Sludge co-incineration adaptability intelligent calculation method and system

Abstract

The present application relates to the technical field of solid waste heat treatment process control, and discloses a sludge collaborative incineration adaptability intelligent calculation method and system, which comprises the following steps: acquiring batch sludge characteristic data, collaborative incineration system boundary data, planned feeding demand data and continuous operation response data, obtaining a reliable data set through time alignment and abnormal isolation processing, generating a batch fluctuation image based on the reliable data set, and constructing an adaptability constraint window according to the collaborative incineration system boundary data; obtaining the upper limit of each dimension of independent sludge feeding through a multi-marginal mapping algorithm model in series, which corresponds to the stable margin of the feed, the evaporation load margin of the moisture, the heat margin and the flue gas compliance margin, and combining the lower limit of the sludge feeding to form an initial sludge feedable boundary. The present application solves the problem that it is difficult to determine the safe feeding boundary before the batch sludge fluctuation enters the collaborative incineration system, can identify the real limiting item among the feed, drying, heat balance and flue gas compliance, and output the corresponding compensation control instruction.

Description

Technical Field

[0001] This invention relates to the field of solid waste thermal treatment process control technology, specifically to an intelligent calculation method and system for the adaptability of sludge co-incineration. Background Technology

[0002] Before entering the incineration system, wastewater treatment plant sludge, industrial park sludge, and some water-containing solid waste typically undergo dewatering, temporary storage, transportation, crushing, mixing, or drying. These processes can cause fluctuations in moisture content, lower heating value, ash content, organic matter, adhesiveness, particle size distribution, and the content of nitrogen, sulfur, and chlorine pollution precursors between different batches of sludge from the same source arriving at the plant.

[0003] For municipal solid waste incinerators or solid waste co-incineration systems, sludge is not simply a substitute fuel. After entering the furnace, sludge simultaneously alters material conveying resistance, moisture evaporation load, furnace heat balance, and tail-end flue gas purification load. When the sludge moisture content increases, the heating and vaporization of the incoming moisture consumes heat, leading to a decrease in the furnace's main control temperature, slower oxygen recovery, and a delayed peak carbon monoxide tailing. When sludge adhesion increases, screw feeders, plunger pumps, or belt conveyors initially exhibit torque increases and intermittent material shortages, followed by localized combustion pulsations within the furnace. When the sludge chlorine or sulfur content increases, even with a high lower heating value, semi-dry deacidification reaction towers, wet scrubbing towers, or dry injection units may still approach emission limits due to insufficient residual reagent treatment capacity.

[0004] The existing operating procedures mostly rely on operators to adjust the sludge dosage based on sludge moisture content, calorific value, furnace main control temperature, and flue gas pollutant concentration. While this calorific value-based dosage calculation method can determine whether the mixture entering the furnace has the basic heat to sustain combustion, it is difficult to identify sudden increases in the load on the feeding device caused by highly viscous sludge, and it is also difficult to predict in advance the occupancy of the remaining absorption capacity of the tail-end purification unit by high-chlorine and high-sulfur sludge.

[0005] Feedback control methods centered on the furnace's main temperature control typically reduce sludge addition after it has entered the furnace, based on temperature drops, changes in oxygen content, or increases in carbon monoxide concentration. At this point, the incineration system has already experienced a thermal disturbance. While intelligent models that output comprehensive scores can simultaneously input multiple parameters, if they only output recommended scores or recommended blending ratios, operators still find it difficult to determine whether the limiting factors originate from feeding, drying, calorific value, or flue gas compliance. Furthermore, compensation control commands are unlikely to correspond accurately to the actual limiting factors.

[0006] Before continuous sludge addition, an executable safe addition boundary needs to be established. This safe addition boundary must avoid constraints such as the maximum allowable torque of the feeding device, moisture evaporation capacity, furnace temperature floor, and flue gas emission limits, and must also be corrected based on the actual response after trial addition. Current technology does not provide an adaptive boundary calculation scheme that combines sludge batch fluctuations, hard and soft constraints of the incineration system, serial calculation of multiple margin terms, and correction based on trial responses. Summary of the Invention

[0007] The purpose of this invention is to provide an intelligent calculation method and system for the adaptability of sludge co-incineration. The technical problem to be solved by this invention is that the moisture content, lower heating value, adhesion and pollution precursor content of sludge batches may fluctuate. The existing sludge addition amount given based on calorific value, furnace temperature or single score cannot reflect the conversion relationship between multiple limiting factors such as feed stability, moisture evaporation, heat balance and flue gas compliance, resulting in a lack of clear, executable and correctable addition boundaries before sludge enters the furnace.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0009] Intelligent computing methods for adaptability of sludge co-incineration include:

[0010] Acquire batch sludge characteristic data, co-incineration system boundary data, planned feed-in demand data, and continuous operation response data. Perform time alignment and anomaly isolation on the batch sludge characteristic data, co-incineration system boundary data, planned feed-in demand data, and continuous operation response data to obtain a reliable dataset. Generate a batch fluctuation profile characterizing the distribution features of physical properties based on the reliable dataset.

[0011] An adaptive constraint window containing hard and soft boundary constraints is constructed based on the boundary data of the co-incineration system.

[0012] The batch fluctuation profile is input into the multi-margin mapping algorithm model. Following a series constraint method—using the rheological transport resistance calculation result as the upper limit of the latent heat consumption phase change calculation, the phase change latent heat consumption calculation result and the rheological transport resistance calculation result together as the upper limit of the thermal equilibrium state calculation, and the rheological transport resistance calculation result and the thermal equilibrium state calculation result together as the upper limit of the pollution conversion rate calculation—the first-dimensional independent sludge addition upper limit corresponding to the feed stability margin, the second-dimensional independent sludge addition upper limit corresponding to the moisture evaporation load margin, the third-dimensional independent sludge addition upper limit corresponding to the heat margin, and the fourth-dimensional independent sludge addition upper limit corresponding to the flue gas compliance margin are obtained sequentially. The tolerance interval coefficient corresponding to the soft boundary constraint is used to correct the first-dimensional independent sludge addition upper limit, the second-dimensional independent sludge addition upper limit, the third-dimensional independent sludge addition upper limit, and the fourth-dimensional independent sludge addition upper limit, generating the multi-margin profile.

[0013] Based on the multi-margin profile and the fitting constraint window, the independent sludge addition upper limit corresponding to each margin is extracted. The minimum value among the independent sludge addition upper limits is selected as the candidate addition upper limit. The sludge addition lower limit is generated based on the planned addition demand data. When the sludge addition lower limit is not higher than the candidate addition upper limit, the initial sludge addition boundary is established.

[0014] When the incineration system is under stable load, a trial dosing command is issued based on the candidate dosing upper limit and the trial dosing safety feed coefficient. Continuous operation response data is obtained and the actual response deviation is calculated. The actual response deviation is compared with the expected response direction and expected response amplitude. Boundary contraction, boundary translation, or restricted release treatment is performed on the initial sludge dosing boundary. The corrected sludge dosing boundary and matching level are output. Among them, the restricted release treatment must simultaneously meet the hard boundary constraint of not exceeding the adaptation constraint window and the allowable range of the current soft boundary constraint tolerance range.

[0015] This invention also discloses a sludge co-incineration adaptability boundary calculation system for executing the sludge co-incineration adaptability intelligent calculation method described above, including:

[0016] The data trust module is configured to acquire batch sludge characteristic data, co-incineration system boundary data, planned dosing demand data, and continuous operation response data. It performs time alignment, source trust verification, and anomaly isolation on the batch sludge characteristic data, co-incineration system boundary data, planned dosing demand data, and continuous operation response data to obtain a trustworthy dataset, and sends the trustworthy dataset to the profile building module.

[0017] The profile building module, which communicates with the data trustworthiness module, is configured to generate a batch fluctuation profile representing the distribution characteristics of physical properties based on the trusted dataset, construct an adaptation constraint window containing hard boundary constraints and soft boundary constraints based on the boundary data of the co-incineration system, dynamically adjust the tolerance interval coefficient corresponding to the soft boundary constraints based on the equipment maintenance status, real-time inventory of purification agents, current combustion load and effective status of the continuous emission monitoring system, and send the batch fluctuation profile, adaptation constraint window and tolerance interval coefficient corresponding to the soft boundary constraints to the margin mapping module.

[0018] The margin mapping module, which communicates with the profile construction module, is configured to input batch fluctuation profiles into the multi-margin mapping algorithm model. It uses a serial constraint method where the rheological transport resistance calculation result is used as the upper limit of the latent heat consumption phase change calculation, the latent heat consumption phase change calculation result and the rheological transport resistance calculation result are used together as the upper limit of the thermal equilibrium state calculation, and the rheological transport resistance calculation result and the thermal equilibrium state calculation result are used together as the upper limit of the pollution conversion rate calculation. This sequentially obtains the first-dimensional independent sludge addition upper limit corresponding to the feed stability margin, the second-dimensional independent sludge addition upper limit corresponding to the moisture evaporation load margin, the third-dimensional independent sludge addition upper limit corresponding to the heat margin, and the fourth-dimensional independent sludge addition upper limit corresponding to the flue gas compliance margin. The tolerance interval coefficient corresponding to the soft boundary constraint is used to correct the upper limits of each dimension of independent sludge addition, generating a multi-margin profile and the expected response direction and expected response amplitude. The multi-margin profile, expected response direction, and expected response amplitude are then sent to the boundary generation module and the feedback correction module.

[0019] The boundary generation module, which communicates with the margin mapping module, is configured to extract the independent sludge dosing upper limit corresponding to each margin based on the multi-margin profile and the adaptation constraint window, select the minimum value among the independent sludge dosing upper limits as the candidate dosing upper limit, generate the sludge dosing lower limit based on the planned dosing demand data, establish the initial sludge dosing boundary when the sludge dosing lower limit is not higher than the candidate dosing upper limit, generate the prohibition dosing instruction when the situation of triggering the prohibition dosing instruction occurs, and send the initial sludge dosing boundary to the feedback correction module.

[0020] The feedback correction module, which communicates with the boundary generation module, is configured to issue a trial addition command based on the candidate addition upper limit and the trial addition safety feed coefficient when the incineration system is in a stable load state. It acquires continuous operation response data and calculates the actual response deviation. It compares the actual response deviation with the expected response direction and expected response amplitude, and performs boundary shrinkage, boundary translation or restricted release treatment on the initial sludge addition boundary to form a corrected sludge addition boundary.

[0021] The strategy output module, which communicates with the feedback correction module, is configured to output the corrected sludge dosing boundary and matching level, and output compensation control instructions based on the restrictions.

[0022] Meanwhile, the present invention also discloses a computer-readable storage medium storing computer program instructions for calculating the adaptability boundary of sludge co-incineration. When the computer program instructions are executed by a processor, the intelligent calculation method for sludge co-incineration adaptability is implemented as described above.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] This invention projects the fluctuating characteristics of batch sludge onto the feed stability margin, moisture evaporation load margin, heat margin, and flue gas compliance margin, independently obtaining the upper limit for each sludge addition. The minimum upper limit is then selected to form a candidate upper limit, ensuring that the dosing boundary is determined by the current constraints of the incineration system, rather than by average calorific value or comprehensive score. The output of the rheological transport resistance calculation serves as the input constraint for the latent heat consumption calculation of phase change. The preceding mass flow rate is further incorporated into the thermal equilibrium state calculation and the pollutant conversion rate calculation, creating a continuous transfer of material flow, heat flow, and pollutant generation flow between each calculation stage. This reduces the risk of conflicting dosing recommendations from independent models.

[0025] After the initial sludge addition boundary is established in this invention, trial addition and continuous operation response data are used to correct the boundary. When the actual response shows that the system's carrying capacity is lower than predicted, the boundary is contracted; when the main limiting factor shifts from heat margin to flue gas compliance margin, the boundary is shifted to a new safe range; when continuous operation response data indicates that the system still has a controlled margin, the boundary is released under restrictions. This release is only performed under the condition that the hard boundary constraints of the adaptation constraint window are not exceeded and the allowable range of the current soft boundary constraint tolerance is not exceeded.

