CN212032002U - Advanced process control system and coal-to-methanol conversion and synthesis system - Google Patents
Advanced process control system and coal-to-methanol conversion and synthesis system Download PDFInfo
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Abstract
The utility model relates to a coal system methyl alcohol transform and synthetic process control technical field especially relate to an advanced process control system and coal system methyl alcohol transform and synthetic system. The advanced process control system comprises a distributed control device and an advanced control device; the advanced control device comprises a dynamic data memory, a model memory, a change trend arithmetic unit and an optimization control component which are mutually communicated and connected; the model memory stores transformation mechanism model data and synthesis mechanism model data; the variation trend calculator predicts the variation trend of the controlled variable; the optimization control assembly calculates an optimal regulating quantity according to the change trend and a preset expected value, and the distributed controller assembly regulates the regulating assembly according to the optimal regulating quantity. The coal-to-methanol conversion and synthesis system includes the advanced process control system. The advanced process control system and the coal-to-methanol conversion and synthesis system can reduce the fluctuation range of controlled variables and improve the automation level, the system stability and the yield of crude methanol.
Description
Technical Field
The utility model relates to a coal system methyl alcohol transform and synthetic process control technical field especially relate to an advanced process control system and coal system methyl alcohol transform and synthetic system.
Background
In the related technology, the coal-to-methanol conversion and synthesis device realizes automatic control of the coal-to-methanol conversion and synthesis through a DCS (distributed control system), and monitors the whole process of the coal-to-methanol conversion and synthesis through detection instruments such as temperature, pressure, flow, liquid level and components.
The coal-to-methanol conversion and synthesis device has a long production flow, and has a strong heat integration condition in the flow, and simultaneously relates to more heat exchange and reaction processes, so the coal-to-methanol conversion and synthesis are typical multivariable, constrained and strongly coupled complex industrial processes.
Because the control scheme of the DCS control system is usually conventional PID (proportional, integral and derivative) and cascade, i.e., a conventional single-input single-output control scheme, the DCS control system has been difficult to solve the problem of the overall control and optimization of the process, and thus the problems of low crude methanol yield, more fusel, more purge gas, etc., are caused due to the large fluctuation of important process parameters such as shift reactor temperature, synthesis reactor pressure, circulating gas flow, etc., of the coal-to-methanol shift and synthesis apparatus, which are always in manual adjustment, low automation level and unstable operation.
SUMMERY OF THE UTILITY MODEL
A first object of the utility model is to provide an advanced process control system to it is undulant big to solve the important technological parameter of coal system methyl alcohol transform and synthesizer sieve among the prior art to a certain extent, and the device is in among the manual adjustment always, the automation is competent low and the operation is unstable, causes coarse methanol productivity low, the fusel is many, the gas volume of blowing out is many scheduling problem.
A second object of the utility model is to provide a coal system methyl alcohol transform and synthesis system to it is undulant big to solve among the prior art coal system methyl alcohol transform and synthesis system's important technological parameter to a certain extent, and the device is in among the manual adjustment always, the automation level is low and the operation is unstable, causes thick methyl alcohol productivity low, miscellaneous mellow wine is many, the many scheduling problems of gas volume of blowing out.
In order to achieve the above object, the present invention provides the following technical solutions;
based on the above purpose, the utility model provides an advanced process control system for coal system methyl alcohol transform and synthesizer, coal system methyl alcohol transform and synthesizer includes transform mechanism, synthesis mechanism and adjusting part, adjusting part set up in transform mechanism and synthesis mechanism;
the advanced process control system comprises a distributed control device and an advanced control device, wherein the distributed control device comprises a detector assembly and a distributed controller assembly which are in communication connection; the advanced control device comprises a dynamic data memory, a model memory, a variation trend arithmetic unit and an optimization control component which are mutually communicated and connected; the model memory stores transformation mechanism model data and synthesis mechanism model data;
the dynamic data storage and the optimization control component are both in communication connection with the distributed controller component; the detector assembly respectively acquires dynamic data of controlled variables of the transformation mechanism and the synthesis mechanism, and transmits and stores the dynamic data to the dynamic data memory; historical data is stored in the dynamic data memory;
the change trend calculator can predict the change trend of the controlled variable within a preset time according to the transformation mechanism model data, the synthesis mechanism model data, the dynamic data and the historical data;
the optimization control component can calculate an optimal regulating quantity for the regulating component according to the change trend and a preset expected value and transmit the optimal regulating quantity to the distributed controller component;
and the distributed controller component regulates the regulating component according to the optimal regulating quantity so that the controlled variable works at the preset expected value.
