Coal Management Control for Cement Kiln Fuel Reduction
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Solution Overview
Problem
Cement production lines face challenges in efficiently reducing coal usage due to the large number of monitoring points, leading to time-consuming and inaccurate adjustments, resulting in increased manufacturing costs and environmental pollution.
Innovation Solution
A coal management system with a central control system and multiple monitoring points that acquire data, select a candidate feature set, construct a coal model, and generate operation recommendations to optimize coal usage across production equipment, reducing coal consumption by automatically adjusting equipment operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large number of monitoring points are used to monitor production equipment, then monitoring data coverage is improved, but the complexity of data analysis and adjustment decision-making increases
Solution Approach 1:
The patent extracts and selects only the most critical monitoring points from the large set of 5,000 monitoring points. The system identifies key parameters that have the greatest impact on coal consumption and kiln operation, extracting a manageable subset of critical data for analysis while discarding redundant information.
Solution Approach 2:
The patent segments the 5,000 monitoring points into different categories and functional groups. By dividing the monitoring system into segments (e.g., temperature monitoring, pressure monitoring, flow monitoring), the system can analyze each segment separately using appropriate algorithms, reducing the overall complexity of data analysis.
2Ease of operation
If manual analysis of monitoring data is performed, then operational flexibility is maintained, but adjustment response time increases
Solution Approach 1:
The patent replaces manual mechanical analysis with automated computer-based analysis systems. The system uses algorithms and computational models to automatically analyze monitoring data, identify optimal adjustments, and generate control recommendations, substituting human manual processes with automated mechanical/electronic systems that operate faster and more consistently.
Solution Approach 2:
The system enables self-service by automatically performing data analysis, identifying optimization opportunities, and generating adjustment recommendations without requiring continuous manual intervention. The automated system serves itself by continuously monitoring, analyzing, and suggesting optimizations, freeing operators from routine analysis tasks.
3Loss of energy
If frequent adjustments to production equipment are made to optimize coal usage, then coal consumption is reduced, but system stability may be compromised
Solution Approach 1:
The patent applies partial action by making targeted, selective adjustments only to specific parameters and equipment that have the greatest impact on coal consumption. Rather than frequently adjusting all parameters, the system identifies and adjusts only the critical few parameters that yield the most significant energy savings, avoiding unnecessary disturbances to system stability.
Solution Approach 2:
The system implements feedback mechanisms where adjustments are made based on continuous monitoring of both coal consumption and system performance. The system monitors the effects of adjustments and uses this feedback to fine-tune parameters, ensuring that optimization does not compromise stability. The feedback loop allows the system to adapt and maintain stability while achieving energy savings.
Data Source
AI summary
A coal management system includes a central control system and a plurality of monitoring points. The plurality of monitoring points are arranged at a plurality of pieces of production equipment. A method of controlling the coal management system includes the plurality of monitoring points acquiring monitoring data, the central control system selecting a candidate feature set and constructing a coal model according to the monitoring data, the central control system generating an operation recommendation of a controlled monitoring point of the plurality of monitoring points according to the coal model, and a piece of production equipment performing an operation according to the operation recommendation to achieve a target operation condition.