[0026] This invention can output limiting parameters and compensation control directions. When the heat margin is insufficient but the flue gas compliance margin meets the requirements, it outputs auxiliary fuel or high-calorific-value co-fuel compensation; when the moisture evaporation load margin is insufficient, it outputs drying heat source compensation, drying target adjustment, or production delay; when the flue gas compliance margin is insufficient, it outputs reducing the blending ratio of chlorine-containing sludge or increasing the pre-filled level of the scrubbing tower; when the feed stability margin is insufficient, it outputs pulse feeding, pre-crushing, or pre-mixing treatment, so that the operation control commands correspond to the technical limiting parameters. Attached Figure Description

[0027] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0028] Figure 1 is a flowchart of the method of the present invention.

[0029] Figure 2 is a flowchart of the multi-margin portrait generation sub-process of the present invention.

[0030] Figure 3 is a flowchart of the time alignment and anomaly isolation sub-process of the present invention.

[0031] Figure 4 is a flowchart of the batch fluctuation profile generation sub-process of the present invention.

[0032] Figure 5 is a flowchart of the adaptive constraint window construction sub-process of the present invention.

[0033] Figure 6 is a flowchart of the branch process for establishing the initial sludge addition boundary of the present invention.

[0034] Figure 7 is a flowchart of the branch generation process for the prohibition of adding instructions in this invention.

[0035] Figure 8 is a flowchart of the actual response deviation calculation sub-process of the present invention.

[0036] Figure 9 is a flowchart of the boundary shrinkage processing branch of the present invention.

[0037] Figure 10 is a system architecture diagram of the present invention. Detailed Implementation

[0038] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the embodiments of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0039] The following is in conjunction with the appendix Figures 1-10 The embodiments of the present invention will be described in detail below.

[0040] Example 1: This example discloses an intelligent calculation method for the adaptability of sludge co-incineration, including:

[0041] Acquire batch sludge characteristic data, co-incineration system boundary data, planned feed-in demand data, and continuous operation response data. Perform time alignment and anomaly isolation on the batch sludge characteristic data, co-incineration system boundary data, planned feed-in demand data, and continuous operation response data to obtain a reliable dataset. Generate a batch fluctuation profile characterizing the distribution features of physical properties based on the reliable dataset.

[0042] An adaptive constraint window containing hard and soft boundary constraints is constructed based on the boundary data of the co-incineration system.

[0043] The batch fluctuation profile is input into the multi-margin mapping algorithm model. Following a series constraint method—using the rheological transport resistance calculation result as the upper limit of the latent heat consumption phase change calculation, the phase change latent heat consumption calculation result and the rheological transport resistance calculation result together as the upper limit of the thermal equilibrium state calculation, and the rheological transport resistance calculation result and the thermal equilibrium state calculation result together as the upper limit of the pollution conversion rate calculation—the first-dimensional independent sludge addition upper limit corresponding to the feed stability margin, the second-dimensional independent sludge addition upper limit corresponding to the moisture evaporation load margin, the third-dimensional independent sludge addition upper limit corresponding to the heat margin, and the fourth-dimensional independent sludge addition upper limit corresponding to the flue gas compliance margin are obtained sequentially. The tolerance interval coefficient corresponding to the soft boundary constraint is used to correct the first-dimensional independent sludge addition upper limit, the second-dimensional independent sludge addition upper limit, the third-dimensional independent sludge addition upper limit, and the fourth-dimensional independent sludge addition upper limit, generating the multi-margin profile.

[0044] Based on the multi-margin profile and the fitting constraint window, the independent sludge addition upper limit corresponding to each margin is extracted. The minimum value among the independent sludge addition upper limits is selected as the candidate addition upper limit. The sludge addition lower limit is generated based on the planned addition demand data. When the sludge addition lower limit is not higher than the candidate addition upper limit, the initial sludge addition boundary is established.

[0045] When the incineration system is under stable load, a trial dosing command is issued based on the candidate dosing upper limit and the trial dosing safety feed coefficient. Continuous operation response data is obtained and the actual response deviation is calculated. The actual response deviation is compared with the expected response direction and expected response amplitude. Boundary contraction, boundary translation, or restricted release treatment is performed on the initial sludge dosing boundary. The corrected sludge dosing boundary and matching level are output. Among them, the restricted release treatment must simultaneously meet the hard boundary constraint of not exceeding the adaptation constraint window and the allowable range of the current soft boundary constraint tolerance range.

[0046] In this embodiment, the trusted dataset is formed by time alignment and anomaly isolation of batch sludge characteristic data, co-incineration system boundary data, planned dosing demand data, and continuous operation response data. The batch fluctuation profile is formed by batch sludge characteristic data from the trusted dataset and historical batch data from the same source. The adaptation constraint window is formed by the co-incineration system boundary data from the trusted dataset. The multi-margin profile consists of the first dimension of independent sludge dosing upper limit, the second dimension of independent sludge dosing upper limit, the third dimension of independent sludge dosing upper limit, the fourth dimension of independent sludge dosing upper limit, and the sorting of restriction items.

[0047] The limiting items are the minimum independent sludge addition limit items among the following: feed stability margin, moisture evaporation load margin, heat margin, and flue gas compliance margin.

[0048] In this embodiment, the preset judgment difference is uniformly taken as... The difference between the upper limits of two or more independent sludge additions shall not exceed [a certain value]. When the difference is not higher than The margin items corresponding to the independent sludge addition upper limit are jointly determined as restriction items.

[0049] The preset historical stability interval is the interval formed by adding or subtracting twice the standard deviation of the mean of historical monitoring data from the same sludge source. When the historical samples are skewed, the preset historical stability interval is the historical monitoring data from the same sludge source. quantile value to The interval formed by quantile values. For batches of normally distributed sludge, a mean fluctuation profile is used; when sludge parameters exhibit a skewed distribution, industrial sludge shows long-tailed fluctuations, or historical samples have large dispersion, a quantile interval profile is used. When there are no historical test samples for the sludge source, the default historical stability interval is the rated allowable fluctuation range of the equipment corresponding to the feeding device, drying equipment, furnace heat balance, and flue gas purification system; the first batch will not generate a batch anomaly marker due to the lack of historical test samples, but the trial addition safety feed coefficient is set to [value missing]. When any characteristic parameter of the current batch exceeds the preset historical stable range, the profile building module determines that the fluctuation range of the current batch exceeds the preset historical stable range and generates a batch anomaly marker.

[0050] A stable load state is an operating state that simultaneously meets the following conditions:

[0051] The main temperature fluctuation range of the furnace does not exceed The rate of change of main steam flow does not exceed The fluctuation range of primary and secondary air pressure shall not exceed The continuous emission monitoring system is in effective condition; the rate of change in basic fuel feed does not exceed [a certain threshold]. A stable load condition is used to proactively issue trial dosing commands. If the incineration system does not meet the stable load condition, or if the operating procedures prohibit proactively issuing trial dosing commands, only natural dosing variation segments can be used as an exception verification method, and the natural dosing variation segments must meet the conditions of complete coverage of material flow lag and non-sludge disturbance elimination.

[0052] The condition for complete coverage of the logistics lag is: extending the total material-flue gas lag time backward from the start to the end of the natural addition change, ensuring that the captured operational segment covers the entire response process of sludge from the feeding device to the sampling point of the continuous emission monitoring system. The condition for excluding non-sludge disturbance is: the rate of change of basic fuel feed rate within the natural addition change segment does not exceed... The rate of change of both primary and secondary air volume does not exceed [a certain value]. The auxiliary fuel supply did not change abruptly; the dosage of purification agents did not change abruptly; the continuous emission monitoring system was in effective condition; there was no furnace soot blowing action; there was no abrupt adjustment of the denitrification ammonia injection rate; there was no furnace load interlock action.

[0053] Necessary control variable acquisition failure refers to any of the following variables being missing for three consecutive sampling cycles, exceeding the sensor's range, or being marked as invalid: sludge moisture content, sludge lower heating value, sludge chlorine content, furnace main control temperature, oxygen content, feeder torque, drying heat source surplus, or the effective status of the continuous emission monitoring system. When necessary control variable acquisition fails, the boundary generation module generates a prohibition on feeding command.

[0054] Sludge adhesion risk data uses apparent viscosity and yield stress as quantitative indicators. Apparent viscosity is less than... And the yield stress is less than At that time, the sludge adhesion risk data was marked as low risk; the apparent viscosity was... to , or yield stress is to At that time, the sludge adhesion risk data was marked as medium risk; the apparent viscosity was higher than... or yield stress higher than At that time, the sludge adhesion risk data was marked as high risk.

[0055] Without rheological testing equipment, the data reliability module uses the feeder torque rise rate, conveying pipe pressure differential, and arch breaker operation frequency as substitute indicators. The feeder torque rise rate is lower than... When the differential pressure in the conveying pipe is lower than the upper limit of the normal conveying differential pressure and the frequency of the arch breaker operation is no more than twice per hour, the sludge adhesion risk data is marked as low risk; the torque rise rate of the feeding device is... to Or, the pressure difference in the delivery pipe exceeds the upper limit of the normal delivery pressure difference but is not higher than the upper limit of the normal delivery pressure difference. When the sludge adhesion risk is higher than twice the normal value, or when the frequency of the arch breaker's operation is 3 to 6 times per hour, the sludge adhesion risk is marked as medium risk; the torque increase rate of the feeding device is higher than... Or the pressure differential in the delivery pipe is higher than the upper limit of the normal delivery pressure differential. When the sludge adhesion risk is higher than 6 times per hour, or the frequency of the arch breaker operation exceeds 6 times per hour, the sludge adhesion risk data is marked as high risk. When multiple indicators conflict, the physical parameters of equipment operation take precedence over the parameters of manual sampling; when multiple physical parameters of equipment operation have inconsistent risk levels, the highest risk level is used as the final classification result.

[0056] Without screening or image detection equipment, the sludge particle size distribution characteristics are determined by the crusher current fluctuation, silo discharge frequency, and manual sampling particle size records. The crusher current fluctuation amplitude does not exceed [a certain percentage] of the rated current. Furthermore, when the proportion of coarse particles detected by manual sampling is lower than the allowable range for the equipment, the particle size risk is marked as low risk; the current fluctuation range of the crusher is within the rated current. to Or, if the proportion of coarse particles detected by manual sampling exceeds the allowable range of the equipment but the excess proportion is not higher than [the specified percentage]. At that time, the particle size risk was marked as medium risk; the crusher current fluctuation amplitude exceeded the rated current. Or, if the proportion of coarse particles detected by manual sampling exceeds the allowable range of the equipment and the excess percentage is higher than [a certain percentage], [the problem is likely related to the issue of particle count]. At that time, particle size risk is marked as high risk. The difference in crusher current fluctuation, hopper discharge frequency, and feeder torque variation has higher priority than manually sampled particle size records; when multiple indicators conflict, the highest risk level is used as the final classification result.

[0057] The trial dosing safety feed coefficient is the ratio of the trial sludge dosing mass flow rate to the candidate dosing upper limit.

[0058] The safety feed coefficient for trial addition in regular batches is taken as follows: The trial feed safety factor for batches with batch anomaly flags is taken as follows: The restricted release preset increment is the increase in the candidate betting limit for each release. The restricted release preset increment is taken as the current candidate betting limit. And the single increase does not exceed The restricted release process must simultaneously satisfy the following conditions: it must not exceed the hard boundary constraints of the adaptation constraint window; and it must not exceed the allowable range of the current soft boundary constraint tolerance interval. The first-dimensional independent sludge addition upper limit, the second-dimensional independent sludge addition upper limit, the third-dimensional independent sludge addition upper limit, and the fourth-dimensional independent sludge addition upper limit serve as prerequisite boundaries for generating candidate addition upper limits and are no longer used as repeated limiting conditions for the restricted release process.

