feeding, cutting off the catalyst feeding, injecting a terminating agent and stopping the whole device is executed. The present application solves the problems of high mis-interlocking rate, rough response and uneven distribution of the terminating agent in the existing safety technology through multi-parameter coupling evaluation and a gradual response mechanism, realizes the whole-chain precise safety protection from early warning to emergency termination in the POE polymerization process, and significantly improves the production safety and continuity.

Description

Technical Field

[0001] This invention relates to the field of safety control technology in polyolefin production, specifically to a multi-parameter coupling control method and apparatus for the POE polymerization reaction stage. Background Technology

[0002] Polyolefin elastomers (POEs), as high-performance polymer materials, are widely used in automotive lightweighting, photovoltaic films, and high-end packaging. Currently, industrial production mainly employs two processes: solution polymerization and high-pressure polymerization. Both rely on olefin polymerization reactions under metallocene catalysts and co-catalyst systems. These reactions are inherently characterized by high temperature, high pressure, and strong exothermicity. Furthermore, the reaction system is a high-viscosity polymer solution, resulting in extremely complex heat and mass transfer conditions, making it highly susceptible to localized overheating and heat accumulation. Existing safety interlocking schemes have significant limitations: single-parameter threshold interlocking schemes rely solely on isolated temperature or pressure values, failing to identify the overall thermal safety status of the reaction system, leading to a high false interlocking rate; multi-condition "OR" logic interlocking schemes, while monitoring more dimensions, employ a crude "stop at the first sign of an overshoot" logic, triggering a complete shutdown of the unit even with slight fluctuations, severely restricting production continuity and economic efficiency; multi-point temperature control schemes, while improving temperature control accuracy, neglect key risk factors such as cooling efficiency degradation and pressure-temperature mismatch, and lack effective emergency termination measures. More importantly, existing technologies have failed to address the problem of coupled evaluation of multi-dimensional safety parameters, making it impossible to achieve a smooth transition from early warning to gradual response, and also making it difficult to ensure the rapid and uniform dispersion of the terminator in high-temperature and high-viscosity environments. Therefore, there is an urgent need for a dedicated safety control device and method that can comprehensively assess the safety status of the reaction, implement precise graded interventions, and possess a highly reliable emergency response mechanism to solve the safety management challenges of the POE polymerization process.

[0003] Therefore, the existing technology still needs further development. Summary of the Invention

[0004] The purpose of this invention is to overcome the above-mentioned technical deficiencies and provide a multi-parameter coupling control method and apparatus for the POE polymerization reaction stage, so as to solve the problems existing in the prior art.

[0005] To achieve the above-mentioned technical objectives, according to a first aspect of the present invention, the present invention provides a multi-parameter coupling control method for the POE polymerization reaction stage, comprising:

[0006] S1. Obtain axial and radial temperature data, cooling medium temperature and flow rate data, and reactor pressure data at multiple points within the POE polymerization reactor;

[0007] S2. Calculate the axial temperature gradient and temperature rise rate based on the temperature data, calculate the real-time heat transfer and total heat transfer coefficient based on the temperature and flow rate data of the cooling medium, and obtain the pressure-temperature deviation based on the matching of the pressure data and temperature data.

[0008] S3. Generate a comprehensive safety index based on the weighted coupling results of the axial temperature gradient, temperature rise rate, relative value of total heat transfer coefficient, and pressure-temperature deviation.

[0009] S4. Based on the preset range of the comprehensive safety index, perform graded response operations, which include at least early warning, adjusting cooling and catalyst feeding, cutting off catalyst feeding, injecting terminator and shutting down the entire unit.

[0010] Specifically, in the step of acquiring axial and radial temperature data at multiple points within the POE polymerization reactor, at least five temperature measuring points are arranged at effective height intervals along the axial direction of the reactor body, and temperature measuring points are arranged in the central region, the intermediate radius region, and the near-wall region along the radial direction of the reactor body. The method also includes a step of self-diagnosing the temperature data: when the signal of any measuring point exceeds the physically reasonable range, remains unchanged for a long time, or deviates from other measuring points by a preset threshold, the measuring point is removed from the safety judgment, and the weight coefficient corresponding to the measuring point is redistributed to the remaining effective measuring points.

[0011] Specifically, the step of calculating the real-time heat transfer and the overall heat transfer coefficient based on the temperature and flow rate data of the cooling medium includes:

[0012] The real-time heat transfer is calculated based on the inlet and outlet temperature difference and flow rate of the cooling medium. The total heat transfer coefficient is calculated based on the real-time heat transfer, heat transfer area, and logarithmic mean temperature difference. The relative value of the total heat transfer coefficient is the ratio of the current total heat transfer coefficient to the baseline value of the total heat transfer coefficient under normal operating conditions. In the graded response operation, when the comprehensive safety index is in the first preset range, an audible and visual alarm is issued. When it is in the second preset range, the cooling medium flow rate is increased and the catalyst feed rate is reduced. When it is in the third preset range, the catalyst feed is cut off and emergency cooling is initiated, while the pre-positioned terminator injection module is activated. When it is in the fourth preset range, all feed is cut off, the terminator is injected, and the material is released into the emergency release tank.

[0013] Specifically, the step of injecting the terminator is performed by a pre-positioned terminator injection module, which is equipped with an annular radial distributor. The annular radial distributor is located inside the reactor, and its pipe diameter is a preset ratio of the reactor's inner diameter. Multiple through holes are opened in the circumferential direction of the pipe wall. After the terminator is pressurized with nitrogen to a preset multiple higher than the reactor's operating pressure, it is delivered to the annular radial distributor through a fast-response injection valve with a response time less than a preset threshold.

[0014] Specifically, the method is also integrated into a redundant safety architecture that includes a DCS control layer, a SIS safety interlock layer, and a local manual emergency layer; the calculation of the comprehensive safety index and the graded response operation are performed by the SIS safety interlock layer, which is independent of the DCS control layer; the local manual emergency layer is equipped with a hard-wired relay circuit and a manual stop button, which can bypass the comprehensive safety index calculation steps and directly trigger the highest level of emergency stop response.

[0015] According to a second aspect of the present invention, a multi-parameter coupling control device for the POE polymerization reaction stage is provided, comprising:

[0016] The multi-point temperature monitoring module is configured to collect temperature signals from multiple locations distributed along the axial and radial directions within the POE polymerization reactor.

[0017] The reaction heat dynamic monitoring module is configured to collect the inlet and outlet temperatures and flow signals of the cooling medium, and calculate the real-time heat transfer and overall heat transfer coefficient.

[0018] The multi-parameter coupled safety judgment module is connected to the multi-point temperature monitoring module and the reaction heat dynamic monitoring module. It is configured to calculate the axial temperature gradient, temperature rise rate, relative value of total heat transfer coefficient and pressure-temperature deviation, and generate a comprehensive safety index based on the weighted coupling result.

[0019] The gradient interlock response module is connected to the multi-parameter coupled safety judgment module and is configured to output graded control signals based on the preset range of the comprehensive safety index. The graded control signals at least include warning signals, feed adjustment signals, cut-off signals and stop signals.

[0020] Specifically, the multi-point temperature monitoring module includes a first axial temperature sensor to a fifth axial temperature sensor arranged at intervals along the axial direction of the reactor body, and a first radial temperature sensor to a third radial temperature sensor arranged radially. The multi-parameter coupling safety judgment module is also equipped with a self-diagnostic unit, which is used to diagnose the signal validity of each temperature sensor and, when a signal fault is determined, redistribute the weight coefficient corresponding to the faulty sensor to the remaining valid sensors. The self-diagnostic unit is further configured to detect whether the signal exceeds the physically reasonable range, whether the signal remains unchanged for a long time, or whether the deviation from other sensor signals exceeds a preset threshold.

[0021] Specifically, the reaction heat dynamic monitoring module includes a cooling water inlet temperature sensor, a cooling water outlet temperature sensor, a cooling water flow meter, and a total heat transfer coefficient calculation unit; the gradient interlock response module is configured as follows: when the comprehensive safety index is in the first preset range, the alarm unit is driven to issue an audible and visual alarm; when it is in the second preset range, a control signal is output to adjust the cooling medium flow rate to the first preset ratio and reduce the catalyst feed rate; when it is in the third preset range, a control signal is output to cut off the catalyst feed and adjust the cooling medium flow rate to the second preset ratio, while simultaneously pre-positioning the emergency terminator rapid dispersion injection module; when it is in the fourth preset range, a control signal is output to cut off all feed, drive the emergency terminator rapid dispersion injection module to inject the terminator, and open the safety relief valve.