In any of the above technical solutions, optionally, the advanced control apparatus further includes a feedback corrector;
the feedback corrector is respectively in communication connection with the dynamic data memory, the model memory, the change trend calculator and the optimization control component;
and the feedback corrector corrects the transformation mechanism model data and the synthesis mechanism model data according to the dynamic data and the change trend.
In any of the above solutions, optionally, the detector assembly includes a first detector assembly and a second detector assembly;
the first detector assembly can acquire first dynamic data of a first controlled variable of the transformation mechanism, and transmit and store the first dynamic data to the dynamic data memory;
the second detector assembly is capable of acquiring second dynamic data of a second controlled variable of the combining mechanism and transmitting and storing the second dynamic data to the dynamic data memory.
In any of the above technical solutions, optionally, the optimization control component includes a conversion controller and a synthesis controller;
the adjusting assembly comprises a first adjusting assembly arranged on the transformation mechanism and a second adjusting assembly arranged on the synthesis mechanism;
the change trend calculator can predict a first change trend of the first controlled variable within the preset time length according to the first dynamic data, the transformation mechanism model and the historical data; the conversion controller is capable of calculating a first optimal adjustment amount for the first adjustment assembly according to the first trend of change and the predetermined desired value;
the change trend calculator is also capable of predicting a second change trend of the second controlled variable within the preset time length according to the second dynamic data, the synthetic mechanism model data and the historical data; the synthesizing controller is capable of calculating a second optimum adjustment amount for the second adjustment component based on the second tendency of change and the predetermined desired value.
In any of the above technical solutions, optionally, the first adjusting component includes a first water separator outlet temperature adjusting part, a shift reactor inlet temperature adjusting part, a shift reactor second bed temperature adjusting valve, a first water separator outlet temperature adjusting part, a shift reactor second bed temperature adjusting valve, a shift outlet CO content adjusting valve, a purified fresh gas flow adjusting valve, a synthesis compressor inlet flow adjusting valve, and a synthesis compressor rotation speed adjuster;
the first detector assembly comprises a shift reactor upper temperature sensor, a shift reactor hot spot temperature sensor, a fresh gas hydrogen-carbon ratio detection piece, a low-temperature methanol washing absorption tower pressure sensor, a synthesis reactor pressure drop sensor and a synthesis circulating gas quantity detection piece;
the conversion mechanism model data is control model data of a set value of the first adjustment module to a detected value of the first detector module.
In any of the above technical solutions, optionally, the second regulating component includes a non-permeate gas discharge valve, a synthesis drum pressure regulating valve, a non-permeate gas discharge valve, a hydrogen compressor primary air inlet pressure regulating valve, a synthesis compressor rotation speed regulator, and a synthesis drum intermediate sub-steam flow regulating valve;
the second detector component comprises a synthesis reactor inlet inert gas content detection piece, a synthesis reactor hot spot temperature sensor, a synthesis reactor inlet pressure sensor, a membrane recovery inlet flowmeter, a membrane recovery permeate gas pressure difference detection piece, a membrane recovery permeate gas pressure difference sensor, a turbine guide vane opening degree detection piece, a synthesis gas compressor inlet pressure sensor and a superheater fuel gas valve position detection piece;
the synthetic mechanism model data is control model data of a set value of the second adjusting component to a detection value of the second detector component.
In any of the above technical solutions, optionally, the distributed controller component further includes a distributed controller, an instruction input component, and a result display component;
the instruction input assembly and the result display assembly are connected with the distributed controller; the instruction input component is used for inputting the threshold value of the regulating quantity and the threshold value of the controlled variable by an operator; and the result display assembly is used for data monitoring of operators.
In any of the above technical solutions, optionally, the apc system further includes a first gateway, a second gateway, and an OPC server:
the distributed control appliance component communicates with the OPC server through the first gateway and the optimization control component communicates with the OPC server through the second gateway.
Based on above-mentioned second purpose, the utility model provides a coal system methyl alcohol transform and synthesis system includes the advanced process control system that coal system methyl alcohol transform and synthesizer and above-mentioned arbitrary technical scheme provided.