[0059] The matching level is determined based on the coverage relationship between the corrected sludge addition boundary and the planned addition demand data. The overlap is calculated using the following formula:

[0060]

[0061] in, For overlap, This refers to the overlap length between the corrected sludge addition boundary and the planned addition demand range. The total length of the planned demand range.

[0062] The remaining proportion of the tolerance interval for soft boundary constraints is calculated using the following formula:

[0063]

[0064] in, This represents the remaining proportion of the tolerance interval for soft boundary constraints. This is the current upper limit of the soft boundary constraint. These are the real-time running values ​​corresponding to soft boundary constraints. This represents the maximum tolerance range width of the soft boundary. When the same matching level judgment involves multiple soft boundary constraints, the minimum value among the remaining proportions of the tolerance ranges of each soft boundary constraint is taken as the input for the matching level judgment.

[0065] The revised sludge addition boundary fully covers the planned addition demand range, and the remaining proportion of the soft boundary constraint tolerance range is not less than [percentage missing]. At that time, the matching level is highly compatible; the overlap between the corrected sludge addition boundary and the planned addition demand range is not less than [percentage missing]. And lower than At that time, the matching level was moderately suitable; the corrected sludge addition boundary overlapped with the planned addition demand range, and the degree of overlap was less than [missing information]. When the corrected sludge addition boundary does not overlap with the planned addition demand range, the matching level is low-fit; when the corrected sludge addition boundary does not overlap with the planned addition demand range, the matching level is unfit.

[0066] The evaporation phase change requirement baseline is the minimum drying heat source required to maintain the minimum stable operation of the drying equipment. This baseline corresponds to the lower limit of sludge moisture evaporation that the drying equipment can handle under the minimum stable feed condition. When the remaining drying heat source is lower than the evaporation phase change requirement baseline, the boundary generation module generates a prohibition on feeding command.

[0067] The results of the mass flow rate calculation are uniformly retained to Actual response deviation calculation results are uniformly retained to two decimal places, and torque ratio, inventory ratio, and fluctuation ratio in percentage form are uniformly retained to [number missing]. The content of polluting elements is uniformly retained to Intermediate calculated values ​​are retained to three significant digits when participating in subsequent calculations, and the final output value is rounded to the nearest whole number according to the above rules.

[0068] The safe limit for oxygen content recovery time is taken as follows The safe limit for the peak duration of carbon monoxide is taken as The safety limit for the torque variation difference of the feeding device is taken as the maximum permissible torque of the feeding device. The safety limits for the gradient of the main control temperature in the furnace and the safety limits for the ramp-up slope of the acid gas concentration are written into the adaptation constraint window according to the incineration system operation procedures.

[0069] The quantitative calculation logic of the multi-margin mapping algorithm model is as follows: While outputting the upper limit of each independent sludge addition, the multi-margin mapping algorithm model simultaneously outputs the expected response direction and expected response amplitude under the corresponding trial sludge addition mass flow rate. The expected response direction and expected response amplitude include predicted values ​​of the furnace main control temperature drop, oxygen content recovery time, carbon monoxide peak duration, acid gas concentration ramp-up slope, and the difference in torque change of the feeding device, which are used as a benchmark for comparing the actual response deviation.

[0070] After the initial independent sludge dosing upper limits for each dimension are calculated, the multi-margin mapping algorithm model performs numerical correction by combining the tolerance interval coefficients of the corresponding soft boundary constraints. The first, second, third, and fourth independent sludge dosing upper limits, corrected by the tolerance interval coefficients of the soft boundary constraints, serve as the final usable independent sludge dosing upper limits for each dimension within the multi-margin profile. The independent sludge dosing upper limits for each dimension, corrected by the tolerance interval coefficients of the soft boundary constraints, must not exceed the hard boundary constraints within the fitting constraint window.

[0071] The tolerance range coefficients are configured for the acid gas absorption and purification capacity, the continuous operation capacity of the feeding device, and the dry heat source margin. The oxygen content recovery response capacity and carbon monoxide concentration control capacity are only used as weighted correction factors for the actual response deviation, and do not participate in the numerical reduction of the first-dimensional independent sludge addition upper limit, the second-dimensional independent sludge addition upper limit, the third-dimensional independent sludge addition upper limit, and the fourth-dimensional independent sludge addition upper limit, and are not configured with tolerance range coefficients.

[0072] Oxygen content recovery response capability is based on the time required for oxygen content recovery. Safety limits for oxygen content recovery time Relationship hierarchy:

[0073] when At that time, the oxygen content recovery response capability was excellent, and the weighted correction factor was taken as... ;

[0074] when At that time, the oxygen content recovery response capability was medium, and the weighted correction factor was taken as... ;

[0075] when At that time, the oxygen content recovery response was weak, and the weighted correction factor was taken as... The carbon monoxide concentration control capability is based on the duration of peak carbon monoxide levels. Safety limits for the duration of peak carbon monoxide Relationship hierarchy: when At that time, the carbon monoxide concentration control capability was excellent, and the weighted correction factor was taken as... ;when At that time, the carbon monoxide concentration control capability was medium, and the weighted correction factor was taken as... ;when At that time, the ability to control carbon monoxide concentration was weak, and the weighted correction factor was taken as... .

[0076] The rheological transport resistance calculation is based on the rated sludge feeding mass flow rate of the feeding device, sludge adhesion risk data, sludge particle size distribution characteristics data, and the torque margin of the feeding device to determine the upper limit of the first-dimensional independent sludge feeding stability margin:

[0077]

[0078] in, The first independent sludge addition limit corresponds to the stable feed margin. The rated sludge dosing mass flow rate of the feeding device, This is the adhesion correction factor. This is the particle size correction factor. This is the maximum permissible torque of the feeding device. The current torque of the feeding device, This is the multiplication operator.

[0079] The adhesion correction factor is determined based on the sludge adhesion risk data: for low risk, the value is [value to be filled in]. Medium-risk High-risk acquisition The particle size correction factor is determined based on the relationship between the proportion of coarse particles and the allowable range of the equipment: when the proportion of coarse particles is lower than the allowable range of the equipment, the value is adjusted accordingly. The proportion of coarse particles exceeds the allowable range of the equipment, but the excess proportion is not higher than [the specified percentage]. Time to take The proportion of coarse particles exceeds the equipment's allowable range and the excess percentage is higher than [a certain percentage]. Time to take .

[0080] The calculation of latent heat consumption of phase change is based on the drying heat source margin, the heat exchange efficiency of the drying equipment, and the proportion of water that needs to be evaporated per unit of wet sludge. The upper limit of the second dimension of independent sludge addition is determined according to the water evaporation load margin.

[0081]

[0082] in, This represents the upper limit of the second independent sludge addition corresponding to the moisture evaporation load margin. This is the remaining heat source for drying. For the heat exchange efficiency of drying equipment. This refers to the proportion of evaporation moisture equivalent that a unit of wet-based sludge needs to be handled by an external drying heat source. The latent heat of water vaporization This is the conversion factor between tons and kilograms. This is a multiplication operator. The heat exchange efficiency of the drying equipment ranges from [value missing]. to .

[0083] The proportion of evaporation moisture equivalent that an external drying heat source must bear per unit of wet-based sludge The moisture content is determined jointly by the upper limit of sludge moisture content fluctuation, the target moisture content for drying, and the calibration curve of the drying equipment. The calibration curve reflects the impact of mechanical pre-dewatering, heat recovery, waste heat compensation, and heat loss in the drying section on the external drying heat source load. Without a calibration curve for the drying equipment, Determine by the following formula:

[0084]

[0085] in, This refers to the percentage of water that needs to be evaporated from a unit of wet-based sludge. The moisture content of the sludge before it enters the drying equipment. The target moisture content for drying. When establishing the calibration curve for the drying equipment, The calibration curve is output, and the input of the calibration curve includes... , The heat recovery ratio and heat loss coefficient of the drying equipment.

[0086] The thermal balance calculation is based on the available heat margin in the furnace, the moisture content of the sludge entering the furnace, the lower heating value of the sludge, and the sensible heat compensation required per unit mass of sludge to maintain the main control temperature of the furnace. The upper limit of the third-dimensional independent sludge addition is determined according to the following:

[0087]

[0088] in, This refers to the upper limit of the third-dimensional independent sludge addition corresponding to the heat margin. To ensure sufficient heat capacity in the furnace, The moisture content of the sludge entering the furnace. The latent heat of water vaporization This is the conversion factor between tons and kilograms. The sensible heat compensation required to maintain the main control temperature of the furnace per unit mass of sludge. The lower heating value of sludge, This is a multiplication operator. The sensible heat compensation required to maintain the furnace master temperature per unit mass of sludge is determined by the difference between the furnace master temperature and the furnace temperature baseline, the flue gas mass flow rate, the flue gas constant pressure specific heat capacity, and the system's historical heat balance calibration results.

[0089] When the denominator of the heat balance calculation formula is not greater than zero, it indicates that the overall calorific value contribution of the sludge is not less than the consumption of water evaporation and sensible heat compensation. The sludge does not negatively disturb the furnace heat after entering the furnace, and the heat margin does not constitute a limiting term. In this case, the upper limit of the third-dimensional independent sludge addition corresponding to the heat margin is taken as the smaller value between the upper limit of the first-dimensional independent sludge addition and the rated sludge addition mass flow rate of the feeding device.

[0090] The pollution conversion rate calculation takes the moisture content of the dried sludge corresponding to the second-dimensional independent sludge addition limit, and calculates the pollutant generation based on the dry basis chlorine content and sulfur content of the dried sludge. The pollution conversion rate calculation calculates the addition limits corresponding to hydrogen chloride and sulfur dioxide respectively, and takes the smaller value as the fourth-dimensional independent sludge addition limit corresponding to the flue gas compliance margin.

[0091]

[0092] in, This represents the upper limit of sludge addition corresponding to the hydrogen chloride treatment capacity. This refers to the residual hydrogen chloride treatment capacity of the semi-dry deacidification reaction tower. This is the conversion factor between tons and kilograms. The moisture content of the sludge entering the furnace. This refers to the dry basis chlorine content of the sludge after drying. The conversion rate of chlorine to hydrogen chloride. This represents the molar mass coefficient of chlorine converted to hydrogen chloride. This is the multiplication operator.

[0093]

[0094] in, This represents the upper limit of sludge addition corresponding to the sulfur dioxide treatment capacity. This refers to the residual sulfur dioxide treatment capacity of the semi-dry desulfurization reaction tower. This is the conversion factor between tons and kilograms. The moisture content of the sludge entering the furnace. This refers to the dry basis sulfur content of the sludge after drying. The conversion rate of sulfur to sulfur dioxide. This represents the molar mass coefficient of sulfur in its conversion to sulfur dioxide. This is the multiplication operator.

[0095]

[0096] in, The upper limit for the fourth dimension of independent sludge addition corresponds to the flue gas compliance margin. This represents the upper limit of sludge addition corresponding to the hydrogen chloride treatment capacity. This represents the upper limit of sludge addition corresponding to the sulfur dioxide treatment capacity. This is an operator that selects the minimum value from the maximum sludge addition limits within the parentheses.

[0097] The soft boundary constraint is dynamically adjusted using a tolerance range coefficient. The tolerance range coefficient corresponding to the acid gas absorption and purification capacity is determined based on the real-time inventory of the deacidifying agent: the real-time inventory of the deacidifying agent is higher than the rated inventory. Time to take The real-time inventory of deacidifying agents is the rated inventory. to Time to take The real-time inventory of deacidifying agents is lower than the rated inventory. Time to take The tolerance coefficient corresponding to the drying heat source margin is taken as the ratio of the drying heat source margin to the design drying heat source requirement: a ratio higher than... Time to take The ratio is to Time to take The ratio is lower than Time to take The tolerance coefficient corresponding to the continuous operating capacity of the feeding device is taken as the ratio of the torque margin of the feeding device to the maximum allowable torque of the feeding device: a ratio higher than... Time to take The ratio is to Time to take The ratio is lower than Time to take .