[0022] Specifically, the emergency termination agent rapid dispersion injection module includes a termination agent storage tank, a nitrogen pressurization pipeline, a heating and insulation jacket, a main delivery pipe, a distribution manifold, and a radial distributor; the radial distributor is an annular pipe installed inside the reactor body, with a pipe diameter that is a preset proportion of the reactor's inner diameter, and multiple through holes are opened circumferentially in the pipe wall; a fast-response injection valve is connected in series on the main delivery pipe, and the response time of the fast-response injection valve is less than a preset threshold; the nitrogen pressurization pipeline is configured to pressurize the termination agent to a preset multiple higher than the reactor's operating pressure.

[0023] Specifically, it also includes a redundant safety architecture, which includes a DCS control layer, a SIS safety interlock layer, and a local manual emergency layer. The multi-parameter coupled safety judgment module and the gradient interlock response module are deployed in the SIS safety interlock layer, which is independent of the DCS control layer. The local manual emergency layer is a hard-wired relay circuit independent of the DCS control layer and the SIS safety interlock layer, and it is equipped with a local manual stop button. The hard-wired relay circuit is configured to respond to the operation of the local manual stop button and directly drive the gradient interlock response module to execute the highest level of emergency stop response.

[0024] Beneficial effects:

[0025] The present invention provides a multi-parameter coupling control method and device for the POE polymerization reaction stage, which has significant technical advantages and practical value.

[0026] First, by constructing a multi-parameter coupled safety judgment mechanism, core parameters such as axial temperature gradient, temperature rise rate, cooling efficiency, and pressure-temperature matching are integrated into a single comprehensive safety index, which realizes a quantitative assessment of the thermal safety status of the reaction system. This fundamentally overcomes the one-sidedness and lag of single-parameter judgment and significantly reduces the probability of false interlocking caused by fluctuations in normal operating conditions.

[0027] Secondly, the innovative gradient interlocking response mechanism establishes a four-level progressive intervention strategy, dynamically adjusting response measures based on changes in the comprehensive safety index. From early warning and feed adjustment to feed cut-off and emergency shutdown, a smooth safety protection chain is formed, effectively avoiding the crude interlocking mode of the existing technology that is either / or, significantly reducing unnecessary shutdowns and ensuring the continuity and stability of the production process.

[0028] Furthermore, considering the high viscosity of the POE reaction system, the designed emergency terminating agent rapid dispersion injection module adopts an annular radial distributor and a multi-point injection structure, combined with high-pressure nitrogen pushing and pre-positioning mechanisms, to ensure the instantaneous uniform dispersion of the terminating agent in the reactor. This solves the technical bottleneck of the terminating agent's difficulty in diffusion in high-viscosity fluids and greatly improves the reliability and response speed of emergency termination.

[0029] Furthermore, by introducing dynamic monitoring technology for the total heat transfer coefficient, early signs of cooling system performance degradation can be keenly detected, shifting the safety control point forward and realizing the transformation from passive over-limit alarm to proactive trend warning.

[0030] Finally, the three-level redundant safety architecture consisting of DCS, SIS and local manual hard-wired circuits not only meets the safety integrity requirements under different process levels, but also ensures that the highest level of safety protection can still be implemented in the event of control system failure or extreme operating conditions, thus comprehensively improving the intrinsic safety level and operational availability of the equipment. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the overall structure of the multi-parameter coupling control device for the POE polymerization reaction stage provided in a specific embodiment of the present invention;

[0032] Figure 2 This is a schematic diagram of the temperature measuring point arrangement of the multi-point temperature monitoring module provided in a specific embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram of the structure and signal flow of the reaction heat dynamic monitoring module provided in a specific embodiment of the present invention;

[0034] Figure 4 This is a structural block diagram of the multi-parameter coupled security judgment module provided in a specific embodiment of the present invention;

[0035] Figure 5 This is a schematic diagram of the hierarchical response logic of the gradient interlocking response module provided in a specific embodiment of the present invention;

[0036] Figure 6 This is a schematic diagram of the structure of the emergency termination agent rapid dispersion injection module provided in a specific embodiment of the present invention;

[0037] Figure 7 This is a schematic diagram of the redundant security architecture provided in a specific embodiment of the present invention;

[0038] Figure 8 This is a logic flowchart of the multi-parameter coupling control method for the POE polymerization reaction stage provided in a specific embodiment of the present invention;

[0039] Figure 9 This is a flowchart of temperature signal self-diagnosis and weight redistribution provided in a specific embodiment of the present invention;

[0040] Figure 10 This is a flowchart illustrating the steps of the multi-parameter coupling control method for the POE polymerization reaction stage provided in a specific embodiment of the present invention.

[0041] The above figures contain the following reference numerals:

[0042] 100. Polymerization reactor; 101. Reactor body; 102. Monomer inlet; 103. Solvent inlet; 104. Catalyst inlet; 105. Reaction product outlet; 106. Cooling jacket; 107. Cooling water inlet; 108. Cooling water outlet; 110. Safety relief valve; 200. Multi-point temperature monitoring module; 201a. First axial temperature sensor; 201b. Second axial temperature sensor; 201c. Third axial temperature sensor; 201d. Fourth axial temperature sensor; 2 01e, Fifth Axial Temperature Sensor; 202a, First Radial Temperature Sensor; 202b, Second Radial Temperature Sensor; 202c, Third Radial Temperature Sensor; 300, Reaction Heat Dynamic Monitoring Module; 301, Cooling Water Inlet Temperature Sensor; 302, Cooling Water Outlet Temperature Sensor; 303, Cooling Water Flow Meter; 304, Pressure Sensor; 305, Overall Heat Transfer Coefficient Calculation Unit; 400, Multi-Parameter Coupling Safety Judgment Module; 401, Temperature Gradient Judgment Unit; 402, Temperature Rise Rate Judgment Unit; 403, Cooling Efficiency Judgment Unit; 404, Pressure-Temperature Matching Judgment Unit; 405, Comprehensive Safety Index Calculation Unit; 406, Self-Diagnosis Unit; 500, Gradient Interlock Response Module; 501, Alarm Unit; 502, Cooling Water Regulating Valve; 503, Catalyst Feed Regulating Valve; 504, Catalyst Feed Cut-off Valve; 505, Monomer Feed Cut-off Valve; 506, Solvent Feed Cut-off Valve; 507, Unit Shutdown Signal; 600, Emergency Termination Agent Rapid Dispersion Injection Module; 601 602. Termination agent storage tank; 603. Nitrogen pressurization pipeline; 604. Heating and insulation jacket; 605. Main delivery pipe; 606. Distribution manifold; 607. Radial distributor; 608. Through hole; 608a. Fast response injection valve; 608b. Fast response injection valve; 608c. Fast response injection valve; 608d. Fast response injection valve; 700. Redundant safety architecture; 701. DCS control layer; 702. SIS safety interlock layer; 703. Local manual emergency layer; 704. Local manual stop button. Detailed Implementation

[0043] To enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Based on the embodiments in this application, other similar embodiments obtained by those skilled in the art without creative effort should all fall within the scope of protection of this application. Furthermore, directional terms mentioned in the following embodiments, such as "up," "down," "left," and "right," are only for reference to the directions in the accompanying drawings; therefore, the directional terms used are for illustrative purposes and not for limiting the invention.

[0044] The present invention will be further described below with reference to the accompanying drawings and preferred embodiments.

[0045] Please see Figure 10 This invention provides a multi-parameter coupling control method for the POE polymerization reaction stage, comprising:

[0046] S1. Obtain axial and radial temperature data, cooling medium temperature and flow rate data, and reactor pressure data at multiple points within the POE polymerization reactor.

[0047] It should be further explained that the control logic of this embodiment relies on the operation of the polymerization reactor 100 and its supporting automation system. First, the temperature field distribution within the reactor body 101 is collected by the multi-point temperature monitoring module 200, and the thermodynamic parameters at the cooling water inlet 107 and cooling water outlet 108 of the cooling jacket 106 are collected by the reaction heat dynamic monitoring module 300. In the acquisition steps, the temperature sampling frequency is set according to the process type: 2Hz for solution-based processes and 5Hz for high-pressure processes, to adapt to the dynamic response requirements under different reaction rates.

[0048] S2. Calculate the axial temperature gradient and temperature rise rate based on the temperature data, calculate the real-time heat transfer and total heat transfer coefficient based on the temperature and flow rate data of the cooling medium, and obtain the pressure-temperature deviation based on the matching of the pressure data and temperature data.

[0049] It should be further explained that the steps for calculating the real-time heat transfer and the overall heat transfer coefficient specifically include the following algorithm flow:

[0050] (1) Real-time heat transfer According to the formula Perform the calculation. In the formula, The real-time heat transfer of the reactor is expressed in kW; This refers to the specific heat capacity of cooling water, expressed in kJ / (kg·℃). This refers to the cooling water flow rate, expressed in kg / s. This refers to the cooling water outlet temperature, in °C. This refers to the inlet temperature of the cooling water, expressed in °C.