Adopt above-mentioned technical scheme, the beneficial effects of the utility model are that:
the utility model provides an advanced process control system, including distributed control device and advanced control device. By establishing the transformation mechanism model data and the synthesis mechanism model data, a more accurate simulation environment is provided for the change trend calculator to predict the change trend, so that the obtained change trend is more fit with the actual change rule, and the accuracy of prejudgment is improved. Furthermore, compared with the scheme of directly obtaining the control instruction through a distributed controller component, the optimal regulating quantity obtained by comparing the variation trend with the preset expected value can be more suitable for the multivariable, constrained and strongly coupled complexity of the coal-to-methanol conversion and synthesis device, the working state of the coal-to-methanol conversion and synthesis device can approach to an ideal state through automatic process control, the operation quantity of operators can be effectively reduced, the labor intensity of the operators can be reduced, the automation level can be improved, and therefore the process parameter fluctuation of the conversion reactor temperature, the synthesis reactor pressure, the circulating gas flow and the like is reduced, the safety and the stability are improved, the environmental friendliness is enhanced, the energy is saved, and the consumption is reduced.
The coal-to-methanol conversion and synthesis system provided by the embodiment comprises the advanced process control system, so that all the beneficial effects realized by the advanced process control system can be realized.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the technical solutions in the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic diagram of a process flow of a methanol distillation apparatus of an advanced process control system according to an embodiment of the present invention;
fig. 2 is a schematic structural diagram of an apc system according to an embodiment of the present invention;
fig. 3 is a schematic structural diagram of an optimization control component of an apc system according to an embodiment of the present invention.
Icon: 1-distributed control device; 2-advanced control means; 20-dynamic data storage; 21-a model memory; 22-a trend of change operator; 23-optimizing the control assembly; 230-a conversion controller; 231-a synthesis controller; 24-a feedback corrector; 30-a changing mechanism; 300-water gas waste heat boiler; 301-a first water separator; 302-medium temperature heat exchanger; 303-shift reactor; 304-a waste heat boiler; 305-a water wash column; 306-low temperature methanol washing section; 31-a synthesis mechanism; 310-a synthesis gas compressor; 311-a guard bed; 312-inlet and outlet heat exchangers; 313-methanol synthesis reactor; 314-a water cooler; 315-methanol high pressure separator; 316-recycle gas compressor; 317-a membrane recovery unit; 318-hydrogen press; 319-stripper column; 4-OPC server.
Detailed Description
The technical solution of the present invention will be described clearly and completely with reference to the accompanying drawings, and obviously, the described embodiments are some, but not all embodiments of the present invention. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative work belong to the protection scope of the present invention.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplification of description, but do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the description of the present invention, it is to be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Example one
The advanced process control system provided by the embodiment is used for a coal-to-methanol conversion and synthesis device.
Referring to fig. 1 to 3, in the advanced process control system according to the present embodiment, the coal-to-methanol conversion and synthesis apparatus includes a conversion mechanism 30, a synthesis mechanism 31, and an adjustment component, and the adjustment component is disposed on the conversion mechanism 30 and the synthesis mechanism 31.
Specifically, referring to fig. 1, the working principle of the conversion mechanism 30 is as follows: the water gas a from the upstream process is at 240 ℃, the pressure is 6.25MPa, the water-gas ratio is 1.4-1.6, the micro-particle dust and a small amount of condensate are separated by a gas-water separator, the water gas is sent into a water-gas waste heat boiler 300, the temperature is reduced to 215 ℃, and meanwhile, saturated steam with the pressure of 1.27MPa is generated and sent to a pipe network. The cooled water gas is separated into a first water gas b, a second water gas c and a third water gas d after condensate is separated from the first water separator 301, the first water gas b is used as a gas distribution and is not adjusted by a shift gas CO concentration adjusting valve through the shift reactor 303, the second water gas c enters the medium temperature heat exchanger 302 and enters the shift reactor 303 after being preheated, the third water gas d enters the middle part of the shift reactor 303 as chilling gas, and the chilling temperature adjusting valve of the shift reactor 303 controls the temperature of a bed layer at the lower section of the shift reactor 303.