[0098] Multiplying the corresponding upper limit of independent sludge addition by the corresponding tolerance range coefficient yields the upper limit of independent sludge addition after soft boundary adjustment:

[0099]

[0100] in, For the first The upper limit of independent sludge addition after correction of the tolerance interval coefficient under soft boundary constraints. For the first The independent sludge addition limit obtained by the corresponding solution formula is... For the first The tolerance interval coefficient corresponding to the soft boundary constraint. This is the multiplication operator.

[0101] The feedback correction module normalizes the actual response parameters and the expected response parameters to form the actual response deviation. Let the first... The actual original value of each response parameter is , No. The expected original value of each response parameter is , No. The security limit for each response parameter is ,but:

[0102]

[0103] in, For the first The actual normalized value of each response parameter For the first The actual original value of each response parameter For the first Safety limits for each response parameter.

[0104]

[0105] in, For the first The expected normalized value of each response parameter. For the first The expected original value of each response parameter For the first Safety limits for each response parameter.

[0106] The actual response deviation is calculated using the following formula:

[0107]

[0108] in, This represents the actual response deviation. The number of response parameters involved in the deviation calculation. For the first Weighted correction factors for each response parameter, For the first The actual normalized value of each response parameter For the first The expected normalized value of each response parameter. For the first The normalized absolute value of the residuals of each response parameter. This is the summation operator.

[0109] The weighted correction factors for oxygen recovery time and carbon monoxide peak duration are determined according to the classification of oxygen recovery response capability and carbon monoxide concentration control capability. When other response parameters are not configured with individual weighted correction factors... Pick .

[0110] The calculation period is the response evaluation period that starts from the initial moment of a trial or natural dosing change and covers the entire material-flue gas lag time. For systems with continuous sampling data, two adjacent calculation periods can be generated in a fixed time window; for batch trial dosing scenarios, two adjacent calculation periods can be formed by two consecutive trial or natural dosing changes.

[0111] To facilitate a better understanding of the present invention by those skilled in the art, the present invention will be further illustrated below with reference to a specific application scenario.

[0112] This embodiment applies to the co-processing of dewatered sludge from municipal wastewater treatment plants in a municipal solid waste mechanical grate incineration line. The sludge enters the plant via sludge transport vehicles, is unloaded into a sealed temporary storage silo, and then transported to a drying device via a plunger pump and sealed pipeline at the bottom of the silo. The dried sludge is then fed into the incinerator feed hopper by a feeding device, and enters the grate combustion zone along with the municipal solid waste. The incineration system includes a feeding device, grate furnace, waste heat boiler, semi-dry deacidification reaction tower, activated carbon injection device, bag filter, induced draft fan, chimney, distributed control system, and continuous emission monitoring system.

[0113] The data trust module acquires batch sludge characteristic data, co-incineration system boundary data, planned dosing demand data, and continuous operation response data.

[0114] Batch sludge characteristic data consists of incoming sludge laboratory data, online moisture content monitoring data, and temporary storage bin weighing data. Incoming laboratory data includes sludge source batch identification, sampling time, sludge moisture content, lower heating value, ash content, organic matter content, nitrogen content, sulfur content, chlorine content, and bulk density. Online moisture content monitoring data is output from a microwave moisture meter at the temporary storage bin outlet and is used to capture fluctuations in moisture content within the same batch of sludge. Temporary storage bin weighing data is used to confirm the sludge feed rate into the drying equipment.

[0115] Sludge particle size distribution data can be output by screening equipment or image detection equipment, including the upper limit of particle size, agglomeration ratio, and proportion of coarse particles. When no screening or image detection equipment is available on-site, the data reliability module extracts particle size risk markers from crusher current fluctuations, silo discharge frequency, and manually sampled particle size records. Sludge adhesion risk data can be output by a rotary rheometer, showing apparent viscosity and yield stress; when no rheometer is available, plunger pump pressure, screw conveyor torque, conveying pipe pressure differential, and number of pauses collectively form sludge adhesion risk data.

[0116] The boundary data of the co-incineration system include the main control temperature of the furnace, the furnace temperature floor, the flue gas residence time, the oxygen content at the furnace outlet, the maximum allowable torque of the feeding device, the current torque of the feeding device, the remaining drying heat source, the availability of auxiliary fuel, the concentration of acidic gas at the inlet of the semi-dry deacidification reaction tower, the inventory of deacidification reagents, the remaining frequency of the dosing pump, the differential pressure of the bag filter, the remaining capacity of the activated carbon injection device, and the effective status of the continuous emission monitoring system. The furnace temperature floor, the flue gas residence time, the safe threshold for oxygen content, and the emission permit red line constitute hard boundary constraints. The continuous operation capability of the feeding device, the remaining drying heat source, the acidic gas absorption and purification capability, the oxygen content recovery response capability, and the carbon monoxide concentration control capability constitute soft boundary constraints.

[0117] Planned feed-in demand data is provided by the production scheduling system, including the target total processing capacity, planned feed-in time window, minimum continuous feed cycle time, minimum disposal flow rate, maximum acceptable temporary storage period, and permissible sludge co-processing sources. Continuous operation response data is provided by the distributed control system and continuous emission monitoring system, including furnace main control temperature, primary air volume, secondary air volume, oxygen content, carbon monoxide concentration, hydrogen chloride concentration, sulfur dioxide concentration, nitrogen oxide concentration, flue gas moisture content, feeder current, feeder torque, drying steam valve position, auxiliary fuel flow rate, and induced draft fan frequency.

[0118] The data reliability module establishes a heterogeneous timeline based on the characteristics of logistics lag. Multiple time delays exist between sludge sampling upon arrival and the formation of a chimney monitoring response: material sampling time corresponds to the sludge source and batch upon arrival; the time of entering the temporary storage silo corresponds to the sludge beginning to enter the plant's material system; the drying equipment processing time corresponds to the period when the sludge moisture content changes; the furnace combustion time corresponds to the period when the sludge begins to alter the furnace's main control temperature and oxygen content; and the flue gas monitoring response time corresponds to the period when the pollutant concentration after sludge combustion reaches the sampling point of the continuous emission monitoring system. The data reliability module estimates the lag time at each stage based on factors such as the conveying pipe length, plunger pump frequency, average residence time in the drying equipment, temporary storage capacity in the feed hopper, grate advance speed, furnace flue gas velocity, and the gas path volume of the waste heat boiler and purification system. It then maps sludge characteristic data and continuous operation response data to the same batch of material in the material chain.

[0119] The current batch of sludge entered the temporary storage silo at 9:20 AM, and the average residence time in the drying equipment is [missing information]. The feed hopper buffer time is The flue gas lag time from the furnace to the sampling point of the continuous emission monitoring system is The data credibility module does not attribute the flue gas hydrogen chloride fluctuation at 9:25 to the current batch of sludge, but instead associates the current batch of sludge with the pollutant response formed after 10:14. When a segment of continuous emission monitoring system data is marked for maintenance, purging, or calibration, the data credibility module isolates that data sequence from the continuous operation response data and does not participate in the calculation of the actual response deviation.

[0120] The data trust module isolates anomalies and outputs a trustworthy dataset. For batch sludge characteristic data, laboratory test data serves as a highly reliable data source for sludge moisture content, lower heating value, ash content, organic matter, and elemental content. Online test data is used to supplement high-frequency changes between laboratory test cycles. Manually entered data serves only as prompts and does not directly participate in boundary calculations. For continuous operation response data, the original sampling points of the distributed control system and the effective data from the continuous emission monitoring system have a high level of trustworthiness. Soft measurement values ​​and operator notes are only used to explain limiting terms and do not replace necessary variables. Soft measurement values ​​are estimated parameters indirectly calculated based on the incineration system's operating parameters through mechanism fitting, statistical regression, or historical calibration models; soft measurement values ​​are not part of the original trustworthy data directly collected by sensors.

[0121] Anomaly isolation includes hard anomaly isolation, inertial anomaly isolation, and necessary variable interruption handling. When data values ​​exceed the sensor's range, time stamps are missing, or invalid markers are present, the data reliability module directly discards the corresponding data. When the furnace main control temperature, oxygen content, and acid gas concentration exhibit isolated jumps that do not conform to thermal inertia within a single sampling cycle, the data reliability module determines whether it is an instrument pulse based on the preceding and following valid points. If any necessary variable—sludge moisture content, sludge lower heating value, sludge chlorine content, furnace main control temperature, feeder torque, drying heat source surplus, or the effective status of the continuous emission monitoring system—is missing for three consecutive sampling cycles, exceeds the sensor's range, or is marked as invalid, the data reliability module generates a necessary control variable acquisition failure flag and blocks the high-adaptation level output.

[0122] The sludge profile building module retrieves data on sludge moisture content, lower heating value, ash content, chlorine content, sulfur content, sludge adhesion risk, and particle size distribution characteristics from historical inspection batches of sludge from the same wastewater treatment plant or industrial park, based on the sludge source batch identifier. For each characteristic data point, the profile building module generates a batch center value, an upper limit of batch fluctuation, and a lower limit of batch fluctuation. For sludge moisture content, chlorine content, sulfur content, sludge adhesion risk data, and coarse particle ratio, the upper limit of batch fluctuation serves as a high-risk input; for lower heating value and organic matter, the lower limit of batch fluctuation serves as a high-risk input; and for ash content, the upper limit of ash content fluctuation is used to determine the reduction in heat contribution and slag load.

[0123] In this embodiment, the parameters for a certain batch of municipal sludge are as follows: the median moisture content of the sludge is... The upper limit of sludge moisture content fluctuation is The lower limit of the net calorific value of sludge is: The upper limit of sludge ash content fluctuation is: The upper limit of chlorine content fluctuation in sludge is... The upper limit of sludge sulfur content fluctuation is The sludge adhesion risk data is low; the sludge particle size distribution data shows that the proportion of coarse particles is below the equipment's allowable range. Based on this, the profile building module generates a batch fluctuation profile and marks the risk status of the batch fluctuation profile as high moisture and low calorific value risk. When the sludge chlorine content and sludge adhesion risk data do not exceed the preset historical stable range, the profile building module does not generate abnormal pollution element markers or adhesion abnormal markers.

[0124] The adaptation constraint window consists of hard boundary constraints and soft boundary constraints. Hard boundary constraints include the furnace temperature floor, minimum flue gas residence time, safe oxygen content threshold, and emission permit limits. Hard boundary constraints are not relaxed due to changes in production tasks. When the furnace main control temperature is close to the furnace temperature floor, the flue gas residence time cannot meet process requirements, the oxygen content is below the safe threshold, or the continuous emission monitoring system is ineffective, the profile construction module directly sends an "unfeasible" status to the boundary generation module.

[0125] Soft boundary constraints include the drying heat source margin, the continuous operation capacity of the feeding device, the acid gas absorption and purification capacity, the oxygen content recovery response capacity, and the carbon monoxide concentration control capacity. Soft boundary constraints are dynamically adjusted according to system conditions. When the lime slurry tank level in the semi-dry deacidification reaction tower is high, the residual frequency of the dosing pump is high, and the bag filter pressure differential is within the normal range, the tolerance range for acid gas absorption and purification capacity remains at its normal value. When the purification agent inventory decreases, the standby pump is under maintenance, or the bag filter pressure differential approaches the alarm value, the tolerance range for acid gas absorption and purification capacity adjusts towards contraction. When the boiler main steam load is high and the amount of steam available for drying is limited, the soft boundary of the drying heat source margin contracts accordingly.

[0126] In this embodiment, the main controlled temperature of the furnace is The minimum furnace temperature is The drying heat source margin is lower than the daily average under normal operation; the lime slurry tank level is sufficient, and the continuous emission monitoring system is effective; the current torque of the feeding device is lower than the rated load. The adaptation constraint window shows that the tolerance ranges for moisture evaporation load margin and heat margin are narrow, while the tolerance ranges for feeding stability margin and flue gas compliance margin are wide.