[0051] (2) Overall heat transfer coefficient According to the formula Perform the calculation. In the formula, The overall heat transfer coefficient is expressed in kW / (m²·℃). This refers to the heat transfer area, expressed in m². The temperature difference is the logarithmic mean, expressed in °C.

[0052] (3) The pressure-temperature matching judgment unit 404 has a pre-stored pressure-temperature correspondence curve within the normal operation window. In actual operation, the actual pressure is calculated. Normal pressure at current temperature The difference.

[0053] like Figure 3 As shown, the reaction heat dynamic monitoring module 300 consists of a cooling water inlet temperature sensor 301, a cooling water outlet temperature sensor 302, a cooling water flow meter 303, and a total heat transfer coefficient calculation unit 305. The cooling water inlet temperature sensor 301 and the cooling water flow meter 303 are installed on the pipeline of the cooling water inlet 107, and the cooling water outlet temperature sensor 302 is installed on the pipeline of the cooling water outlet 108. The cooling water flows from bottom to top in the cooling jacket 106 and carries away the heat released by the reaction. The three sensor signals are fed into the total heat transfer coefficient calculation unit 305. The total heat transfer coefficient calculation unit 305 calculates the real-time heat transfer of the reactor Q according to the formula Q=Cp×F×(Tout−Tin), and calculates the total heat transfer coefficient U according to the formula U=Q / (A×ΔTm), and then obtains the relative value of the total heat transfer coefficient U / U0. Subsequently, the real-time heat transfer of Q and the relative value of the total heat transfer coefficient U / U0 are output to the multi-parameter coupled safety judgment module 400 as a direct basis for judging whether the cooling efficiency has decreased.

[0054] S3. Generate a comprehensive safety index based on the weighted coupling results of the axial temperature gradient, temperature rise rate, relative value of total heat transfer coefficient, and pressure-temperature deviation.

[0055] It should be further explained that the Comprehensive Safety Index (CSI) is calculated using a weighted algorithm: In the formula, This is a temperature gradient anomaly signal (0 or 1); This is an abnormal temperature rise rate signal (0 or 1). This is a cooling attenuation signal (0 or 1); The pressure-temperature matching anomaly signal (0 or 1) is used. The weighting coefficients 30, 25, 25, and 20 correspond to the risk contributions of the four dimensions of temperature gradient, temperature rise rate, cooling efficiency, and pressure-temperature matching, respectively. The sum is normalized to 100 for easy and intuitive understanding of the safety risk level.

[0056] S4. Based on the preset range of the comprehensive safety index, perform graded response operations, which include at least early warning, adjusting cooling and catalyst feeding, cutting off catalyst feeding, injecting terminator and shutting down the entire unit.

[0057] like Figure 10As shown, the multi-parameter coupling control method for the POE polymerization reaction stage in this embodiment includes four steps executed sequentially: S1, acquiring axial and radial temperature data, cooling medium temperature and flow rate data, and reactor pressure data at multiple points within the POE polymerization reactor; S2, calculating the axial temperature gradient and temperature rise rate based on the temperature data, calculating the real-time heat transfer and total heat transfer coefficient based on the cooling medium temperature and flow rate data, and obtaining the pressure-temperature deviation based on the matching of the pressure and temperature data; S3, generating a comprehensive safety index based on the weighted coupling result of the axial temperature gradient, temperature rise rate, relative value of the total heat transfer coefficient, and pressure-temperature deviation; S4, executing graded response operations according to the preset range in which the comprehensive safety index is located, the graded response operations including at least early warning, adjusting cooling and catalyst feeding, cutting off catalyst feeding, injecting terminator, and shutting down the entire unit. Figure 10 The main process of the method is summarized, from data acquisition, parameter calculation, coupled evaluation to hierarchical execution. Figure 8 The detailed judgment logic shown corresponds to each other and is also included as an abstract diagram of this application.

[0058] It should be further explained that the preset interval is divided into four levels: the first level is... The second level is The third level is Level 4 is .

[0059] like Figure 8 As shown, the complete logical flow of the method in this embodiment is as follows: After starting, in step S1, the multi-point temperature monitoring module 200 collects temperature data, the reaction heat dynamic monitoring module 300 collects cooling water temperature and flow data, and simultaneously collects reactor pressure data; then, the parallel judgment stage is entered, the temperature gradient judgment unit 401 calculates the axial temperature gradient ΔT and judges whether it exceeds the preset threshold to set SG1, the temperature rise rate judgment unit 402 calculates the temperature rise rate dT / dt and judges whether it exceeds the preset threshold to set SG2, the cooling efficiency judgment unit 403 calculates the total heat transfer coefficient ratio U / U0 and judges whether it is less than 0.7 to set SG3, and the pressure-temperature matching judgment unit 404 calculates the pressure... The force-temperature deviation |ΔP| is measured and it is determined whether it exceeds the preset threshold to set SG4; the comprehensive safety index calculation unit 405 calculates the comprehensive safety index according to the formula CSI=30×SG1+25×SG2+25×SG3+20×SG4; then it is classified according to the CSI range: CSI<60 is normal operating condition and monitoring continues, 60≤CSI<70 executes the first-level warning response, 70≤CSI<80 executes the second-level warning response, 80≤CSI<90 executes the third-level interlock response, and CSI≥90 executes the fourth-level emergency stop response; after the gradient interlock response module 500 executes the corresponding graded response operation, the process returns to continue monitoring, forming a closed-loop periodic safety scan.

[0060] Understandably, by introducing the overall heat transfer coefficient... Dynamic calculations can detect early signs of fouling or heat transfer deterioration in heat exchangers, which is more proactive than simply monitoring temperature. Furthermore, the use of a weighted coupling algorithm to generate a single CSI index solves the problem of high misjudgment rates for single parameters, enabling the control system to quantitatively assess the overall safety status of the reactor, rather than relying solely on simple "OR" logic.

[0061] Specifically, in the step of acquiring axial and radial temperature data at multiple points within the POE polymerization reactor, at least five temperature measuring points are arranged at effective height intervals along the axial direction of the reactor body, and temperature measuring points are arranged in the central region, the intermediate radius region, and the near-wall region along the radial direction of the reactor body. The method also includes a step of self-diagnosing the temperature data: when the signal of any measuring point exceeds the physically reasonable range, remains unchanged for a long time, or deviates from other measuring points by a preset threshold, the measuring point is removed from the safety judgment, and the weight coefficient corresponding to the measuring point is redistributed to the remaining effective measuring points.

[0062] It should be further explained that the spatial arrangement strategy of the multi-point temperature monitoring module 200 fully considers the characteristic that high-viscosity fluids easily form temperature gradients in the POE solution polymerization reaction. Axial temperature measuring points include a first axial temperature sensor 201a, a second axial temperature sensor 201b, a third axial temperature sensor 201c, a fourth axial temperature sensor 201d, and a fifth axial temperature sensor 201e, located at 20% (upper part), 40% (upper middle part), 50% (middle part), 60% (lower middle part), and 80% (lower part) of the effective height of the reactor, respectively. Radial temperature measuring points include a first radial temperature sensor 202a, a second radial temperature sensor 202b, and a third radial temperature sensor 202c, located at the center of the reactor, at half the radius from the center, and near the wall at 50 mm from the wall surface, respectively. Furthermore, the execution logic of the self-diagnostic function includes the following decision sub-steps:

[0063] (1) Physical rationality check: The reasonable range of the set temperature is If the signal at a certain measuring point is detected to be outside this range, it is determined to be a hardware failure.

[0064] (2) Signal activity check: Monitor the rate of change of the signal. If the value of a certain measuring point remains unchanged for more than a preset time (e.g., 5 minutes), it is determined that the communication is interrupted or the sensor is stuck.

[0065] (3) Deviation cross-check: compare the readings of adjacent or symmetrical measuring points. If the deviation of a certain measuring point from other measuring points is continuously greater than the preset threshold (e.g., 15℃), it is judged as a suspected fault.

[0066] (4) Dynamic weight redistribution: When a measurement point is determined to be faulty, the system automatically removes it from the safety assessment. For example, ... Figure 9 As shown, the 30-point weight of SG1 is originally evenly distributed among the 5 axial temperature measurement points, with each measurement point having 6 points. If one of the axial temperature measurement points fails, the system will evenly distribute the 6-point weight of the failed measurement point among the remaining 4 valid axial measurement points, making the weight of each valid measurement point 7.5 points. This ensures that the denominator of the calculation formula for the Comprehensive Safety Index (CSI) remains valid and maintains the continuity of the judgment.

