A dry quenching coke charging process full tank misalignment alarm control system and a control method thereof

Abstract

The present application belongs to the technical field of automatic control of coking production, and provides a dry quenching coke charging process full tank misalignment alarm control system and a control method thereof. The system comprises a programmable logic controller, a signal input module, a timer module, an alarm output module and a main control operation interface. The control method process comprises the following steps: defining a monitoring time window for coke charging and presetting a trigger alarm time threshold; the programmable logic controller continuously runs monitoring logic; an abnormal alarm is triggered and output; an operator manually intervenes. The present application automatically judges full tank misalignment abnormality by real-time monitoring of the action timing of the elevator and the coke tank car, and timely sends an alarm signal when an abnormality occurs, notifying the operator to intervene, thereby effectively avoiding secondary coke charging and red coke landing accidents, and improving safety production and automation level.

Description

Technical Field

[0001] This invention belongs to the field of automated control technology in coking production, and relates to the safety protection of coking operations in coordination between dry quenching elevators and coking tank cars. Specifically, it is a full tank misalignment alarm control system and its control method for the coking process in dry quenching. Background Technology

[0002] Dry quenching is an environmentally friendly and energy-saving technology that utilizes inert circulating gas to cool red-hot coke and recover waste heat. In the dry quenching production process, coke loading is a crucial step, and its process is as follows: A coke car loaded with a full can of red-hot coke travels to the bottom of the hoist derrick for initial alignment; the active pressure clamping device (APS) clamps the car, and the hoist lowers the empty can onto the coke car; the APS releases, and the coke car moves to a full can for re-alignment; the APS clamps again, and the hoist extracts the full can of red-hot coke into the loading device, completing one coke loading cycle.

[0003] In actual production, a special abnormal situation exists: after the hoist lowers an empty coke can, due to mechanical failure, signal transmission interruption, or operational error, it fails to retrieve a full can in time. Meanwhile, a coke car, carrying a full can of red-hot coke, leaves the hoisting frame to prepare for reloading. If neither the coke car driver nor the operator in the dry quenching control room notices the abnormality, the coke car will proceed with the reloading operation, resulting in the same full can being repeatedly loaded into two furnaces of red-hot coke, causing "secondary coke loading." The direct consequence of secondary coke loading is that red-hot coke overflows from the can, causing a red-hot coke spillage accident.

[0004] The hazards of red-hot coke falling to the ground are extremely serious: red-hot coke with a temperature of over 1000℃ exposed to the environment is very likely to cause a fire, posing a threat to personnel safety; the accident leads to an emergency shutdown, and the cleanup is difficult and time-consuming, seriously affecting the continuous operation of the coke oven system; the high-temperature red-hot coke may damage ground facilities, cables, tracks and other equipment; at the same time, it causes coke loss and huge economic losses due to production stoppage.

[0005] Currently, dry quenching control systems generally lack automatic monitoring and alarm functions for the "full tank misalignment" abnormal condition. Traditional methods rely on manual observation and judgment by operators, who must simultaneously monitor multiple devices, making it difficult to detect such sporadic anomalies in a timely manner. Communication between the coke tank truck driver and the control room is via walkie-talkie, which introduces information delays and the possibility of misjudgment. Therefore, there is an urgent need for a method that can automatically monitor the coke loading process, promptly detect full tank misalignment anomalies, and trigger an alarm. Summary of the Invention

[0006] The purpose of this invention is to provide a full tank misalignment alarm control system and its control method for the dry quenching coke loading process, which can automatically monitor the dry quenching coke loading process, detect full tank misalignment abnormalities, and issue timely alarms.

[0007] The technical solution adopted by the present invention to achieve the above objectives is as follows: A full tank misalignment alarm control system for dry quenching coke loading process includes a programmable logic controller, a signal input module, a timer module, an alarm output module, and a main control operation interface. Programmable logic controller (PLC) is used for monitoring dry quenching production, receiving signals, timing and judging, and triggering alarms. The signal input module is used to receive empty and full can centering signals from the coke oven control system; The timer module is used to measure the time window; The alarm output module is used to communicate with the main control interface and output to the alarm device. The main control interface is an industrial control computer with configuration software installed, used to display alarm information and record alarm logs.

[0008] Furthermore, the programmable logic controller adopts the Siemens S7 series industrial-grade programmable logic controller.

[0009] Furthermore, the signal input module is implemented using a digital input module.

[0010] Furthermore, the timer module is a software timer inside the programmable logic controller.

[0011] A control method for a full-tank misalignment alarm control system during dry quenching coke loading includes: S1. Define the monitoring time window for coke loading and preset the alarm trigger time threshold; S2, Programmable Logic Controller continuously monitors the logic; The monitoring logic includes: Upon receiving the "empty can aligned" signal, a timer is immediately started. The timer continues to run, waiting to receive the "full tank centering" signal; If the programmable logic controller successfully receives the "full tank alignment" signal before the timer reaches the preset alarm triggering time threshold, it determines that the coking operation is normal, the timer is reset to zero, and it waits for the next empty tank alignment signal. If the programmable logic controller (PLC) still does not receive the "full tank alignment" signal when the timer reaches the preset alarm trigger time threshold, it will determine that a "full tank misalignment" abnormality has occurred.