[0127] In this embodiment, the rated sludge feeding mass flow rate of the feeding device is Adhesion correction factor is taken The particle size correction factor is taken as The current torque of the feeding device is 1 / 3 of the maximum allowable torque of the feeding device. According to the rheological transport resistance calculation formula, the upper limit of the first-dimensional independent sludge addition corresponding to the feed stability margin is:

[0128]

[0129] in, The first independent sludge addition limit corresponds to the stable feed margin. The value of the rated sludge feed mass flow rate of the feeding device is given, in units of... The first The second is the adhesion correction factor. This is the particle size correction factor. This is the ratio of the current torque of the feeding device to the maximum allowable torque. This is a multiplication operator. Intermediate calculated values ​​are rounded to three significant digits. Finally, the mass flow rate is retained according to the added mass flow rate. The rule is that the upper limit for the addition of the first-dimensional independent sludge is taken as follows: The margin mapping module uses the first-dimensional independent sludge addition upper limit as the input constraint for subsequent latent heat consumption calculation of phase change, so that subsequent evaporation and heat calculations do not use sludge addition mass flow rates that are detached from the actual feeding capacity.

[0130] In this embodiment, the remaining amount of the drying heat source is: The heat exchange efficiency of the drying equipment is taken The proportion of evaporation moisture equivalent that a unit of wet sludge needs to be handled by an external drying heat source is output from the calibration curve of the drying equipment. Water vaporization latent heat extraction According to the formula for calculating the latent heat of phase change, the upper limit of the second-dimensional independent sludge addition corresponding to the moisture evaporation load margin is:

[0131]

[0132] in, This represents the upper limit of the second independent sludge addition corresponding to the moisture evaporation load margin. This represents the remaining heat source for drying, in units of... , For the heat exchange efficiency of drying equipment. This refers to the percentage of water equivalent that needs to be evaporated from a unit of wet-based sludge. The latent heat of vaporization of water is expressed in units of 1. , Conversion factor between tons and kilograms Intermediate calculated values ​​should be rounded to three significant figures. Finally, the mass flow rate is retained according to the added mass flow rate. The rule is that the upper limit for the addition of the second independent sludge is taken as follows: The second-dimensional independent sludge addition limit is lower than the first-dimensional independent sludge addition limit, indicating that the current system is not limited by the feeding machinery, but by the moisture evaporation load margin.

[0133] In this embodiment, the furnace heat can be taken as a margin. The moisture content of the sludge fed into the furnace is taken as the target moisture content after drying. Water vaporization latent heat extraction The sensible heat compensation required per unit mass of sludge to maintain the main control temperature of the furnace is taken as The lower limit of the calorific value of sludge is taken as According to the formula for calculating the heat balance state, the upper limit for the third-dimensional independent sludge addition corresponding to the heat margin is:

[0134]

[0135] in, This refers to the upper limit of the third-dimensional independent sludge addition corresponding to the heat margin. This refers to the available heat margin in the furnace, in units of , The moisture content of the sludge entering the furnace. The latent heat of vaporization of water is expressed in units of 1. , Conversion factor between tons and kilograms , The sensible heat compensation required to maintain the main control temperature of the furnace per unit mass of sludge, in units of , The lower heating value of sludge is given in units of... Intermediate calculated values ​​should be rounded to three significant figures. Finally, the mass flow rate is retained according to the added mass flow rate. The rule is that the upper limit for the addition of the third-dimensional independent sludge is taken as follows: The third dimension's independent sludge addition limit is higher than the second dimension's independent sludge addition limit, indicating that the moisture evaporation load margin is the primary limiting factor for the current batch, while the heat margin is a secondary concern.

[0136] In this embodiment, the dry basis chlorine content of the dried sludge is taken as follows: The conversion rate of chlorine to hydrogen chloride is taken as The residual hydrogen chloride treatment capacity of the semi-dry deacidification reaction tower is taken as The moisture content of the sludge entering the furnace is taken as follows: According to the pollution conversion rate calculation formula, the upper limit of sludge addition corresponding to the hydrogen chloride treatment capacity is:

[0137]

[0138] in, This represents the upper limit of sludge addition corresponding to the hydrogen chloride treatment capacity. The unit is the residual hydrogen chloride treatment capacity of the semi-dry deacidification reaction tower. , for , The moisture content of the sludge entering the furnace. This refers to the dry basis chlorine content of the sludge after drying. The conversion rate of chlorine to hydrogen chloride. for Finally, the mass flow rate is retained according to the added mass flow rate. The rules take .

[0139] In this embodiment, the dry basis sulfur content of the dried sludge is taken as... The conversion rate of sulfur to sulfur dioxide is taken as The remaining sulfur dioxide treatment capacity of the semi-dry desulfurization reaction tower is taken as The moisture content of the sludge entering the furnace is taken as follows: According to the pollution conversion rate calculation formula, the upper limit of sludge addition corresponding to the sulfur dioxide treatment capacity is:

[0140]

[0141] in, This represents the upper limit of sludge addition corresponding to the sulfur dioxide treatment capacity. The residual sulfur dioxide treatment capacity of the semi-dry desulfurization reaction tower is expressed in units of... , This refers to the dry basis sulfur content of the sludge after drying. The conversion rate of sulfur to sulfur dioxide. for Finally, the mass flow rate is retained according to the added mass flow rate. The rules take The smaller value is taken as the upper limit for the fourth dimension of independent sludge addition corresponding to the flue gas compliance margin. .

[0142] The margin profile includes four independent sludge dosing limits: the first dimension, the second dimension, the third dimension, and the fourth dimension. The boundary generation module inputs these four independent sludge dosing limits into the minimum boundary selection logic.

[0143]

[0144] in, Add an upper limit to the number of candidate votes. The first independent sludge addition limit corresponds to the stable feed margin. This represents the upper limit of the second independent sludge addition corresponding to the moisture evaporation load margin. This refers to the upper limit of the third-dimensional independent sludge addition corresponding to the heat margin. The upper limit for the fourth dimension of independent sludge addition corresponds to the flue gas compliance margin. This is an operator that selects the minimum value from the individual sludge addition limits within the parentheses.

[0145] The boundary generation module then generates the sludge dosing lower limit based on the planned dosing demand data. The sludge dosing lower limit is derived from the minimum continuous feeding cycle time, the minimum stable stroke of the plunger pump, the planned minimum treatment flow rate, and the odor control and venting requirements of the temporary storage silo. When the planning system does not enforce a minimum treatment flow rate, the sludge dosing lower limit can be set to zero or the lowest permissible trial sludge dosing mass flow rate. When the planning system requires a certain batch processing volume to be completed on a given day, the sludge dosing lower limit is the lowest sludge dosing mass flow rate that meets the requirements for continuous equipment operation and production scheduling.

[0146] In this embodiment, the upper limit for the addition of the first-dimensional independent sludge is: The upper limit for the addition of the second independent sludge is The upper limit for the addition of independent sludge in the third dimension is... The upper limit for the addition of independent sludge in the fourth dimension is... The boundary generation module selects the second-dimensional independent sludge dosing upper limit as the candidate dosing upper limit and compares the sludge dosing lower limit with the candidate dosing upper limit. When the sludge dosing lower limit is not higher than the candidate dosing upper limit, the initial sludge dosing boundary is established; when the sludge dosing lower limit is higher than the candidate dosing upper limit, the boundary generation module outputs a prohibition on dosing command.

[0147] The upper limit for candidate votes is The lower limit for sludge addition is The initial sludge addition boundary is... to The ranking of constraints shows that the moisture evaporation load margin is the primary constraint, while the heat margin is a secondary concern.

[0148] Before issuing a trial feed command, the feedback correction module determines whether the incineration system is in a stable load state. The conditions for determining a stable load state include: furnace main control temperature fluctuations are within the set range; main steam flow does not change rapidly; primary and secondary air pressures are within normal control ranges; the continuous emission monitoring system is effective; and the basic waste feeding is not undergoing significant adjustments. If any condition is not met, the feedback correction module will not proactively issue a trial feed command; if a trial feed command cannot be proactively issued but natural feed changes occur during actual operation, the feedback correction module will respond and verify by substituting these natural feed changes for proactive trial feed.

[0149] In this embodiment, the incineration system is under stable load, and the safety feed coefficient is tentatively added. The maximum number of candidate votes is [number missing]. The calculated mass flow rate for sludge addition is as follows:

[0150]

[0151] in, To test the sludge addition mass flow rate, Add a maximum value to the candidate votes. To test the safety feed coefficient, the feed rate was retained at the specified level. The rules were used to test the sludge addition mass flow rate. .

[0152] The feedback correction module collects the gradient of furnace main control temperature change, oxygen content recovery time, carbon monoxide peak duration time, acid gas concentration ramp-up slope, and feed device torque change difference before and after trial addition, and compares them with the expected response direction and expected response amplitude.

[0153] In this embodiment, the input for calculating the response parameters is shown in Table 1 below:

[0154] Table 1:

[0155] Furnace main control temperature drop Oxygen content recovery time Peak duration of carbon monoxide Slope of acid gas concentration climb Torque variation difference of feeding device

[0156] According to the actual response deviation formula, the actual response deviation is:

[0157]

[0158] in, The actual response deviation is represented by the product of the weighted correction factor and the normalized residual in the numerator, and the sum of the weighted correction factors in the denominator.

[0159] In this embodiment, the oxygen content recovery time in two consecutive calculation cycles is as follows: and All were higher than expected. of The feedback correction module performs boundary contraction on the candidate dosing upper limit. This boundary contraction does not change the sludge dosing lower limit; it only lowers the candidate dosing upper limit, narrowing the dosing range. If, after contraction, the candidate dosing upper limit falls below the sludge dosing lower limit, the system outputs a prohibition on dosing command.

[0160] Actual response deviations indicate that when the primary limiting factor shifts, the feedback correction module performs boundary shifting. For example, the initial limiting factor ranking shows that heat margin is the primary limiting factor, but after trial addition, the furnace main control temperature and oxygen content return to normal, while the acid gas concentration ramp-up slope remains higher than the predicted value. The feedback correction module updates the limiting factor to flue gas compliance margin and shifts the addition range to the low-risk range corresponding to the flue gas compliance margin. Boundary shifting also changes the compensation control direction, causing the system to shift from heat compensation to purification capacity compensation or low-chlorine sludge blending.

[0161] The actual response deviation was lower than 1% for three consecutive calculation cycles. When the continuous emission monitoring system is effective, the feedback correction module performs a restricted release. The restricted release process simultaneously satisfies the following constraints: it does not exceed the hard boundary constraints of the adaptation constraint window; and it does not exceed the allowable range of the current soft boundary constraint tolerance interval.

[0162] In this embodiment, the trial response did not trigger the transfer of flue gas compliance margin, but the time taken for oxygen content recovery was higher than the expected value for two consecutive calculation cycles. The above feedback correction module increases the upper limit for candidate submissions from... Shrink to The revised sludge addition boundary is... to The upper limit for candidate votes has been adjusted. It does not exceed the hard boundary constraints of the adaptation constraint window, nor does it exceed the allowable range of the current soft boundary constraint tolerance interval.

[0163] In this embodiment, the planned demand is: to The revised sludge addition boundary is... to Total length of planned demand range. for The overlapping interval is to Overlap length for The degree of overlap is:

[0164]

[0165] in, For overlap, The overlap length is expressed in units of 1. , The total length of the planned demand interval, in units of The degree of overlap is retained as a percentage. ,Pick The strategy output module's output is moderately adapted; it is recommended to lower the plan's maximum deployment limit. Within this range, the boundary is recalculated after the remaining heat source from the drying process is restored.

[0166] Example 1 shows that in scenarios where municipal sludge has high water content and conventional pollutants, the present invention can pinpoint the main limiting factor as the water evaporation load margin, thereby forming an executable sludge addition range and corresponding compensation strategy.