The shift reactor 303 is filled with a cobalt-molybdenum sulfur-resistant catalyst, the second water gas c and the third water gas d are subjected to shift reaction in the shift reactor 303 to obtain shift gas e, the CO content of the shift gas e flowing out of the shift reactor 303 is about 6-8%, and the temperature is about 420 ℃. The converted gas e continues to enter the waste heat boiler 304, 1.27MPa saturated steam is generated in the waste heat boiler 304 and sent to a pipe network, and the temperature of the converted gas is reduced to 382 ℃. And mixing the cooled shift gas with the first strand of water gas b, wherein the CO content in the mixed shift gas is 19-22%, and the temperature is 308 ℃.
The mixed conversion gas enters a low-pressure boiler feed water heater, the temperature is reduced to 210 ℃, the conversion gas is sent to a low-pressure waste heat boiler 304, and 0.3MPa saturated steam is generated and sent to a pipe network. And separating the condensate from the converted gas by a second water separator, feeding the separated condensate into a medium-pressure boiler feed water heater, reducing the temperature to 191 ℃, heating the medium-pressure boiler feed water pumped by the medium-pressure boiler feed water to 145 ℃, and feeding the heated medium-pressure boiler feed water into a synthetic waste boiler. The converted gas enters desalted water for heating, and then enters the converted gas water cooler for cooling to 40 ℃. And then enters the lower part of the water washing tower 305, ammonia gas in the converted gas is washed away by the washing water in the water washing tower 305, and then the converted gas is sent to a downstream low-temperature methanol washing section 306.
The condensate separated from the bottom of the water washing tower 305 enters the upper tower plate of the stripping tower 319, part of non-condensable gas flashed from the condensate tank and high-flash gas from gasification enter the middle part of the stripping tower 319 together, low-pressure steam is introduced into the bottom of the stripping tower 319, low-temperature conversion condensate is stripped in the stripping tower 319 to separate out non-condensable gas and water, the non-condensable gas is sent to sulfur recovery after the stripping gas ejected from the top of the stripping tower 319 is cooled, and the condensate at the bottom of the stripping tower 319 is pressurized and sent to the gasification process through a condensate pump.
The working principle of the combining mechanism 31 is as follows: the fresh gas f at 30 ℃ and 5.4Mpa from the low-temperature methanol washing section 306 and the permeation gas h mainly comprising hydrogen of the membrane recovery device 317 are used as the inlet gas of the synthesis gas compressor 310, and the inlet gas is compressed and pressurized and then enters the guard bed 311 which is operated in parallel for reaction. Guard bed 311 is loaded with an organosulfur hydrolysis catalyst to remove sulfides from the inlet gas. The inlet gas after fine desulfurization is mixed with the gas from the recycle gas compression to form the feed gas, and then the feed gas enters the inlet and outlet heat exchangers 312 and exchanges heat with the outlet gas of the methanol synthesis reactor 313 in the inlet and outlet heat exchangers 312, so that the feed gas is heated to about 230 ℃.
The raw gas then enters a methanol synthesis reactor 313, and chemical reaction occurs under the action of the catalyst, the concentration of methanol is increased to 13.24%, and the temperature of the catalyst bed is adjusted by the pressure of a steam drum. The primary synthesis gas exiting the methanol synthesis reactor 313 enters the tube side of the inlet/outlet heat exchanger 312, exchanges heat with the shell-side tower inlet mixed gas, and is cooled to 121 ℃, and methanol in the primary synthesis gas begins to condense.
The primary synthesis gas then enters the water cooler 314 where it is cooled further to 40 c to condense most of the methanol and form a gas-liquid mixture. The gas-liquid mixture enters the methanol high-pressure separator 315, the liquid methanol of the gas-liquid mixture is separated, and the gas component of the gas-liquid mixture is sent to the inlet of the recycle gas compressor 316 for recycling. The gas component of the gas-liquid mixture is split off before entering the recycle gas compressor 316 and sent to the membrane recovery unit 317 to keep the inert gas constant throughout the recycle loop. The liquid methanol separated in the methanol high-pressure separator 315 is sent to a methanol rectification step as crude methanol g. The permeate gas h, which is mainly hydrogen, from the hydrogen compressor 318 is mixed with fresh gas and enters the inlet of the synthesis gas compressor 310, while the tail gas, i.e. the non-permeate gas i, is sent to the fuel gas pipe network.