[0067] like Figure 9 As shown, the self-diagnostic unit 406 performs three levels of checks on the temperature signals input from the first axial temperature sensor 201a to the fifth axial temperature sensor 201e and the first radial temperature sensor 202a to the third radial temperature sensor 202c: physical rationality check, determining whether the signal exceeds the physical rationality range of -50℃ to 500℃; signal activity check, determining whether the change in the signal within 300 seconds is less than 0.1℃; deviation cross-check, determining whether the deviation of the signal from adjacent or symmetrical measuring points is greater than 15℃; if any check fails, the measurement is deemed to be faulty. If a faulty sensor is detected, the system removes the faulty sensor from the safety assessment, issues an audible and visual alarm, and redistributes the weight of the faulty sensor to the remaining valid sensor points. Signals from all valid sensor points are considered valid and participate in the CSI calculation. The example in the figure shows the specific method of weight redistribution: the 30-point weight of SG1 was originally evenly distributed among the 5 axial sensor points, with 6 points for each sensor point. After a sensor point fails, it is redistributed to the remaining 4 valid sensor points, with 7.5 points for each sensor point. This ensures the continuity and reliability of the output of the comprehensive safety index calculation unit 405 even when a single sensor fails.

[0068] Understandably, sensor failure is a common problem in high-risk processes like POE polymerization. Traditional solutions often involve directly triggering interlocking shutdowns. However, this solution's self-diagnosis and weight redistribution mechanisms ensure that even in non-critical situations where a single or a few sensors fail, the system can still maintain safe monitoring functions using the remaining valid measurement points. This significantly improves the online rate and availability of the device and avoids unplanned shutdowns caused by instrument malfunctions.

[0069] Specifically, the step of calculating the real-time heat transfer and the overall heat transfer coefficient based on the temperature and flow rate data of the cooling medium includes:

[0070] The real-time heat transfer is calculated based on the inlet and outlet temperature difference and flow rate of the cooling medium. The total heat transfer coefficient is calculated based on the real-time heat transfer, heat transfer area, and logarithmic mean temperature difference. The relative value of the total heat transfer coefficient is the ratio of the current total heat transfer coefficient to the baseline value of the total heat transfer coefficient under normal operating conditions. In the graded response operation, when the comprehensive safety index is in the first preset range, an audible and visual alarm is issued. When it is in the second preset range, the cooling medium flow rate is increased and the catalyst feed rate is reduced. When it is in the third preset range, the catalyst feed is cut off and emergency cooling is initiated, while the pre-positioned terminator injection module is activated. When it is in the fourth preset range, all feed is cut off, the terminator is injected, and the material is released into the emergency release tank.

[0071] It should be further explained that the relative value of the overall heat transfer coefficient It is the core indicator for judging cooling efficiency, among which This is the baseline value calibrated under full-load normal operating conditions. The graded response operation is executed through the gradient interlocking response module 500, with the specific action mapping as follows:

[0072] (1) When (First preset interval), execute Level 1 early warning response. The system issues an audible and visual alarm signal, prompting the operator to manually confirm within 60 seconds. At this time, automatic control and adjustment have not yet been initiated.

[0073] (2) When (Second preset interval), execute level two early warning response. While maintaining the alarm, the system automatically adjusts the cooling water flow rate of the cooling jacket 106, increasing the flow rate from the normal 100% to 150%; at the same time, it reduces the catalyst feed rate by 20% through the catalyst feed regulating valve 503 to reduce the reaction exothermic rate.

[0074] (3) When (Third preset interval), execute three-level interlock response. The system completely cuts off the catalyst feed through catalyst feed cut-off valve 504, terminating the exothermic reaction at the source; starts the emergency cooling program, increasing the cooling water flow rate to 200% of the maximum design flow rate; at the same time, the emergency termination agent rapid dispersion injection module 600 enters the pre-position state, with the pre-position time controlled within 10 seconds.

[0075] (4) When (Fourth preset interval), execute a level four emergency shutdown response. The system cuts off all feed through the monomer feed cut-off valve 505 and the solvent feed cut-off valve 506; opens the fast response injection valves 608a~608d to inject the terminator; opens the safety relief valve 110 to release the material to the emergency relief tank; and triggers the entire unit shutdown signal 507.

[0076] like Figure 5As shown, the gradient interlock response module 500 receives the CSI output by the comprehensive safety index calculation unit 405 and compares the CSI with four preset intervals: when CSI < 60, it is determined to be a normal operating condition, no intervention is triggered, and monitoring continues; when 60 ≤ CSI < 70, a first-level early warning response is executed, driving the alarm unit 501 to issue an audible and visual alarm, prompting the operator to confirm manually; when 70 ≤ CSI < 80, a second-level early warning response is executed, outputting a control signal to increase the opening of the cooling water regulating valve 502 (located on the pipeline of the cooling water inlet 107) and increase the cooling water flow to 150% of the normal flow, while simultaneously driving the catalyst feed regulating valve 503 to reduce the catalyst feed rate. The response time is 20% lower; when 80≤CSI<90, a three-level interlock response is executed, driving the catalyst feed cut-off valve 504 to cut off the catalyst feed, increasing the cooling water flow rate to 200% of the maximum design flow rate, and putting the emergency terminator rapid dispersion injection module 600 into the pre-position state; when CSI≥90, a four-level emergency shutdown response is executed, simultaneously driving the monomer feed cut-off valve 505 and the solvent feed cut-off valve 506 to cut off all feed, opening the rapid response injection valves 608a~608d to inject the terminator, opening the safety relief valve 110 to release the material to the emergency relief tank, and triggering the full unit shutdown signal 507, thus forming a four-level progressive protection chain from early warning to emergency shutdown.

[0077] Furthermore, the rationale for selecting the aforementioned thresholds and actions is as follows: the POE polymerization reaction is highly exothermic, but has a certain hysteresis. Setting a range of 60-70°C serves as an early warning, giving operators an opportunity to intervene; setting a range of 70-80°C for dosage reduction utilizes the catalyst's ability to reduce the cumulative effect on reaction heat; setting a range of 80-90°C cuts off the catalyst and pre-positions the terminator because the heat accumulation is approaching the critical point; setting a range above 90°C triggers an emergency shutdown to prevent over-temperature and over-pressure explosions. This progressive design avoids the "one-time shutdown" approach of existing technologies, balancing safety and economy.

[0078] Understandably, by introducing cooling efficiency ( ) as a basis for judgment, when The timely triggering of the cooling attenuation signal SG3 can sensitively detect the heat transfer deterioration caused by polymer adhesion to the walls, which is impossible with traditional methods that only consider temperature. Preemptively cutting off the catalyst and pre-positioning the terminator provides a valuable time window for emergency response.

[0079] Specifically, the step of injecting the terminator is performed by a pre-positioned terminator injection module, which is equipped with an annular radial distributor. The annular radial distributor is located inside the reactor, and its pipe diameter is a preset ratio of the reactor's inner diameter. Multiple through holes are opened in the circumferential direction of the pipe wall. After the terminator is pressurized with nitrogen to a preset multiple higher than the reactor's operating pressure, it is delivered to the annular radial distributor through a fast-response injection valve with a response time less than a preset threshold.

[0080] It should be further explained that the execution details of the emergency termination agent rapid dispersion injection module 600 are as follows: The termination agent in the termination agent storage tank 601 is pressurized via the nitrogen pressurization pipeline 602. The pressurization strategy varies depending on the process.

[0081] For the solution process, the pressurization pressure is set to 1.3 times the operating pressure of the polymerization reactor;

[0082] For the high-pressure method, the pressurization pressure is set to 1.25 times the operating pressure of the polymerization reactor.

[0083] The heating and insulation jacket 603 is used to maintain the flowability of the terminating agent; the insulation temperature under solution method is... Under high pressure method The pressurized terminating agent reaches the radial distributor 606 via the delivery main pipe 604 and the distribution manifold 605.

[0084] Furthermore, the specific structural parameters of the radial distributor 606 are as follows: it is an annular tube disposed inside the reactor body 101, with a diameter of 50% to 60% of the reactor's inner diameter. 18 to 30 through holes 607, each with a diameter of 3 mm to 5 mm, are uniformly opened along the circumference of the tube wall. This porous radial injection design aims to overcome the resistance of the high viscosity of the POE reaction system and achieve rapid microscale dispersion of the terminator. The selection of the fast-response injection valves 608a to 608d strictly limits the response time: less than 2 seconds under solution methods and less than 1.5 seconds under high-pressure methods.

[0085] Understandably, in the high-viscosity, high-temperature, and high-pressure POE reaction environment, conventional single-point injection can lead to the ineffective diffusion of the terminator, creating a "short circuit" and causing the local reaction to continue. This invention, through a ring distributor and multi-hole design, combined with high-pressure nitrogen propulsion, allows the terminator to radially and instantaneously fill the reactor cross-section, solving the technical challenge of mixing high-viscosity fluids and ensuring the thoroughness and reliability of emergency termination.