[0167] Example 2: This example is applicable to the co-processing of dried industrial sludge in a circulating fluidized bed boiler or fluidized bed sludge incineration system. Compared with Example 1, the sludge moisture content in this example has been reduced to a lower level, the lower heating value of the sludge meets the requirements of the incineration system, and the chlorine and sulfur content of the sludge are within the permissible range. However, the sludge exhibits agglomeration, clumping, and enhanced adhesion after temporary storage and drying. Highly adhesive sludge entering the feeding device can cause torque fluctuations in the screw feeder, discontinuous feeding, and localized combustion pulsations in the bed, which can lead to abnormal bed pressure and the risk of localized bed collapse in severe cases.

[0168] The data trust module acquires batch sludge characteristic data of highly adhesive industrial sludge. In the batch sludge characteristic data, the median sludge moisture content is... The lower limit of the net calorific value of sludge is The upper limit of chlorine content fluctuation in sludge is The upper limit of sludge sulfur content fluctuation is Data on sludge particle size distribution showed that the proportion of coarse particles was higher than the preset historical stable range. Data on sludge adhesion risk showed an increase in the difference between the no-load and carrying torque of the screw feeder, an increase in the differential pressure in the conveying pipe, and an increase in the frequency of the silo arch breaker's operation. The above data were entered into the trusted dataset after time alignment and anomaly isolation.

[0169] For circulating fluidized bed systems, in addition to the furnace main control temperature, flue gas residence time, oxygen content, emission permit, drying heat source margin, and purification capacity listed in Example 1, the adaptation constraint window also includes bed pressure fluctuation variance, air chamber pressure drop, return feeder temperature, bed differential pressure, primary air lower limit, feed screw allowable torque, and arch breaker allowable operation frequency. Bed pressure fluctuation variance and air chamber pressure drop are used to determine whether agglomerated sludge disrupts the fluidization state after entering the bed. The primary air lower limit is a hard boundary for maintaining the fluidization state, the feed screw allowable torque is a hard boundary for the stable feed margin, and the arch breaker operation frequency and bed pressure fluctuation variance are soft boundaries.

[0170] The batch fluctuation profile generated by the profile building module shows that the sludge's lower heating value and moisture evaporation load margin are in a relatively good state, and pollutant elements do not pose a primary limitation. However, the sludge adhesion risk data and the proportion of coarse particles exceed the preset historical stable range. The profile building module generates batch anomaly markers for the batch fluctuation profile and configures a low trial dosing safety feed coefficient.

[0171] In this embodiment, the rated sludge feeding mass flow rate of the feeding device is taken as... The sludge adhesion risk data is medium risk, and the adhesion correction factor is taken as... The proportion of coarse particles exceeds the allowable range of the equipment, but the excess proportion is not higher than [the specified percentage]. The particle size correction factor is taken as The current torque of the feeding device is equal to the maximum allowable torque of the feeding device. According to the rheological transport resistance calculation formula, the upper limit of the first-dimensional independent sludge addition corresponding to the feed stability margin is:

[0172]

[0173] in, The first independent sludge addition limit corresponds to the stable feed margin. The rated sludge feed mass flow rate of the feeding device, in units of , This is the adhesion correction factor. This is the particle size correction factor. This is the ratio of the current torque of the feeding device to the maximum allowable torque. Intermediate calculated values ​​are retained to three significant figures. Finally, the mass flow rate is retained according to the added mass flow rate. The rule is that the upper limit for the addition of the first-dimensional independent sludge is taken as follows: .

[0174] The latent heat of phase change is calculated by reading the first-dimensional independent sludge addition limit and sludge moisture content data. Since the sludge moisture content is low and the drying heat source is sufficient, the second-dimensional independent sludge addition limit is... The thermal balance state calculation reads the lower bound of the sludge's lower heating value and the furnace's main control temperature. Since the sludge's heat contribution meets the system's requirements, the upper limit for the third-dimensional independent sludge addition is... The pollution conversion rate calculation reads the upper bound of sludge chlorine content fluctuation, the upper bound of sludge sulfur content fluctuation, and the purification capacity. The fourth dimension, the independent sludge addition upper limit, is... The aforementioned upper limits for independent sludge addition in the second, third, and fourth dimensions are all retained based on the addition mass flow rate. The rules are output.

[0175] The multi-margin profile shows that the upper limit of the first-dimensional independent sludge addition is the lower limit of the minimum independent sludge addition. The boundary generation module identifies the feed stability margin as the primary constraint and outputs the initial sludge addition boundary. The lower limit of sludge addition is... The boundary generation module establishes the initial sludge addition boundary as follows: to .

[0176] When the circulating fluidized bed is in a stable bed pressure, stable load, and stable oxygen content state, the feedback correction module issues a trial dosing command. The trial dosing safety feed coefficient is determined according to the batch anomaly flag. The maximum number of candidate votes is The calculated mass flow rate for sludge addition is as follows:

[0177]

[0178] in, To test the sludge addition mass flow rate, Add an upper limit to the number of candidate votes, in units of , To test the waters, a safety feed factor was added. Intermediate calculated values ​​were rounded to three significant figures. Finally, the mass flow rate is retained according to the added mass flow rate. The rules were used to test the sludge addition mass flow rate. The material is fed into the furnace using a short-pulse feeding method. The feedback correction module collects the difference in feed screw torque, torque fluctuation frequency, bed pressure fluctuation variance, local bed temperature changes, oxygen content recovery time, and carbon monoxide peak duration before and after the trial addition.

[0179] After the trial addition, the torque of the feeding screw decreased from the maximum allowable torque of the feeding device. Rise to Torque spikes occurred 6 times within the trial window; bed pressure fluctuation variance was higher than predicted. Locally, the bed temperature showed a downward dispersion point, and the carbon monoxide peak did not have a sustained tail, but the recovery time of oxygen content increased. The above response indicates that although the highly adhesive sludge has sufficient calorific value and the pollutant elements are not exceeded, the actual transport and bed diffusion conditions are lower than the predicted carrying capacity. The feedback correction module determines that the actual response deviation diverges along the feed stability margin and performs boundary contraction on the candidate dosing upper limit.

[0180] After the boundary shrinks, the upper limit of candidate deployments is increased from... Decrease to The revised sludge addition boundary is... to The upper limit for candidate votes has been adjusted. Without exceeding the hard boundary constraints of the adaptation constraint window, and without exceeding the allowable range of the current soft boundary constraint tolerance range, the matching level is adjusted from medium adaptation to low adaptation. The strategy output module outputs the following control commands: change continuous conveying to intermittent pulse conveying; improve the arch breaker's action preparation state; reduce the duration of a single screw feed; increase the premixing ratio with low-viscosity, low-moisture co-fuel; and add crushing, screening, or remixing treatment before the next batch enters the furnace.

[0181] In this embodiment, the system does not provide a high sludge feed mass flow rate based on the calorific value requirement, nor does it use oxygen content and furnace temperature as the sole feedback indicators. Instead, it identifies the primary limiting factor as the feed stability margin through rheological transport resistance calculation and torque response deviation. For highly adhesive sludge, lowering the candidate feed upper limit can reduce the probability of screw jamming, agglomerates entering the bed, and abnormal bed pressure. The compensation strategy also corresponds to the feed stability margin.

[0182] Example 3: This example applies to a scenario where a solid waste co-incineration system receives high-calorific-value chemical sludge. After dewatering and drying, the chemical sludge has a low moisture content and a high lower heating value, making it a viable alternative fuel from an energy perspective. However, batch testing shows a high upper limit for chlorine content fluctuations in the sludge. The flue gas purification system has insufficient deacidification reagent inventory, the dosing pump is operating at low reserve, and the wet scrubbing tower's preparatory liquid level is below normal. If only calorific value and moisture content are considered, the system may assign a higher dosage ratio; if the remaining purification capacity at the tail end is ignored, the high-chlorine sludge entering the furnace will rapidly increase the hydrogen chloride load, impacting the emission permit limits.

[0183] The data trust module acquires batch characteristics and system boundaries of chemical sludge. In the batch sludge characteristic data, the center value of sludge moisture content is... The lower limit of the net calorific value of sludge is The upper limit of sludge ash content fluctuation is The upper limit of chlorine content fluctuation in sludge is The upper limit of sludge sulfur content fluctuation is The sludge adhesion risk data indicates a medium risk. Boundary data from the co-incineration system show that the furnace main control temperature is higher than the conventional load temperature, the oxygen content recovery response is good, the feeder torque margin is sufficient, and the drying heat source margin does not pose a limitation; however, the real-time inventory of deacidification reagents is lower than the rated inventory. The alkalinity of the circulating liquid in the wet scrubbing tower is too low, the residual frequency of the dosing pump is insufficient, and the continuous discharge monitoring system is effective.

[0184] The profiling module compared historical batches from the same source and found that the upper limit of the chlorine content fluctuation in the current batch of sludge exceeded the preset historical stable range, and the lower limit of the sludge's lower heating value was higher than that of conventional municipal sludge. The profiling module generated batch anomaly markers and marked the batch fluctuation profile risk status as high chlorine and high calorific value risk. The limiting sources of high chlorine and high calorific value risk differ from those of high moisture and low calorific value risk. High moisture and low calorific value risk mainly consumes drying heat sources and furnace heat, and the compensation direction is drying or auxiliary fuel; high chlorine and high calorific value risk mainly consumes the remaining capacity of the tail-end purification, and the compensation direction is to reduce the blending ratio of chlorinated sludge, increase the amount of alkali prepared, or delay its addition.

[0185] The rheological transport resistance calculation shows that the feeding device can meet the high sludge feeding mass flow rate, and the upper limit of the first dimension independent sludge feeding is... The latent heat of phase change calculation shows that the sludge moisture content is low, and the remaining heat source for drying does not pose a limitation. The upper limit for the addition of the second independent sludge dimension is... The thermal balance calculation shows that the sludge has a high lower heating value, the furnace has sufficient heat, and the upper limit for the third-dimensional independent sludge addition is [value missing]. All the above values ​​are retained based on the added mass flow rate. The rules are output.

[0186] In this embodiment, the dry basis chlorine content of the dried sludge is taken as follows: The conversion rate of chlorine to hydrogen chloride is taken as The residual hydrogen chloride treatment capacity of the semi-dry deacidification reaction tower is taken as The moisture content of the sludge entering the furnace is taken as follows: According to the pollution conversion rate calculation formula, the upper limit of sludge addition corresponding to the hydrogen chloride treatment capacity is:

[0187]

[0188] in, This represents the upper limit of sludge addition corresponding to the hydrogen chloride treatment capacity. The remaining hydrogen chloride treatment capacity is expressed in units of... , The moisture content of the sludge entering the furnace. This refers to the dry basis chlorine content of the sludge after drying. This represents the conversion rate of chlorine to hydrogen chloride. Intermediate calculation values ​​are rounded to three significant figures. Finally, the mass flow rate is retained according to the added mass flow rate. The rules take To preserve the computational chain for dynamic adjustment of soft boundary constraints, the following tolerance interval coefficient corrections use unrounded intermediate calculated values. Participate in the calculation.

[0189] In this embodiment, the dry basis sulfur content of the dried sludge is taken as... The conversion rate of sulfur to sulfur dioxide is taken as The remaining sulfur dioxide treatment capacity of the semi-dry desulfurization reaction tower is taken as The moisture content of the sludge entering the furnace is taken as follows: According to the pollution conversion rate calculation formula, the upper limit of sludge addition corresponding to the sulfur dioxide treatment capacity is:

[0190]

[0191] in, This represents the upper limit of sludge addition corresponding to the sulfur dioxide treatment capacity. The remaining sulfur dioxide treatment capacity is expressed in units of... , This refers to the dry basis sulfur content of the sludge after drying. This represents the conversion rate of sulfur to sulfur dioxide. Intermediate calculation values ​​are rounded to three significant figures. Finally, the mass flow rate is retained according to the added mass flow rate. The rules take The upper limit for sludge addition corresponding to sulfur dioxide treatment capacity is higher than the upper limit for sludge addition corresponding to hydrogen chloride treatment capacity. Therefore, the original constraint value of the fourth dimension independent sludge addition upper limit corresponding to the flue gas compliance margin is taken as... .