Referring to fig. 2, the apc system includes a distributed control apparatus 1 and an advanced control apparatus 2, wherein the distributed control apparatus 1 includes a detector assembly and a distributed controller assembly which are communicatively connected; the advanced control device 2 comprises a dynamic data memory 20, a model memory 21, a trend of change operator 22 and an optimization control component 23, which are communicatively connected to each other.
The model memory 21 stores conversion mechanism model data and synthesis mechanism model data. The conversion mechanism model data is model data of a multi-input multi-output mode obtained by taking the conversion mechanism 30 as a modeling object, and can more accurately simulate the working mechanism in the conversion mechanism 30, and similarly, the synthesis mechanism model data is model data of a multi-input multi-output mode obtained by taking the synthesis mechanism 31 and the modeling object, so that the working mechanism in the synthesis mechanism 31 is more accurately simulated, and the working mechanism of the coal-to-methanol conversion and synthesis process is more accurately simulated.
Both the dynamic data store 20 and the optimization control component 23 are communicatively coupled to the distributed controller component. It should be noted that the communication connection means that two connected components can transmit electric signals therebetween, and specifically, the communication connection can be through wired communication or wireless communication.
The detector assembly respectively acquires dynamic data of controlled variables of the transformation mechanism 30 and the synthesis mechanism 31, and transmits and stores the dynamic data to the dynamic data memory 20; the dynamic data memory 20 stores therein history data. It will be appreciated that the dynamic data acquired, transferred and stored in the dynamic data store 20 at the previous time becomes historical data for the next time. The controlled variables of the conversion means 30 and the synthesis means 31 are values corresponding to control targets such as temperature, pressure, flow rate, and liquid level.
The variation trend calculator 22 can predict the variation trend of the controlled variable within a preset time according to the transformation mechanism model data, the synthesis mechanism model data, the dynamic data and the historical data; the optimization control component 23 can calculate an optimal adjustment quantity for the adjustment component according to the variation trend and a preset expected value, and transmit the optimal adjustment quantity to the distributed controller component; the distributed controller component adjusts the adjusting component according to the optimal adjusting quantity so that the controlled variable works at a preset expected value.
Specifically, in combination with process and equipment constraints, the optimization control component 23 can perform calculations according to the numerical ranges of the controlled variables and the adjustment quantities, thereby maximizing economic benefits. The distributed controller assembly is typically self-contained with the coal-to-methanol conversion and synthesis plant, so that it is not necessary to redevelop or introduce a distributed controller assembly.
That is to say, by establishing the transformation mechanism model data and the synthesis mechanism model data, a more accurate simulation environment is provided for the variation trend calculator 22 to predict the variation trend, so that the obtained variation trend is more in accordance with the actual variation rule, and the accuracy of prejudgment is improved. Furthermore, compared with the scheme of directly obtaining the control instruction through a distributed controller component, the optimal regulating quantity obtained by comparing the variation trend with the preset expected value can be more suitable for the multivariable, constrained and strongly coupled complexity of the coal-to-methanol conversion and synthesis device, the working state of the coal-to-methanol conversion and synthesis device can approach to an ideal state through automatic process control, the operation quantity of operators can be effectively reduced, the labor intensity of the operators can be reduced, the automation level can be improved, and therefore the fluctuation of process parameters such as the temperature of a conversion reactor, the temperature and the pressure of a methanol synthesis reactor, the circulating gas flow and the like is reduced, the safety and the stability are improved, the environmental friendliness is enhanced, the energy is saved, and the consumption is reduced.
Specifically, the advanced process control system realizes automatic adaptation to flow fluctuation and component fluctuation of gas from a gasification section, and reduces manual intervention; the fluctuation range of key process parameters can be reduced by 46.66%, and the running stability and safety of the device are greatly improved; the method realizes the control of the clamping edge, improves the reaction efficiency by optimizing the hydrogen-carbon ratio, the non-permeation gas emission amount and the like of the synthesis reactor, improves the yield of crude methanol by 0.69 percent, improves the yield of superheated steam, and greatly improves the direct economic benefit.
Alternatively, the advanced control device 2 runs on a separate dedicated server, specifically a rack-mounted APC server or a tower-type APC server.