[0086] Specifically, the method is also integrated into a redundant safety architecture that includes a DCS control layer, a SIS safety interlock layer, and a local manual emergency layer; the calculation of the comprehensive safety index and the graded response operation are performed by the SIS safety interlock layer, which is independent of the DCS control layer; the local manual emergency layer is equipped with a hard-wired relay circuit and a manual stop button, which can bypass the comprehensive safety index calculation steps and directly trigger the highest level of emergency stop response.

[0087] It should be further explained that the redundant safety architecture 700 adopts a three-layer physical isolation design. The DCS control layer 701 uses either Honeywell Experion PKS (for solution processes) or Yokogawa CENTUM VP (for high-pressure processes), mainly responsible for daily process control, data display, and routine adjustments, and does not directly participate in safety interlock logic operations. The SIS safety interlock layer 702 uses a dedicated safety instrumented system independent of the DCS, and its Safety Integrity Level (SIL) is set according to process risk, with SIL2 for solution processes and SIL3 for high-pressure processes. The SIS layer directly carries the logic operations of the multi-parameter coupled safety judgment module 400 and the gradient interlock response module 500, and has the highest control over actuators (such as valves and pumps). The local manual emergency layer 703 is the lowest physical defense line. It does not rely on software logic and communication networks, but is composed of a hard-wired relay circuit powered by 24VDC. This layer is equipped with a local manual stop button 704. When the operator presses the button, the current signal directly drives the relay to actuate, forcibly closing the relevant valve.

[0088] Furthermore, the rationale behind this three-tier architecture is to prevent "common cause failures." The DCS system is responsible for routine control, but its software is complex and susceptible to virus attacks or software bugs; the SIS system is specifically responsible for security, with its hardware and software specially certified and highly reliable; the hard-wired manual circuit is completely independent of the computer system, and even in extreme cases such as a plant-wide power outage or a burnout of the control system's CPU, a shutdown can still be triggered via physical wiring.

[0089] Understandably, placing CSI calculation and response logic at the SIS layer rather than the DCS layer complies with the requirements of the IEC 61511 functional safety standard, ensuring the priority and independence of safety logic. Simultaneously, allowing the SIS layer and local manual layer to bypass complex CSI calculations and directly shut down the system ensures that the most decisive measures can be taken immediately in extreme emergencies (such as the discovery of open flames or severe leaks), reflecting the priority principle of safety design.

[0090] Please see Figure 1The present invention provides another embodiment, which provides a multi-parameter coupling control device for the POE polymerization reaction stage, the multi-parameter coupling control device for the POE polymerization reaction stage comprising:

[0091] The multi-point temperature monitoring module is configured to collect temperature signals from multiple locations distributed along the axial and radial directions within the POE polymerization reactor.

[0092] The reaction heat dynamic monitoring module is configured to collect the inlet and outlet temperatures and flow signals of the cooling medium, and calculate the real-time heat transfer and overall heat transfer coefficient.

[0093] The multi-parameter coupled safety judgment module is connected to the multi-point temperature monitoring module and the reaction heat dynamic monitoring module. It is configured to calculate the axial temperature gradient, temperature rise rate, relative value of total heat transfer coefficient and pressure-temperature deviation, and generate a comprehensive safety index based on the weighted coupling result.

[0094] The gradient interlock response module is connected to the multi-parameter coupled safety judgment module and is configured to output graded control signals based on the preset range of the comprehensive safety index. The graded control signals at least include warning signals, feed adjustment signals, cut-off signals and stop signals.

[0095] like Figure 1As shown, the multi-parameter coupling control device for the POE polymerization reaction stage in this embodiment is based on the polymerization reactor 100. The top of the reactor body 101 is provided with a monomer inlet 102, a solvent inlet 103, and a catalyst inlet 104, and the bottom is provided with a reaction product outlet 105. The outer wall of the reactor body 101 is provided with a cooling jacket 106. The lower part of the cooling jacket 106 is connected to a cooling water inlet 107, and the upper part is connected to a cooling water outlet 108. The top of the reactor body 101 is also provided with a safety relief valve 110. The multi-point temperature monitoring module 200 includes a first axial temperature sensor 201a to a fifth axial temperature sensor 201e arranged along the axial direction of the reactor body 101 and a first radial temperature sensor 202a to a third radial temperature sensor 202c arranged along the radial direction. The reaction thermal dynamic monitoring module 300 includes a cooling water inlet temperature sensor 301 and a cooling water flow meter 303 set at the cooling water inlet 107 and a cooling water outlet temperature sensor 302 set at the cooling water outlet 108. The multi-point temperature monitoring module 200 and the reaction The signal output terminals of the thermal dynamic monitoring module 300 are all connected to the multi-parameter coupled safety judgment module 400. The output terminals of the multi-parameter coupled safety judgment module 400 are connected to the gradient interlock response module 500. The gradient interlock response module 500 is connected to the catalyst feed regulating valve 503, the catalyst feed shut-off valve 504, the monomer feed shut-off valve 505, the solvent feed shut-off valve 506, the safety relief valve 110, the rapid response injection valves 608a~608d, and the unit shutdown signal 507, as well as the emergency termination agent rapid dispersion. The injection module 600 is internally connected to the reactor body 101 via the radial distributor 606; the multi-parameter coupled safety judgment module 400 and the gradient interlock response module 500 are deployed in the SIS safety interlock layer 702 of the redundant safety architecture 700. The redundant safety architecture 700 also includes a DCS control layer 701 and a local manual emergency layer 703. The local manual emergency layer 703 is directly connected to each actuator on site through hard wiring, thus forming a complete safety control chain of "signal acquisition - coupled judgment - graded execution - redundancy fallback".

[0096] It should be further noted that this device corresponds to Figure 1The overall structure is shown. The polymerization reactor 100 serves as the core container. Its reactor body 101 has a monomer inlet 102, a solvent inlet 103, and a catalyst inlet 104 at the top, and a reaction product outlet 105 at the bottom. The multi-point temperature monitoring module 200 physically consists of the aforementioned five axial sensors and three radial sensors, which are connected to the multi-parameter coupling safety judgment module 400 via shielded cables. The reaction heat dynamic monitoring module 300 comprises a cooling water inlet temperature sensor 301, a cooling water outlet temperature sensor 302, and a cooling water flow meter 303. Its signal output is connected to the total heat transfer coefficient calculation unit 305 within the multi-parameter coupling safety judgment module 400. The pressure sensor 304 is located at the top of the reactor body 101 and is used to collect reactor pressure signals in real time. Its signal output is connected to the pressure-temperature matching judgment unit 404 within the multi-parameter coupling safety judgment module 400. The multi-parameter coupled safety judgment module 400 is logically divided into a temperature gradient judgment unit 401, a temperature rise rate judgment unit 402, a cooling efficiency judgment unit 403, a pressure-temperature matching judgment unit 404, and a comprehensive safety index calculation unit 405. The gradient interlock response module 500 is connected via hardwired or fieldbus to the catalyst feed regulating valve 503, the catalyst feed shut-off valve 504, the monomer feed shut-off valve 505, the solvent feed shut-off valve 506, and the unit shutdown signal 507.

[0097] like Figure 4 As shown, the multi-parameter coupled safety judgment module 400 receives the temperature signal input from the multi-point temperature monitoring module 200, the real-time heat transfer Q and the relative value of the total heat transfer coefficient U / U0 input from the reaction heat dynamic monitoring module 300, and the reactor pressure signal input from the pressure sensor 304. The temperature signal first enters the self-diagnosis unit 406 for effectiveness diagnosis. Signals that pass the diagnosis are sent to the temperature gradient judgment unit 401 and the temperature rise rate judgment unit 402, respectively. The temperature gradient judgment unit 401 calculates the axial temperature gradient and outputs the temperature gradient abnormality signal SG1, and the temperature rise rate judgment unit 402 calculates the temperature rise rate and outputs the temperature rise rate abnormality signal SG1. The normal signal SG2, the cooling efficiency judgment unit 403 outputs the cooling attenuation signal SG3 based on the relative value of the total heat transfer coefficient U / U0, and the pressure and temperature matching judgment unit 404 outputs the pressure and temperature matching abnormal signal SG4 based on the matching relationship between the reactor pressure signal and the temperature signal. The four abnormal signals SG1~SG4 are sent to the comprehensive safety index calculation unit 405, which generates the comprehensive safety index CSI by weighted coupling according to the formula CSI=30×SG1+25×SG2+25×SG3+20×SG4, and outputs the CSI to the gradient interlock response module 500, thereby realizing the conversion of multi-dimensional safety parameters into a single quantitative index.