[0012] S3. When a "full tank misalignment" abnormality is detected, the programmable logic controller automatically triggers the alarm logic, which is as follows: generate an alarm signal and output it to the main control operation interface of the dry quenching control room; and display the alarm in the corresponding alarm area on the dry quenching elevator operation screen of the main control operation interface. S4. The personnel in the central control room communicate with the personnel at the coke loading site to confirm the current operating status of the coke tank car. If it is confirmed that the tank is full and has not been lifted, the personnel immediately order the coke receiving to stop and reposition the tank for lifting and loading operations.

[0013] Furthermore, S1 analyzes the timing patterns of the coke car, elevator, and clamping device based on the dry quenching and coking operation process. The time from emptying the coke car to extracting a full coke car is defined as the monitoring time window. The value of the monitoring time window is determined by the coke car's running distance, centering time, and clamping and releasing time of the clamping device, and is determined through on-site measurement or statistical analysis of historical data. The preset alarm triggering time threshold is set to 1.3 times the monitoring time window time.

[0014] Furthermore, the alarm prompt in S3 uses a prominent red flashing pattern.

[0015] The beneficial effects of this invention are: 1. High degree of automation: No additional hardware equipment is required. The existing dry quenching PLC system is fully utilized, and automatic monitoring is achieved through software programming. The investment cost is low and the implementation cycle is short.

[0016] 2. High real-time performance: The PLC program monitors the coke loading sequence in real time and immediately alarms if any abnormality occurs. The response speed is far superior to manual observation, and timely intervention can be carried out before secondary coke loading occurs.

[0017] 3. The alarm method is intuitive and obvious: It adopts a red flashing alarm, which is different from the conventional status display, making it easy for operators to quickly identify the type and location of the abnormality.

[0018] 4. Improved inherent safety level: By using technical means, the safety hazard of red coke falling to the ground due to misalignment of the full tank is eliminated, avoiding accidents caused by human negligence or communication delays, and significantly improving the safety level of the production site.

[0019] 5. Reduced workload for operators: It reduces the reliance on continuous manual monitoring by operators, allowing them to focus their attention on other critical tasks, while avoiding the high-intensity labor of cleaning up charred residue after an accident. Attached Figure Description

[0020] Figure 1 This is a logic diagram illustrating the continuous operation and monitoring of the programmable logic controller in this invention. Detailed Implementation

[0021] The present invention will be further described below with reference to embodiments: Taking the company's four dry quenching coke plants as an example, based on the programmable logic controller of the dry quenching coke body, the abnormal detection and alarm of misalignment of the full coke trough during the coke loading process is realized by monitoring the key timing windows of the coke loading operation.

[0022] The dry quenching coke loading process full tank misalignment alarm control system includes a programmable logic controller (Siemens S7 series industrial-grade PLC) for the dry quenching coke body, a signal input module, a timer module, an alarm output module, and a main control operation interface; Programmable logic controller (PLC) is used for monitoring dry quenching production, receiving signals, timing and judging, and triggering alarms. The signal input module is used to receive the "empty can aligned" signal and the "full can aligned" signal from the coke oven control system, and is implemented using a digital input module. The timer module is a software timer inside the programmable logic controller (PLC) used to measure time windows; Alarm output module: including communication interface with main control operation interface and alarm device output; The main control interface is an industrial control computer with configuration software installed, used to display alarm information and record alarm logs.

[0023] The control method of the above-mentioned dry quenching coke loading process full tank misalignment alarm control system includes: S1. Define the monitoring time window for coke loading and preset the alarm trigger time threshold; Based on the normal coke loading process of dry quenching, the timing patterns of the coke car, elevator, and clamping device (APS) are analyzed to determine the following key time nodes: T0: The PLC program of the dry quenching coke body receives the "empty tank has been aligned" signal sent by the tank truck control system (that is, the empty tank alignment is completed and the elevator is ready to release the empty tank).

[0024] T1: The PLC program of the dry quenching coke body receives the "full tank centering" signal sent by the tank truck control system (that is, the full tank side centering is completed and the elevator is ready to extract the full tank).

[0025] A monitoring time window Δt = T1 - T0 is defined. This time window is relatively fixed in actual normal production, and its value is determined by factors such as the coke car's running distance, alignment time, and APS clamping / releasing time. It can be determined through on-site measurement or statistical analysis of historical data. An alarm time threshold T_threshold is preset in the PLC program. This threshold is slightly larger than 1.3 times the maximum time under normal operating conditions and is used to determine whether an abnormality has occurred.