In an alternative of this embodiment, the advanced control device 2 further comprises a feedback corrector 24; the feedback corrector 24 is in communication with the dynamic data storage 20, the model storage 21, the trend of change operator 22 and the optimization control component 23, respectively. The feedback corrector 24 corrects the conversion mechanism model data and the synthesis mechanism model data based on the dynamic data and the variation tendency.
By continuously correcting the conversion mechanism model data, the synthesis mechanism model data, and the synthesis mechanism model data, it is possible to prevent the control effect of the advanced control apparatus 2 from being excessively deviated from the ideal state due to the mismatch of the respective model data and the environmental disturbance.
Optionally, the dynamic data storage 20 is used to store all relevant information such as dynamic data from the distributed control apparatus 1 during the operation of the advanced control apparatus 2, process data, operation records, modification records, fault and error diagnosis, etc. of the trend calculator 22, the feedback corrector 24 and the optimization control component 23, so as to facilitate system debugging or problem analysis.
In an alternative of this embodiment, the detector assembly comprises a first detector assembly and a second detector assembly.
The first detector assembly is capable of acquiring first dynamic data of a first controlled variable of the transformation mechanism 30 and transmitting and storing the first dynamic data to the dynamic data memory 20. The second detector assembly is capable of acquiring second dynamic data of the second controlled variable of the combining mechanism 31 and transmitting and storing the second dynamic data to the dynamic data memory 20.
That is, the conversion mechanism 30 and the combining mechanism 31 are detected by the first detector assembly and the second detector assembly, respectively, to monitor the operating states of the conversion mechanism 30 and the combining mechanism 31.
In an alternative to this embodiment, and as shown in FIG. 3, the optimization control component 23 includes a shift controller 230 and a composition controller 231.
The adjusting unit includes a first adjusting unit provided to the changing mechanism 30 and a second adjusting unit provided to the combining mechanism 31. That is, the conversion mechanism 30 and the combining mechanism 31 are adjusted by the first adjusting assembly and the second adjusting assembly, respectively.
The variation trend calculator 22 can predict a first variation trend of the first controlled variable within a predetermined time period according to the first dynamic data, the transformation mechanism model data and the historical data; the shift controller 230 is capable of calculating a first optimal adjustment amount for the first adjustment component based on the first trend of change and a predetermined desired value. Thus, the first controlled variable of the switching mechanism 30 is ensured to work at a preset expected value, namely, the working state of the switching mechanism 30 reaches an ideal state.
The variation trend calculator 22 is further capable of predicting a second variation trend of the second controlled variable within the predetermined time period according to the second dynamic data, the synthetic mechanism model data and the historical data; the composition controller 231 can calculate a second optimum adjustment amount for the second adjustment member based on the second tendency of change and a predetermined desired value. Thereby ensuring that the second controlled variable of the synthesizing mechanism 31 operates at the predetermined desired value, i.e. the operating state of the synthesizing mechanism 31 reaches the ideal state.
Thus, by the cooperative use of the shift controller 230, the synthesis controller 231, the first adjustment assembly, the second adjustment assembly, the first detector assembly and the second detector assembly, the optimal control capability of the optimal control assembly 23 can be further improved to further optimize the shift outlet CO concentration, the fresh gas to carbon ratio, the synthesis reactor pressure, the recycle gas flow rate, and the like.
Optionally, the optimization control component 23 is a rolling optimization control component, which can take into account the influence caused by uncertainty factors such as model mismatch, time variation or interference and can make compensation optimization in time, thereby optimizing the automatic control effect. The rolling optimization control component is a control component with a rolling optimization function, which calculates an optimal regulating quantity in each control period so as to minimize the deviation of the controlled variable from a preset expected value in a preset time period.
Optionally, the control period of the roll optimization control assembly is 30 seconds.
In an alternative of this embodiment, the first adjusting assembly includes a first water separator outlet temperature adjusting member, a shift reactor inlet temperature adjusting member, a shift reactor second bed temperature adjusting valve, a first water separator outlet temperature adjusting member, a shift reactor second bed temperature adjusting valve, a shift outlet CO content adjusting valve, a purified fresh gas flow adjusting valve, a synthesis compressor inlet flow adjusting valve, and a synthesis compressor rotational speed adjuster.
The first detector assembly comprises a shift reactor upper temperature sensor, a shift reactor hot spot temperature sensor, a fresh gas hydrogen-carbon ratio detection piece, a low-temperature methanol washing absorption tower pressure sensor, a synthesis reactor pressure drop sensor and a synthesis circulating gas quantity detection piece.