[0098] Furthermore, the selection and connection relationships of each hardware module are as follows: The temperature sensor uses an armored thermocouple, type K or N, with an outer diameter of 6mm-8mm. The armor material is 316L stainless steel or Inconel alloy to meet the stringent operating requirements of 350℃-450℃ temperature resistance and 25MPa-35MPa pressure resistance. The cooling water flow meter 303 uses a high-precision electromagnetic flow meter or Coriolis mass flow meter to ensure the accuracy of the flow data, because the flow... It is a calculation Key parameters.

[0099] Understandably, this modular hardware architecture design allows the device to be integrated as a whole in new projects or superimposed on existing DCS systems as a retrofit solution (achieved by adding a separate SIS system). The clear signal flow between modules (acquisition-calculation-judgment-execution) conforms to the control habits of process industries, facilitating engineering implementation and maintenance.

[0100] Specifically, the multi-point temperature monitoring module includes a first axial temperature sensor to a fifth axial temperature sensor arranged at intervals along the axial direction of the reactor body, and a first radial temperature sensor to a third radial temperature sensor arranged radially. The multi-parameter coupling safety judgment module is also equipped with a self-diagnostic unit, which is used to diagnose the signal validity of each temperature sensor and, when a signal fault is determined, redistribute the weight coefficient corresponding to the faulty sensor to the remaining valid sensors. The self-diagnostic unit is further configured to detect whether the signal exceeds the physically reasonable range, whether the signal remains unchanged for a long time, or whether the deviation from other sensor signals exceeds a preset threshold.

[0101] It needs to be further explained that, such as Figure 2 As shown, the spatial topology of the multi-point temperature monitoring module 200 constitutes a sensing neural network for the temperature field inside the reactor. The vertical distribution of the first axial temperature sensor 201a to the fifth axial temperature sensor 201e can effectively capture the sensible heat changes of the reactants during the flow process and the possible "hot spots". In particular, the fifth axial temperature sensor 201e, located at 80% height and close to the reaction product outlet 105, can promptly reflect the conversion status at the end of the reaction. The three radial sensors focus on monitoring the heat transfer near the wall, because polymers are prone to coking or sticking to the wall, causing an abnormally high reading of the third radial temperature sensor 202c.

[0102] like Figure 2 As shown, Figure 2(a) is a schematic diagram of the axial measuring point arrangement. The first axial temperature sensor 201a to the fifth axial temperature sensor 201e are arranged at intervals along the effective height direction of the reactor body 101, and are located at 20%, 40%, 50%, 60% and 80% of the effective height, respectively. The 20% height corresponds to the upper region of the reactor, and the 80% height corresponds to the lower region near the reaction product outlet 105, thereby completely covering the axial temperature distribution of the reactant material from the inlet to the outlet. Figure 2 (b) is a schematic diagram of the radial measuring point arrangement. Within the same cross-section of the reactor body 101, the first radial temperature sensor 202a is located at the center of the reactor, the second radial temperature sensor 202b is located at a distance of 1 / 2 radius (R / 2) from the center, and the third radial temperature sensor 202c is located at a position near the wall surface 50 mm away from the wall surface. The three radial measuring points form a temperature measuring chain of "center-middle-near wall" along the radial direction, which can effectively identify the radial temperature difference between the central area and the near wall area of ​​the high viscosity material, and promptly detect the local heat transfer deterioration caused by polymer adhesion to the wall or coking.

[0103] Furthermore, the self-diagnostic unit 406 is integrated into the internal firmware of the multi-parameter coupled safety judgment module 400. Its specific diagnostic logic circuit executes the following steps:

[0104] (1) Set physical boundaries: Define the legal range of temperature signals as follows to If the collected value exceeds this range, it is determined to be an open circuit or short circuit fault.

[0105] (2) Setting the rate of change dead zone: The system has a built-in timer. If the change of a certain channel value within a set period (such as 300 seconds) is less than the set dead zone, the system will set the dead zone. If so, it is determined to be a signal freezing fault.

[0106] (3) Redundancy comparison logic is set: The system calculates the temperature difference between the first axial temperature sensor 201a and the second axial temperature sensor 201b in real time. Since the heat exchange conditions at adjacent axial positions are similar, the temperature difference should not be too large under normal circumstances. If the difference continues to exceed [a certain value], [the system will fail to implement a redundancy comparison logic]. If so, a voting mechanism is initiated, and the radial data is used to determine which sensor is more likely to be the source of the fault.

[0107] (4) Weight redistribution algorithm: Assuming that the 30 weights of SG1 were originally evenly distributed to 5 axial temperature measurement points (6 points for each measurement point), if one of the sensors fails, the weight of the failed measurement point will be evenly distributed to the remaining 4 valid measurement points (7.5 points for each measurement point), ensuring that the total CSI value will not jump due to sensor failure.

[0108] Understandably, sensor drift and failure are unavoidable during long-term operation of chemical plants. The self-diagnostic and adaptive functions of this device effectively give it the ability to "operate with defects" (meaning under non-fatal instrument failures), which has extremely high economic value for continuous production POE units, preventing a complete shutdown due to a single thermometer failure.

[0109] Specifically, the reaction heat dynamic monitoring module includes a cooling water inlet temperature sensor, a cooling water outlet temperature sensor, a cooling water flow meter, and a total heat transfer coefficient calculation unit; the gradient interlock response module is configured as follows: when the comprehensive safety index is in the first preset range, the alarm unit is driven to issue an audible and visual alarm; when it is in the second preset range, a control signal is output to adjust the cooling medium flow rate to the first preset ratio and reduce the catalyst feed rate; when it is in the third preset range, a control signal is output to cut off the catalyst feed and adjust the cooling medium flow rate to the second preset ratio, while simultaneously pre-positioning the emergency terminator rapid dispersion injection module; when it is in the fourth preset range, a control signal is output to cut off all feed, drive the emergency terminator rapid dispersion injection module to inject the terminator, and open the safety relief valve.

[0110] It needs to be further explained that, such as Figure 3 As shown, the reaction heat dynamic monitoring module 300 infers the heat release from the reaction by acquiring the enthalpy change of the cooling medium. The total heat transfer coefficient calculation unit 305 has a built-in microprocessor that runs the heat transfer model in real time. The output of the gradient interlock response module 500 is connected to the specific actuator. When the system is in the second preset range, the control signal output by the module is transmitted to the cooling water regulating valve 502 (e.g., ...). Figure 1 As shown, the control signal is sent to the catalyst feed regulating valve 503 (located on the cooling water inlet 107) to increase its opening, thereby increasing the flow rate to 150% of the normal flow rate. Simultaneously, a control signal is transmitted to the catalyst feed regulating valve 503, reducing its opening by 20%. When in the third preset range, the control signal drives the catalyst feed shut-off valve 504 from the normally open state to the closed state. When in the fourth preset range, the control signal is simultaneously sent to the monomer feed shut-off valve 505 and the solvent feed shut-off valve 506 to close them, and an electrical signal is sent to the fast response injection valves 608a~608d and the safety relief valve 110 to open them.

[0111] Furthermore, regarding the implementation of the arming mechanism: During the third-level response, the device does not immediately inject the terminating agent. Instead, it pre-opens the isolation valve downstream of the terminating agent storage tank 601 (not shown in the figure, but part of module 600) and activates the nitrogen pressurization pipeline 602 to pre-pressurize the terminating agent, making its pressure 1.3 times (solution method) or 1.25 times (high-pressure method) of the operating pressure. In this way, when actual injection is required, the fast-response injection valves 608a~608d only need to overcome a very small pipeline resistance to open instantaneously, and the response time can be controlled within 2 seconds (solution method) or 1.5 seconds (high-pressure method).

[0112] Understandably, this two-step "pre-positioning-injection" design cleverly solves the engineering challenge of delayed fluid injection within high-pressure vessels. By completing pressurization and pipeline preparation in advance during the third-stage response, the actual action time during the fourth-stage response is significantly shortened, gaining crucial seconds to contain the runaway reaction. In the millisecond-critical environment of a polymerization runaway accident, this is a critical factor determining success or failure.

[0113] Specifically, the emergency termination agent rapid dispersion injection module includes a termination agent storage tank, a nitrogen pressurization pipeline, a heating and insulation jacket, a main delivery pipe, a distribution manifold, and a radial distributor; the radial distributor is an annular pipe installed inside the reactor body, with a pipe diameter that is a preset proportion of the reactor's inner diameter, and multiple through holes are opened circumferentially in the pipe wall; a fast-response injection valve is connected in series on the main delivery pipe, and the response time of the fast-response injection valve is less than a preset threshold; the nitrogen pressurization pipeline is configured to pressurize the termination agent to a preset multiple higher than the reactor's operating pressure.