[0192] In this embodiment, the real-time inventory of deacidifying agents is lower than the rated inventory. The tolerance range coefficient corresponding to the acid gas absorption and purification capacity is taken as... The tolerance range coefficient for the fourth-dimensional independent sludge addition limit corresponding to the flue gas compliance margin is adjusted using soft boundary constraints:

[0193]

[0194] in, This is the upper limit for the fourth dimension of independent sludge addition, after correction by the tolerance interval coefficient. This is the unrounded original constraint value, in units of , This represents the tolerance range coefficient corresponding to the acid gas absorption and purification capacity. Intermediate calculated values ​​are retained to three significant figures. Finally, the mass flow rate is retained according to the added mass flow rate. The rules take To prevent the engineering output from losing its safety meaning after being rounded to zero, the strategy output module also retains the unrounded internal constraint values. As a basis for determining whether to prohibit sludge addition, if the upper limit of the fourth dimension of independent sludge addition corresponding to the flue gas compliance margin is lower than the minimum stable sludge addition mass flow rate of the equipment, it indicates that the current batch of sludge does not meet the conditions for continuous addition under the existing flue gas purification capacity.

[0195] The lower limit for sludge addition in the planned addition demand data is This stems from the minimum stable cycle time of the feeding device and the minimum continuous processing requirements of the production schedule. The boundary generation module identifies the fourth-dimensional independent sludge addition upper limit as the minimum independent sludge addition upper limit and uses the fourth-dimensional independent sludge addition upper limit as a candidate addition upper limit. This is due to the lower limit of sludge addition. The internal constraint value exceeds the upper limit of candidate addition. The boundary generation module does not establish an initial sludge addition boundary and directly generates a prohibition on addition command. The prohibition on addition command is triggered by insufficient flue gas compliance margin, insufficient real-time inventory of deacidification agents, abnormal batch markers for chlorinated sludge, and the planned addition lower limit being higher than the candidate addition upper limit.

[0196] In this embodiment, the system does not perform trial dosing. The upper limit of the candidate dosing limit is already lower than the lower limit of sludge dosing, and any dosing action that would allow for continuous operation of the equipment may enter the unsafe range. The feedback correction module is suspended, and the strategy output module directly outputs the incompatibility level, locks the current batch of sludge induction enable signal, and outputs control suggestions such as raising the preparatory liquid level of the scrubbing tower, replenishing the deacidification agent, reducing the blending ratio of chlorine-containing sludge, and recalculating the boundary after premixing with low-chlorine, high-ash materials.

[0197] In another triggering scenario, if the continuous emission monitoring system shows that the real-time concentration of hydrogen chloride reaches the emission permit limit. If the pollutant concentration reaches the emission permit threshold, the boundary generation module will directly trigger a prohibition on sludge addition command, without needing to further calculate the fourth-dimensional independent sludge addition limit corresponding to the flue gas compliance margin. This rule is used to prioritize emission safety when the pollutant concentration is close to the emission permit threshold.

[0198] In this embodiment, the system does not output highly adapted due to the high calorific value and low moisture content. Instead, it identifies tail-end purification restrictions by calculating the pollution conversion rate, correcting the tolerance interval coefficient corresponding to the soft boundary constraint, and determining the emission permit red line. This prevents high-chlorine, high-calorific-value sludge from entering the incineration system when the deacidification agent inventory is insufficient.

[0199] Only when it is impossible to actively issue a trial dosing command will the feedback correction module use a natural dosing variation segment instead of actively issuing a trial dosing command. Situations where it is impossible to actively issue a trial dosing command include situations where the incineration system does not meet the stable load condition, or where the operating procedures prohibit the control system from actively issuing a trial dosing command.

[0200] Natural dosing variations arise from fluctuations in the actual dosing rate during operation, and can be triggered by adjustments to planned dosing demand. For example, changes in the production cycle time for a particular batch of sludge can cause the actual sludge dosing mass flow rate to naturally decrease from its initial value. Rise to The changes were small and did not trigger significant control actions not related to sludge addition.

[0201] The feedback correction module captures the complete logistics lag window before and after the natural dosing change, extracting the gradient of the furnace main control temperature change, the oxygen content recovery time, the carbon monoxide peak duration time, the acid gas concentration ramp-up slope, and the difference in feed device torque. When the non-sludge dosing related control variables remain stable during the natural dosing change, the feedback correction module uses the natural dosing change segment as the input for calculating the actual response deviation and performs boundary contraction, boundary translation, or restricted release processing.

[0202] Batch fluctuation profiles can be constructed using either mean fluctuation profiles or quantile interval profiles. Mean fluctuation profiles use the historical sample mean and fluctuation amplitude to form the batch center value, upper bound, and lower bound of batch fluctuation. Quantile interval profiles use the historical sample quantile values ​​to form the batch center value, upper bound, and lower bound of batch fluctuation.

[0203] For sludge batches with a normal distribution, a mean fluctuation profile is used. When sludge parameters exhibit a skewed distribution, industrial sludge shows long-tail fluctuations, or historical samples have large dispersion, the profile construction module uses a quantile interval profile. For high-risk variables, such as sludge moisture content, chlorine content, sulfur content, sludge adhesion risk data, and coarse particle ratio, the profile construction module selects a high quantile interval as the upper bound of batch fluctuation; for low-risk variables, such as sludge lower heating value and sludge organic matter, the profile construction module selects a low quantile interval as the lower bound of batch fluctuation. The quantile interval profile can be directly incorporated into the multi-margin mapping algorithm model, and the data interfaces for subsequent rheological transport resistance calculation, latent heat consumption of phase change calculation, thermal equilibrium state calculation, and pollution conversion rate calculation do not need to be changed.

[0204] Regardless of whether mean fluctuation profile or quantile interval profile is used, the output objects of batch fluctuation profile are the batch center value, the upper bound of batch fluctuation, the lower bound of batch fluctuation, and the batch anomaly marker, which represent the distribution characteristics of physical attributes.

[0205] The soft boundary constraints in the adaptation constraint window are not fixed thresholds. Taking acid gas absorption and purification capacity as an example, when the real-time inventory of deacidifying agents is sufficient, the remaining frequency of the dosing pump is sufficient, the alkalinity of the circulating liquid in the wet scrubbing tower is sufficient, and the pressure difference of the bag filter is stable, the pollution conversion rate can be calculated using the conventional flue gas compliance margin. When any of the above conditions decreases, the profile construction module shrinks the tolerance range of acid gas absorption and purification capacity, causing the upper limit of the fourth-dimensional independent sludge addition to be lowered in advance.

[0206] Taking the drying heat source margin as an example, when the boiler load is high, steam extraction is limited, or the heat exchange efficiency of the drying equipment decreases, the moisture evaporation load margin shrinks in advance, and the upper limit of the second-dimensional independent sludge addition is lowered. Taking the continuous operation capacity of the feeding device as an example, when the conveyor is in the break-in period after maintenance or the reducer temperature is high, the stable feeding margin shrinks in advance, and the upper limit of the first-dimensional independent sludge addition is lowered.

[0207] The release of soft boundary constraints is limited by hard boundary constraints. It is only possible to release them if, over three consecutive calculation cycles, the relevant equipment remains stable, the continuous emission monitoring system is effective, and the actual response deviation is below a certain threshold. Only then will the image construction module release the soft boundary constraints. The release of soft boundary constraints must not exceed the furnace temperature floor, minimum flue gas residence time, safe oxygen content threshold, and emission permit limit, nor may it exceed the allowable range of the current soft boundary constraint tolerance interval.

[0208] The boundary generation module generates a prohibition on sludge addition command under any of the following circumstances: the lower limit of sludge addition is higher than the upper limit of candidate addition; the necessary control variable acquisition fails; the continuous emission monitoring system is in an invalid state; the furnace main control temperature reaches the furnace temperature bottom line; the flue gas residence time is lower than the minimum flue gas residence time; the oxygen content is lower than the oxygen content safety threshold; the pollutant concentration reaches the emission permit red line; the actual torque of the feeding device exceeds the maximum allowable torque of the feeding device; the drying heat source margin is lower than the evaporation phase change demand baseline.

[0209] Real-time monitoring of pollutant concentrations reached emission permit limits When the pollutant concentration is deemed to have reached the emission permit threshold, a prohibition on addition command is triggered. After the boundary generation module generates the prohibition command, the feedback correction module does not issue a trial addition command, and the strategy output module outputs the mismatch level and corresponding compensation control command.

[0210] The sludge co-incineration adaptability boundary calculation system can be deployed on the edge computing server of the incineration plant, the host computer of the distributed control system, or a standalone industrial computer. The system connects to the laboratory database, production scheduling system, distributed control system, continuous emission monitoring system, feed device frequency converter, drying equipment controller, and flue gas purification system controller via communication interfaces.

[0211] The data trustworthiness module includes a data access unit, a time axis alignment unit, a source acceptance unit, and an anomaly isolation unit. The data access unit receives batch sludge characteristic data, co-incineration system boundary data, planned feed-in requirements data, and continuous operation response data. The time axis alignment unit establishes a heterogeneous time axis based on material sampling time, temporary storage bin entry time, drying equipment processing time, furnace combustion time, and flue gas monitoring response time. The source acceptance unit determines the acceptance order based on the source determination hierarchy of laboratory test data, online monitoring data, distributed control system data, continuous emission monitoring system data, and manually entered data. The anomaly isolation unit removes data sequences that exceed sensor range, have missing time stamps, or contain invalid automatic monitoring markers, and outputs a trustworthy dataset.

[0212] The profile construction module includes a batch distribution unit, an anomaly marking unit, and an adaptation constraint window unit. The batch distribution unit generates a batch center value, an upper bound for batch fluctuation, and a lower bound for batch fluctuation based on a trusted dataset. The anomaly marking unit generates an anomaly mark when the currently received batch exceeds a preset historical stability range. The adaptation constraint window unit reads the boundary data of the co-incineration system, using the furnace temperature floor, minimum flue gas residence time, oxygen content safety threshold, and emission permit red line as hard boundary constraints, and oxygen content recovery response capability, carbon monoxide concentration control capability, acid gas absorption and purification capability, continuous operation capability of the feeding device, and drying heat source surplus as soft boundary constraints. It dynamically adjusts the tolerance interval coefficients corresponding to the soft boundary constraints based on equipment maintenance status, real-time inventory of purification agents, current combustion load, and the effective status of the continuous emission monitoring system.

[0213] The margin mapping module includes a rheological transport resistance calculation unit, a latent heat consumption phase change calculation unit, a thermal equilibrium state calculation unit, and a contaminant conversion rate calculation unit. The rheological transport resistance calculation unit outputs the first-dimensional independent sludge dosing upper limit; the latent heat consumption phase change calculation unit receives the first-dimensional independent sludge dosing upper limit and outputs the second-dimensional independent sludge dosing upper limit; the thermal equilibrium state calculation unit receives the first-dimensional and second-dimensional independent sludge dosing upper limits and outputs the third-dimensional independent sludge dosing upper limit; the contaminant conversion rate calculation unit receives the first-dimensional independent sludge dosing upper limit, the dried sludge moisture content corresponding to the second-dimensional independent sludge dosing upper limit, and the third-dimensional independent sludge dosing upper limit, and outputs the fourth-dimensional independent sludge dosing upper limit. The margin mapping module uses the tolerance coefficient corresponding to the soft boundary constraints to correct the upper limits of each independent sludge dosing dimension, combines the corrected four independent sludge dosing upper limits into a multi-margin profile, and outputs the desired response direction and the desired response amplitude.