[0026] S2, Programmable Logic Controller continuously monitors the logic; The monitoring logic is as follows: Figure 1 As shown, it includes: After the program starts running and the system initializes, continuous monitoring will continue. Upon receiving the "empty can aligned" signal, a timer is immediately started to begin timing; The timer continues to run, waiting to receive the "full tank centering" signal; If the programmable logic controller successfully receives the "full tank alignment" signal before the timer reaches the preset alarm triggering time threshold, it determines that the coking operation is normal, the timer is reset to zero, and it waits for the next empty tank alignment signal. If the programmable logic controller (PLC) still does not receive the "full tank alignment" signal when the timer reaches the preset alarm trigger time threshold, it will determine that a "full tank misalignment" abnormality has occurred.

[0027] S3. When an "overfill misalignment" abnormality is detected, the programmable logic controller automatically triggers the alarm logic. The alarm logic is as follows: an alarm signal is generated and output to the main control operation interface of the dry quenching coke central control room; the alarm is displayed in the corresponding alarm area on the dry quenching coke elevator operation screen of the main control operation interface, and the alarm is displayed in a prominent red flashing mode. After the alarm signal is triggered, manual intervention is required.

[0028] S4. Upon seeing the alarm, the operator in the central control room immediately contacts the coke truck driver at the coke loading site via communication tools to confirm the current operating status of the coke truck, inquire whether the driver is performing manual operation, and whether the full tank has been lifted by the hoist. If it is confirmed that the full tank has not been lifted, the operator immediately issues a stop coke receiving command and repositions the truck for coke loading.

[0029] This invention automatically detects abnormalities such as full tanks not being extracted by real-time monitoring of the operation sequence of the hoist and coke tank car, and promptly issues an alarm signal when an abnormality occurs to notify the operator to intervene, thereby effectively avoiding secondary coke receiving and red coke falling to the ground accidents, and improving the level of safe production and automation.

Claims

1. A full-tank misalignment alarm control system for the dry quenching coke loading process, characterized in that: It includes a programmable logic controller, a signal input module, a timer module, an alarm output module, and a main control operation interface; The programmable logic controller is used to monitor dry quenching production, receive signals, perform timing judgments, and trigger alarms. The signal input module is used to receive empty and full can centering signals from the coke oven control system; The timer module is used to measure the time window; The alarm output module is used to communicate with the main control interface and output to the alarm device; The main control interface is an industrial control computer with configuration software installed, used to display alarm information and record alarm logs.

2. The full tank misalignment alarm control system for the dry quenching coke loading process according to claim 1, characterized in that: The programmable logic controller (PLC) is a Siemens S7 series industrial-grade PLC.

3. The full tank misalignment alarm control system for the dry quenching coke loading process according to claim 1, characterized in that: The signal input module is implemented using a digital input module.

4. The full tank misalignment alarm control system for the dry quenching coke loading process according to claim 1, characterized in that: The timer module is a software timer inside the programmable logic controller.

5. The control method of the full tank misalignment alarm control system for the dry quenching coke loading process according to claim 1, characterized in that: include: S1. Define the monitoring time window for coke loading and preset the alarm trigger time threshold; S2, Programmable Logic Controller continuously monitors the logic; The monitoring logic includes: Upon receiving the "empty can aligned" signal, a timer is immediately started. The timer continues to run, waiting to receive the "full tank, center" signal; If the programmable logic controller successfully receives the "full tank alignment" signal before the timer reaches the preset alarm trigger time threshold, it determines that the coking operation is normal, the timer is reset to zero, and it waits for the next empty tank alignment signal. If the programmable logic controller still does not receive the "full tank alignment" signal when the timer reaches the preset alarm trigger time threshold, it will determine that a "full tank misalignment" abnormality has occurred. S3. When a "full tank misalignment" abnormality is detected, the programmable logic controller automatically triggers the alarm logic, which is as follows: generate an alarm signal and output it to the main control operation interface of the dry quenching control room; and display the alarm in the corresponding alarm area on the dry quenching elevator operation screen of the main control operation interface. S4. The personnel in the central control room communicate with the personnel at the coke loading site to confirm the current operating status of the coke tank car. If it is confirmed that the tank is full and has not been lifted, the personnel immediately order the coke receiving to stop and reposition the tank for lifting and loading operations.

6. The control method of the full tank misalignment alarm control system for the dry quenching coke loading process according to claim 5, characterized in that: S1 analyzes the timing patterns of the actions of the coke car, elevator, and clamping device according to the dry quenching and coking operation process. The time window from the moment the empty car is released to the moment the full car is extracted is defined as the monitoring time window. The value of the monitoring time window is determined by the coke car's running distance, centering time, and clamping and releasing time of the clamping device, and is determined through on-site measurement or statistical analysis of historical data. The preset alarm triggering time threshold is set to 1.3 times the monitoring time window time.

7. The control method of the full tank misalignment alarm control system for the dry quenching coke loading process according to claim 5, characterized in that: The alarm signal in S3 uses a prominent red flashing pattern.

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