The conversion mechanism model data is control model data of a set value of the first adjustment module to a detected value of the first detector module.
That is, the controlled variables specifically include shift reactor overhead temperature, shift reactor hot spot temperature, fresh gas hydrogen to carbon ratio, low temperature methanol wash absorber pressure, synthesis reactor pressure drop, and synthesis recycle gas volume.
Specifically, the transformation mechanism model data includes: a control model for changing the set value of the outlet temperature of the first water separator to the upper temperature of the shift reactor, a control model for changing the set value of the inlet temperature of the shift reactor to the upper temperature of the shift reactor, a control model for changing the opening of a second bed temperature regulating valve of the shift reactor to the upper temperature of the shift reactor, a control model for changing the set value of the outlet CO content to the upper temperature of the shift reactor, a control model for changing the set value of the outlet temperature of the first water separator to the hot spot temperature of the shift reactor, a control model for changing the set value of the inlet temperature of the shift reactor to the hot spot temperature of the shift reactor, a control model for changing the set value of the outlet CO content to the fresh gas-to-carbon ratio, a control model for changing the set value of the outlet CO content to the pressure of the low-temperature methanol washing and absorbing tower, a control model for changing the set value, A control model for changing the set value of the CO content at the outlet to the pressure drop of the synthesis reactor and a control model for changing the set value of the CO content at the outlet to the synthesis circulating gas quantity. That is, the conversion mechanism model data is a multi-input multi-output control model, and can more appropriately simulate the actual operation mechanism of the conversion mechanism 30.
Optionally, the transformation mechanism model data comprises: an interference model of the opening of the CO content regulating valve at the shift outlet on the hot spot temperature of the shift reactor; an interference model of the actual value of the purified fresh gas flow to the hydrogen-carbon ratio of the fresh gas; synthesizing an interference model of the actual value of the inlet flow of the compressor to the hydrogen-carbon ratio of the fresh gas; synthesizing an interference model of the actual value of the rotating speed of the compressor to the hydrogen-carbon ratio of the fresh gas; fresh gas CO2An interference model of the actual value of the content to the hydrogen-carbon ratio of the fresh gas; synthesizing an interference model of the actual value of the rotating speed of the compressor to the pressure of the low-temperature methanol washing absorption tower; fresh gas CO2An interference model of the actual value of the content to the pressure of the low-temperature methanol washing absorption tower; fresh gas CO2An interference model of the actual value of the content with the pressure drop of the synthesis reactor; an interference model of the actual value of the purified fresh gas flow to the synthetic circulating gas flow; synthesizing an interference model of the actual value of the rotating speed of the compressor to the synthetic circulating gas quantity; fresh gas CO2The actual value of the content is a disturbance model for the amount of the synthetic recycle gas.
In order to simulate the influence of disturbance such as fresh gas composition and synthetic compressor rotation speed change on the synthetic mechanism 31, the disturbance model of the multi-input multi-output conversion mechanism 30 is constructed, so as to further improve the simulation precision of the model data of the conversion mechanism, be beneficial to reducing the fluctuation of the controlled variable and enable the conversion mechanism 30 to operate in the optimized interval.
In an alternative of this embodiment, the second regulating component includes a non-permeate gas discharge valve, a synthesis drum pressure regulating valve, a non-permeate gas discharge valve, a first-stage inlet gas pressure regulating valve of the hydrogen compressor, a synthesis compressor speed regulator, and a synthesis drum mid-sub-steam flow regulating valve.
The second detector component comprises a synthesis reactor inlet inert gas content detection piece, a synthesis reactor hot spot temperature sensor, a synthesis reactor inlet pressure sensor, a membrane recovery inlet flow meter, a membrane recovery permeate gas pressure difference detection piece, a membrane recovery permeate gas pressure difference sensor, a turbine guide vane opening degree detection piece, a synthesis gas compressor inlet pressure sensor and a superheater fuel gas valve position detection piece.
The synthetic mechanism model data is control model data of a set value of the second adjusting component to a detected value of the second detector component.