[0114] It needs to be further explained that, such as Figure 6As shown, the emergency terminating agent rapid dispersion injection module 600 is a highly integrated mechanical subsystem. The volume of the terminating agent storage tank 601 is precisely calculated and set to 5% (solution method) or 8% (high-pressure method) of the effective reactor volume to ensure instantaneous inhibition of the reaction after injection. A nitrogen pressurization line 602 connects to the gas phase space of the storage tank, providing a continuous and stable gas source pressure. A heating and insulation jacket 603 wraps around the outer wall of the storage tank and the main delivery pipe 604 to prevent the terminating agent from precipitating out at low temperatures or increasing in viscosity. The main delivery pipe 604 passes through the reactor wall and connects to the distribution manifold 605 located inside the reactor. The distribution manifold 605 acts as a diversion and pressure stabilizer, evenly distributing the fluid to each radial distributor 606. The annular pipe diameter of the radial distributor 606 is 50% to 60% of the reactor's inner diameter. This size ensures coverage of the central area of ​​the reactor while avoiding wear or coking blockage caused by being too close to the wall. The pipe wall has 18-30 through holes (607) with a diameter of 3-5mm. This small-diameter, multi-orifice design generates a high jet velocity, which is beneficial for penetrating high-viscosity POE materials. The fast-response injection valves (608a-608d) are either pneumatic ball valves or piezoelectric ceramic valves to ensure rapid operation.

[0115] like Figure 6 As shown, the emergency terminating agent rapid dispersion injection module 600 includes a terminating agent storage tank 601, a nitrogen pressurization pipeline 602, a heating and insulation jacket 603, a main delivery pipe 604, a distribution manifold 605, a radial distributor 606, a through-hole 607, and rapid response injection valves 608a~608d. The nitrogen pressurization pipeline 602 is connected to the gas phase space of the terminating agent storage tank 601 to provide injection power for the terminating agent. The heating and insulation jacket 603 covers the outer wall of the terminating agent storage tank 601 to maintain the fluidity of the terminating agent. The terminating agent is delivered to the distribution manifold inside the reactor body 101 via the main delivery pipe 604. 605, the distribution manifold 605 evenly distributes the terminator to the annular radial distributor 606. The diameter of the annular tube of the radial distributor 606 is 50%~60% of the inner diameter of the reactor. 18~30 through holes 607 with a diameter of 3mm~5mm are evenly opened on the circumference of its tube wall. Four fast-response injection valves 608a~608d are connected in series along the circumferential direction on the injection path from the main conveying pipe 604 to the radial distributor 606. During injection, high-pressure nitrogen gas pushes the terminator through each through hole 607 and injects it radially into the cross-section of the reactor, quickly forming a uniform dispersion in the high-viscosity material, thus achieving instantaneous termination of the reaction.

[0116] Furthermore, the optimal selection of the number and diameter of the orifices is based on hydrodynamic calculations. In the high-viscosity POE system, the Reynolds number is low, indicating laminar flow. To break the laminar boundary layer, high injection kinetic energy is required. A number of 18-30 orifices with a diameter of 3mm-5mm can achieve the optimal injection velocity and coverage at a given flow rate, avoiding injection dead zones. Simultaneously, the selection of the terminator tank volume takes reaction kinetics into account; a volume ratio of 5%-8% is sufficient to provide an excess of terminating groups, ensuring complete capture of reactive free radicals.

[0117] Understandably, this module is highly targeted, specifically addressing the pain points of "fast reaction, high viscosity, and difficulty in extinguishing" in POE production. Compared to the single-point injection or simple spraying commonly found in existing technologies, the annular multi-point matrix spray design of this module is equivalent to building a three-dimensional "fire extinguishing network" inside the reactor, allowing the terminator to quickly fill the entire reaction space like a gas, thereby achieving truly rapid and uniform dispersion.

[0118] Specifically, it also includes a redundant safety architecture, which includes a DCS control layer, a SIS safety interlock layer, and a local manual emergency layer. The multi-parameter coupled safety judgment module and the gradient interlock response module are deployed in the SIS safety interlock layer, which is independent of the DCS control layer. The local manual emergency layer is a hard-wired relay circuit independent of the DCS control layer and the SIS safety interlock layer, and it is equipped with a local manual stop button. The hard-wired relay circuit is configured to respond to the operation of the local manual stop button and directly drive the gradient interlock response module to execute the highest level of emergency stop response.

[0119] It needs to be further explained that, such as Figure 7As shown, the redundant safety architecture 700 constructs a triple protection system. The DCS control layer 701, as the top layer, is responsible for daily PID adjustment, trend display, and report printing; its connection to field instruments is typically achieved through I / O cards. The SIS safety interlock layer 702, as the core protection layer, has its internal bus physically isolated from the DCS. The logic code of the multi-parameter coupled safety judgment module 400 and the gradient interlock response module 500 is embedded in the SIS CPU. The SIS layer connects to the field intelligent valve controllers via a dedicated safety network (such as Profisafe or Foundation Fieldbus SIS). The local manual emergency layer 703 is the bottom layer, consisting of the simplest electrical components: a 24VDC power supply, a local manual stop button 704, intermediate relays, and time relays. When the local manual stop button 704 is pressed, the 24VDC power supply directly energizes the relay coil, closing the relay's normally open contacts, directly connecting the solenoid valve circuit or disconnecting the motor contactor circuit, thereby closing critical valves such as the catalyst feed shut-off valve 504 and the individual feed shut-off valve 505.

[0120] like Figure 7 As shown, the redundant safety architecture 700 consists of three layers from top to bottom: a DCS control layer 701, a SIS safety interlock layer 702, and a local manual emergency layer 703. The DCS control layer 701 handles daily process control and routine adjustments, and only exchanges communication data with the SIS safety interlock layer 702. The SIS safety interlock layer 702 is independent of the DCS control layer 701, and houses the multi-parameter coupled safety judgment module 400 and the gradient interlock response module 500. The SIS safety interlock layer 702 receives signals from the multi-point temperature monitoring module 200 and the reaction heat dynamic monitoring module 300, and responds to on-site actions. The actuators (catalyst feed regulating valve 503, catalyst feed shut-off valve 504, monomer feed shut-off valve 505, solvent feed shut-off valve 506, safety relief valve 110, and fast response injection valves 608a~608d) have the highest control authority; the local manual emergency layer 703 is a hard-wired relay circuit with a local manual stop button 704. This circuit does not go through any software logic and directly drives the field actuators to perform the highest level of emergency stop action through hard wiring; the three-layer architecture is functionally independent and has a hierarchical fallback in terms of control authority, ensuring that the unit can still be safely stopped in the event of failure of any single point.

[0121] Furthermore, the safety integrity level (SIL) of the SIS layer is set based on process risk assessment: the Insite solution method has relatively mild reaction conditions (80℃-150℃, 1.0MPa-4.9MPa) and relatively low risk, so it is set as SIL2; the Exxpol high-pressure method has harsh reaction conditions (120℃-200℃, 10MPa-12MPa), higher energy density, and greater risk, so it is set as SIL3. This differentiated design satisfies safety requirements while controlling costs. In addition, the hard-wired circuit of the local manual emergency layer 703 does not depend on any software scan cycle, and its response time is only the mechanical action time of the relay (usually less than 50ms), which is much faster than the logic scan cycle of the SIS system (usually 100ms-500ms).

[0122] Understandably, this dual-safety design of "electronic system + hard-wired backup" significantly enhances the intrinsic safety level of the plant. Even in the event of a cyberattack causing DCS failure or a logical error in the SIS system, on-site operators still retain final physical control. This design philosophy fully complies with the Independent Protection Layer (IPL) requirements in Process Safety Management (PSM), ensuring that the plant can be safely shut down under any single point of failure, preventing catastrophic accidents.

[0123] In a preferred embodiment, this application also provides an electronic device, the electronic device comprising:

[0124] The computer device includes a memory and a processor, wherein the memory stores computer-readable instructions that, when executed by the processor, implement the multi-parameter coupling control method for the POE polymerization reaction stage. The computer device can be broadly categorized as a server, terminal, or any other electronic device with the necessary computing and / or processing capabilities. In one embodiment, the computer device may include a processor, memory, network interface, communication interface, etc., connected via a system bus. The processor of the computer device can be used to provide the necessary computing, processing, and / or control capabilities. The memory of the computer device may include a non-volatile storage medium and internal memory. The non-volatile storage medium may store an operating system, computer programs, etc. The internal memory can provide an environment for the operation of the operating system and computer programs in the non-volatile storage medium. The network interface and communication interface of the computer device can be used to connect and communicate with external devices via a network. When the computer program is executed by the processor, it performs the steps of the method of the present invention.