[0214] The boundary generation module includes an upper limit filtering unit, a lower limit generation unit, a boundary establishment unit, and a prohibition on sludge dosing unit. The upper limit filtering unit selects the smallest independent sludge dosing upper limit from the multi-margin profile as a candidate dosing upper limit. The lower limit generation unit generates a sludge dosing lower limit based on planned dosing demand data. The boundary establishment unit forms an initial sludge dosing boundary when the sludge dosing lower limit is not higher than the candidate dosing upper limit. The prohibition on sludge dosing unit outputs a prohibition on sludge dosing command when a prohibition on sludge dosing command is triggered.

[0215] The feedback correction module includes a stable load judgment unit, a trial feeding control unit, a response extraction unit, a deviation calculation unit, and a boundary correction unit. The stable load judgment unit confirms whether the incineration system is in a stable load state. The trial feeding control unit issues a trial feeding command when the incineration system is in a stable load state; when it cannot actively issue a trial feeding command, it extracts effective operating segments from natural feeding changes. The response extraction unit extracts the gradient of furnace main control temperature changes, oxygen content recovery time, carbon monoxide peak duration time, acid gas concentration ramp-up slope, and the difference in feeder torque changes. The deviation calculation unit calculates the actual response deviation. The boundary correction unit performs boundary contraction, boundary shift, or restricted release processing based on the actual response deviation. The upper limit of candidate feeding after restricted release processing must not exceed the hard boundary constraints of the adaptation constraint window, nor exceed the allowable range of the current soft boundary constraint tolerance interval.

[0216] The strategy output module includes a matching level unit and a compensation control unit. The matching level unit outputs a high-fit, medium-fit, low-fit, or no-fit rating based on the coverage relationship between the corrected sludge dosing boundary and the planned dosing requirement data. The compensation control unit outputs control commands based on the constraints. When the heat margin is insufficient but the flue gas compliance margin meets the requirements, the compensation control unit outputs control commands to increase the auxiliary fuel supply or increase the blending ratio of high-calorific-value co-fuels; when the moisture evaporation load margin is insufficient, the compensation control unit outputs control commands to increase the drying heat source supply, increase the drying target moisture content within the allowable range of the heat margin, reduce the sludge dosing mass flow rate, or postpone batch production; when the flue gas compliance margin is insufficient, the compensation control unit outputs control commands to reduce the blending ratio of chlorinated sludge or increase the pre-washing tower liquid level; when the feed stability margin is insufficient, the compensation control unit outputs control commands to reduce the duration of a single feed, adjust the pulse feed frequency, or increase pre-crushing and pre-mixing treatment.

[0217] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the invention.

[0218] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. It should be noted that any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An intelligent calculation method for the adaptability of sludge co-incineration, characterized in that, include: Acquire batch sludge characteristic data, co-incineration system boundary data, planned feed-in demand data, and continuous operation response data. Perform time alignment and anomaly isolation on the batch sludge characteristic data, co-incineration system boundary data, planned feed-in demand data, and continuous operation response data to obtain a reliable dataset. Generate a batch fluctuation profile characterizing the distribution features of physical properties based on the reliable dataset. An adaptive constraint window containing hard and soft boundary constraints is constructed based on the boundary data of the co-incineration system. The batch fluctuation profile is input into the multi-margin mapping algorithm model. Following a series constraint method—using the rheological transport resistance calculation result as the upper limit of the latent heat consumption phase change calculation, the phase change latent heat consumption calculation result and the rheological transport resistance calculation result together as the upper limit of the thermal equilibrium state calculation, and the rheological transport resistance calculation result and the thermal equilibrium state calculation result together as the upper limit of the pollution conversion rate calculation—the first-dimensional independent sludge addition upper limit corresponding to the feed stability margin, the second-dimensional independent sludge addition upper limit corresponding to the moisture evaporation load margin, the third-dimensional independent sludge addition upper limit corresponding to the heat margin, and the fourth-dimensional independent sludge addition upper limit corresponding to the flue gas compliance margin are obtained sequentially. The tolerance interval coefficient corresponding to the soft boundary constraint is used to correct the first-dimensional independent sludge addition upper limit, the second-dimensional independent sludge addition upper limit, the third-dimensional independent sludge addition upper limit, and the fourth-dimensional independent sludge addition upper limit, generating the multi-margin profile. Based on the multi-margin profile and the fitting constraint window, the independent sludge addition upper limit corresponding to each margin is extracted. The minimum value among the independent sludge addition upper limits is selected as the candidate addition upper limit. The sludge addition lower limit is generated based on the planned addition demand data. When the sludge addition lower limit is not higher than the candidate addition upper limit, the initial sludge addition boundary is established. When the incineration system is under stable load, a trial dosing command is issued based on the candidate dosing upper limit and the trial dosing safety feed coefficient. Continuous operation response data is obtained and the actual response deviation is calculated. The actual response deviation is compared with the expected response direction and expected response amplitude. Boundary contraction, boundary translation, or restricted release treatment is performed on the initial sludge dosing boundary. The corrected sludge dosing boundary and matching level are output. Among them, the restricted release treatment must simultaneously meet the hard boundary constraint of not exceeding the adaptation constraint window and the allowable range of the current soft boundary constraint tolerance range.

2. The intelligent calculation method for the adaptability of sludge co-incineration according to claim 1, characterized in that, The generation of the multi-margin profile includes: Input the rheological characteristic parameters in the batch fluctuation profile into the rheological transport resistance calculation, and output the first-dimensional independent sludge dosing limit in the form of mass flow rate; The upper limit of the first-dimensional independent sludge addition is used as the input limit for the calculation of the latent heat consumption of phase change. The upper limit of the sludge moisture content fluctuation, the target moisture content of drying, the heat exchange efficiency of drying equipment, and the remaining heat source of drying are combined to output the upper limit of the second-dimensional independent sludge addition. The first-dimensional independent sludge addition limit and the second-dimensional independent sludge addition limit are used together as inputs for the thermal balance state calculation to obtain the third-dimensional independent sludge addition limit that maintains the furnace temperature stability. The first dimension of the independent sludge addition limit, the moisture content of the dried sludge corresponding to the second dimension of the independent sludge addition limit, and the third dimension of the independent sludge addition limit are input into the pollution conversion rate to calculate the fourth dimension of the independent sludge addition limit that meets the emission constraints. The first-dimensional independent sludge dosing limit, the second-dimensional independent sludge dosing limit, the third-dimensional independent sludge dosing limit, and the fourth-dimensional independent sludge dosing limit are combined to form a multi-margin profile.

3. The intelligent calculation method for the adaptability of sludge co-incineration according to claim 1, characterized in that, The batch sludge characteristic data includes sludge source batch identifier, sludge moisture content, sludge lower heating value, sludge ash content, sludge organic matter, sludge nitrogen content, sludge sulfur content, sludge chlorine content, sludge particle size distribution characteristics data, and sludge adhesion risk data.

4. The intelligent calculation method for the adaptability of sludge co-incineration according to claim 1, characterized in that, The time alignment and anomaly isolation include: A heterogeneous time axis based on the characteristics of logistics lag is established according to the material sampling time, the time of entering the temporary storage warehouse, the processing time of the drying equipment, the combustion time in the furnace, and the response time of flue gas monitoring. The data acceptance order is set according to the source determination hierarchy of laboratory test data, online test data, distributed control system data, continuous emission monitoring system data, and manually entered data; Data sequences that exceed the sensor's range, are missing time stamps, or have invalid automatic monitoring markers are discarded.

5. The intelligent calculation method for the adaptability of sludge co-incineration according to claim 1, characterized in that, The generation of the batch fluctuation profile includes: Extract the characteristic detection distribution set of the same sludge source in the current received batch and historical inspection batches, and calculate the batch center value, upper bound of batch fluctuation and lower bound of batch fluctuation of the distribution set respectively; When the fluctuation range of the current received batch exceeds the preset historical stable range, a batch anomaly marker is generated, and a corresponding trial addition safety feed coefficient is configured.

6. The intelligent calculation method for the adaptability of sludge co-incineration according to claim 1, characterized in that, The construction of the adaptation constraint window includes: The furnace temperature floor, the minimum residence time of flue gas, the safe threshold for oxygen content, and the emission permit red line are set as hard boundary constraints. The oxygen content recovery response capability, carbon monoxide concentration control capability, acid gas absorption and purification capability, continuous operation capability of the feeding device, and drying heat source margin are set as soft boundary constraints. The tolerance range of the soft boundary constraint and the corresponding tolerance range coefficient of the soft boundary constraint are dynamically adjusted based on the equipment maintenance status, real-time inventory of purification agents, current combustion load, and effective status of the continuous emission monitoring system. Among them, the tolerance range coefficients corresponding to the acid gas absorption and purification capacity, the continuous operation capacity of the feeding device, and the dry heat source margin configuration; the oxygen content recovery response capacity and the carbon monoxide concentration control capacity are used as weighted correction factors for the actual response deviation, and do not participate in the numerical reduction of the first dimension independent sludge addition limit, the second dimension independent sludge addition limit, the third dimension independent sludge addition limit, and the fourth dimension independent sludge addition limit.

7. The intelligent calculation method for the adaptability of sludge co-incineration according to claim 1, characterized in that, The establishment of the initial sludge addition boundary includes: The upper limit of candidate sludge addition is used as the upper boundary of the initial sludge addition boundary, and the lower limit of sludge addition is used as the lower boundary of the initial sludge addition boundary. When the lower limit of sludge addition is higher than the upper limit of candidate addition, an instruction to prohibit addition is output, and the issuance of trial addition instructions is blocked.

8. The intelligent calculation method for the adaptability of sludge co-incineration according to claim 1, characterized in that, The process of acquiring continuous operational response data and calculating the actual response deviation includes: The gradient of furnace main control temperature change, oxygen content recovery time, carbon monoxide peak duration, acid gas concentration ramp-up slope, and feed device torque change difference were obtained before and after the execution of the trial feeding command. The residuals of the changes in the furnace main control temperature gradient, oxygen content recovery time, carbon monoxide peak duration time, acid gas concentration ramp-up slope, and feed device torque variation difference are compared with the expected response direction and expected response amplitude output by the multi-margin mapping algorithm model.

9. The intelligent calculation method for the adaptability of sludge co-incineration according to claim 1, characterized in that, The boundary contraction, boundary translation, or restricted release processes include: For the response parameter corresponding to the same margin constraint, the oxygen content recovery time is higher than the predicted value for two consecutive calculation cycles. The peak duration of carbon monoxide was higher than the predicted value for two consecutive calculation periods. The above-mentioned acid gas concentration ramp-up slope has been higher than the predicted value for two consecutive calculation periods. The above indicates that the torque variation difference of the feeding device is higher than the predicted value for two consecutive calculation cycles. The above, or the bed pressure fluctuation variance is higher than the predicted value for two consecutive calculation periods. When the above conditions are met, a boundary shrinking is performed on the candidate submission limit; When the actual response deviation indicates that the main operating limit has shifted from the heat margin to the flue gas compliance margin, the initial sludge dosing boundary range is shifted to a dosing range that matches the allowable limit of the flue gas compliance margin. The actual response deviation was lower than [a certain value] over three consecutive calculation periods. Furthermore, when the continuous emission monitoring system is in an effective state, a restricted release process is performed without exceeding the hard boundary constraints of the adaptation constraint window or the allowable range of the current soft boundary constraint tolerance interval.

10. A sludge co-incineration adaptability boundary calculation system, used to execute the intelligent calculation method for sludge co-incineration adaptability as described in any one of claims 1-9, characterized in that, It includes a data trustworthiness module, a profile building module, a margin mapping module, a boundary generation module, a feedback correction module, and a policy output module. The profile building module communicates with the data trustworthiness module, the margin mapping module communicates with the profile building module, the boundary generation module communicates with the margin mapping module, the feedback correction module communicates with the boundary generation module, and the policy output module communicates with the feedback correction module.

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