[0125] This invention can be implemented as a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, causes the steps of the methods of embodiments of the invention to be performed. In one embodiment, the computer program is distributed across multiple network-coupled computer devices or processors, such that the computer program is stored, accessed, and executed in a distributed manner by one or more computer devices or processors. A single method step / operation, or two or more method steps / operations, may be executed by a single computer device or processor or by two or more computer devices or processors. One or more method steps / operations may be executed by one or more computer devices or processors, and one or more other method steps / operations may be executed by one or more other computer devices or processors. One or more computer devices or processors may execute a single method step / operation, or execute two or more method steps / operations.

[0126] Those skilled in the art will understand that the method steps of this invention can be performed by a computer program instructing related hardware, such as a computer device or processor, to perform the steps of this invention when executed. Depending on the context, any references herein to memory, storage, databases, or other media may include non-volatile and / or volatile memory. Examples of non-volatile memory include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), flash memory, magnetic tape, floppy disk, magneto-optical data storage device, optical data storage device, hard disk, solid-state drive, etc. Examples of volatile memory include random access memory (RAM), external cache memory, etc.

[0127] The technical features described above can be combined arbitrarily. Although not all possible combinations of these technical features are described, any combination of these technical features should be considered to be covered by this specification, provided that such combination does not contain contradictions.

[0128] The specific embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. Any other corresponding changes and modifications made in accordance with the technical concept of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for multi-parameter coupling control of the POE polymerization reaction stage, characterized in that, include: S1. Obtain axial and radial temperature data, cooling medium temperature and flow rate data, and reactor pressure data at multiple points within the POE polymerization reactor; S2. Calculate the axial temperature gradient and temperature rise rate based on the temperature data, calculate the real-time heat transfer and total heat transfer coefficient based on the temperature and flow rate data of the cooling medium, and obtain the pressure-temperature deviation based on the matching of the pressure data and temperature data. S3. Generate a comprehensive safety index based on the weighted coupling results of the axial temperature gradient, temperature rise rate, relative value of total heat transfer coefficient, and pressure-temperature deviation. S4. Based on the preset range of the comprehensive safety index, perform graded response operations, which include at least early warning, adjusting cooling and catalyst feeding, cutting off catalyst feeding, injecting terminator and shutting down the entire unit.

2. The method according to claim 1, characterized in that, In the step of acquiring axial and radial temperature data at multiple points within the POE polymerization reactor, at least five temperature measuring points are arranged at effective height intervals along the axial direction of the reactor body, and temperature measuring points are arranged in the central region, the intermediate radius region, and the near-wall region along the radial direction of the reactor body. The method also includes a step of self-diagnosing the temperature data: when the signal of any measuring point exceeds the physically reasonable range, remains unchanged for a long time, or deviates from other measuring points by a preset threshold, the measuring point is removed from the safety judgment, and the weight coefficient corresponding to the measuring point is redistributed to the remaining effective measuring points.

3. The method according to claim 2, characterized in that, The steps of calculating the real-time heat transfer and overall heat transfer coefficient based on the temperature and flow rate data of the cooling medium specifically include: The real-time heat transfer is calculated based on the inlet and outlet temperature difference and flow rate of the cooling medium. The total heat transfer coefficient is calculated based on the real-time heat transfer, heat transfer area, and logarithmic mean temperature difference. The relative value of the total heat transfer coefficient is the ratio of the current total heat transfer coefficient to the baseline value of the total heat transfer coefficient under normal operating conditions. In the graded response operation, when the comprehensive safety index is in the first preset range, an audible and visual alarm is issued. When it is in the second preset range, the cooling medium flow rate is increased and the catalyst feed rate is reduced. When it is in the third preset range, the catalyst feed is cut off and emergency cooling is initiated, while the pre-positioned terminator injection module is activated. When it is in the fourth preset range, all feed is cut off, the terminator is injected, and the material is released into the emergency release tank.

4. The method according to claim 3, characterized in that, The step of injecting the terminator is performed by a pre-positioned terminator injection module, which is equipped with an annular radial distributor. The annular radial distributor is located inside the reactor, and its pipe diameter is a preset ratio of the reactor's inner diameter. Multiple through holes are opened in the circumferential direction of the pipe wall. After the terminator is pressurized with nitrogen to a preset multiple higher than the reactor's operating pressure, it is delivered to the annular radial distributor through a fast-response injection valve with a response time less than a preset threshold.

5. The method according to claim 4, characterized in that, The method is also integrated into a redundant safety architecture that includes a DCS control layer, a SIS safety interlock layer, and a local manual emergency layer. The calculation of the comprehensive safety index and the graded response operation are performed by the SIS safety interlock layer, which is independent of the DCS control layer. The local manual emergency layer is equipped with a hard-wired relay circuit and a manual stop button, which can bypass the comprehensive safety index calculation steps and directly trigger the highest level of emergency stop response.

6. A multi-parameter coupling control device for the POE polymerization reaction stage, characterized in that, include: The multi-point temperature monitoring module is configured to collect temperature signals from multiple locations distributed along the axial and radial directions within the POE polymerization reactor. The reaction heat dynamic monitoring module is configured to collect the inlet and outlet temperatures and flow signals of the cooling medium, and calculate the real-time heat transfer and overall heat transfer coefficient. The multi-parameter coupled safety judgment module is connected to the multi-point temperature monitoring module and the reaction heat dynamic monitoring module. It is configured to calculate the axial temperature gradient, temperature rise rate, relative value of total heat transfer coefficient and pressure-temperature deviation, and generate a comprehensive safety index based on the weighted coupling result. The gradient interlock response module is connected to the multi-parameter coupled safety judgment module and is configured to output graded control signals based on the preset range of the comprehensive safety index. The graded control signals at least include warning signals, feed adjustment signals, cut-off signals and stop signals.

7. The apparatus according to claim 6, characterized in that, The multi-point temperature monitoring module includes a first axial temperature sensor to a fifth axial temperature sensor arranged at intervals along the axial direction of the reactor body, and a first radial temperature sensor to a third radial temperature sensor arranged radially. The multi-parameter coupling safety judgment module is also equipped with a self-diagnostic unit. The self-diagnostic unit is used to diagnose the signal validity of each temperature sensor, and when a signal fault is determined, the weight coefficient corresponding to the faulty sensor is redistributed to the remaining valid sensors. The self-diagnostic unit is further configured to detect whether the signal exceeds the physically reasonable range, whether the signal remains unchanged for a long time, or whether the deviation from other sensor signals exceeds a preset threshold.

8. The apparatus according to claim 7, characterized in that, The reaction heat dynamic monitoring module includes a cooling water inlet temperature sensor, a cooling water outlet temperature sensor, a cooling water flow meter, and a total heat transfer coefficient calculation unit; the gradient interlock response module is configured as follows: when the comprehensive safety index is in the first preset range, the alarm unit is driven to issue an audible and visual alarm; when it is in the second preset range, a control signal is output to adjust the cooling medium flow rate to the first preset ratio and reduce the catalyst feed rate; when it is in the third preset range, a control signal is output to cut off the catalyst feed and adjust the cooling medium flow rate to the second preset ratio, while simultaneously positioning the emergency termination agent rapid dispersion injection module. When the device is in the fourth preset range, the output control signal cuts off all feed, drives the emergency terminating agent rapid dispersion injection module to inject the terminating agent, and opens the safety relief valve.

9. The apparatus according to claim 8, characterized in that, The emergency termination agent rapid dispersion injection module includes a termination agent storage tank, a nitrogen pressurization pipeline, a heating and insulation jacket, a main delivery pipe, a distribution manifold, and a radial distributor. The radial distributor is an annular pipe installed inside the reactor body, with a pipe diameter that is a preset proportion of the reactor's inner diameter, and multiple through holes are opened circumferentially in the pipe wall. A fast-response injection valve is connected in series on the main delivery pipe, and the response time of the fast-response injection valve is less than a preset threshold. The nitrogen pressurization pipeline is configured to pressurize the termination agent to a preset multiple higher than the reactor's operating pressure.

10. The apparatus according to claim 9, characterized in that, It also includes a redundant safety architecture, which comprises a DCS control layer, a SIS safety interlock layer, and a local manual emergency layer. The multi-parameter coupled safety judgment module and the gradient interlock response module are deployed in the SIS safety interlock layer, which is independent of the DCS control layer. The local manual emergency layer is a hard-wired relay circuit independent of the DCS control layer and the SIS safety interlock layer, and it is equipped with a local manual stop button. The hard-wired relay circuit is configured to respond to the operation of the local manual stop button and directly drive the gradient interlock response module to execute the highest level of emergency stop response.

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