That is, the controlled variables also include synthesis reactor inlet inert gas content, synthesis reactor hot spot temperature, synthesis reactor inlet pressure, membrane recovery inlet flow meter, membrane recovery permeate gas pressure differential, turbine vane opening detection, synthesis gas compressor inlet pressure, and superheater fuel gas valve position. And correspondingly adjusting a non-permeable gas discharge valve, a synthesis steam drum pressure adjusting valve, a non-permeable gas discharge valve, a primary gas inlet pressure adjusting valve of the hydrogen compressor 318, a synthesis compressor rotating speed adjuster and a synthesis steam drum medium sub-steam flow adjusting valve according to the second optimal adjusting quantity calculated by the synthesis controller 231.
Specifically, the synthetic mechanism model data includes: the control model of the opening of the non-permeable gas discharge valve for the content of inert gas at the inlet of the synthesis reactor, the control model of the set value of the pressure of the synthesis steam drum for the hot spot temperature of the synthesis reactor, the control model of the opening of the non-permeable gas discharge valve for the inlet pressure of the synthesis reactor, the control model of the opening of the non-permeable gas discharge valve for the flow of the membrane recovery inlet, the control model of the opening of the non-permeable gas discharge valve for the pressure difference of the membrane recovery permeate gas, the control model of the set value of the pressure of the primary stage gas of the hydrogen compressor for the pressure difference of the membrane recovery permeate gas, the control model of the set value of the rotating speed of the synthesis compressor for the opening of the turbine guide vane, the control model of the set value of the rotating speed of the synthesis compressor for the inlet pressure of the synthesis gas compressor, and. That is to say, the multiple-input multiple-output control model of the synthetic mechanism model data component can be more closely fitted to the actual working mechanism of the mechanism 31, so that the change trend of the mechanism 31 can be more accurately fitted by the model.
The conversion mechanism model data and the synthesis mechanism model data can be obtained by performing model identification on data obtained by performing step test on the coal-to-methanol conversion and synthesis device.
In an alternative of this embodiment, the distributed controller assembly further includes a distributed controller, an instruction input assembly, and a result display assembly; the instruction input assembly and the result display assembly are connected with the distributed controller; the instruction input component is used for inputting a threshold value of an adjusting quantity and a threshold value of a controlled variable by an operator; and the result display component is used for monitoring data by an operator.
Optionally, the distributed controller assembly further comprises a logic control circuit connected between the distributed controller and the optimization controller. The logic control circuit adopts communication handshake logic, controller switching logic, loop switching logic, out-of-limit logic or card limit alarm logic.
In an alternative of this embodiment, the apc system further includes a first gateway, a second gateway, and an OPC server 4: the distributed control apparatus 1 communicates with the OPC server 4 through a first gateway, and the optimization control component 23 communicates with the OPC server 4 through a second gateway.
The operator can set the value ranges and the predetermined desired values of the controlled variables and the regulating components on the dedicated operation interface of the distributed control apparatus 1, and send the cutting or commissioning instruction to the optimization control component 23. After receiving the commissioning command, the advanced control device 2 first updates the real-time data of each controlled variable, and then performs further calculation and control work.
Optionally, the first gateway and the second gateway are network cards that communicate in a wired manner, so that the OPC server 4 can communicate with the distributed control apparatus 1 and the optimization control component 23 respectively through the ethernet.
Alternatively, the OPC server 4 may be provided separately or may be multiplexed after the engineer station or the operator station of the distributed control apparatus 1 activates the OPC service authorization. In an alternative of this embodiment, the apc system further includes a system configuration, where the system configuration includes an address of the OPC server 4, operation information, configuration of input/output points, various file paths, configuration of control parameters, configuration of optimization parameters, and the like required by the optimization control component 23.
Example two
The second embodiment provides a coal-to-methanol conversion and synthesis system, the second embodiment includes the advanced process control system of the first embodiment, the technical features of the advanced process control system disclosed in the first embodiment are also applicable to the second embodiment, and the technical features of the advanced process control system disclosed in the first embodiment are not described repeatedly.
Referring to fig. 1 to 3, the coal-to-methanol conversion and synthesis system provided in this embodiment includes a coal-to-methanol conversion and synthesis apparatus and an advanced process control system as in the first embodiment.
The coal-to-methanol shift and synthesis system of the present embodiment has the advantages of the advanced process control system of the first embodiment, and the advantages of the advanced process control system disclosed in the first embodiment are not repeated herein.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; although the present invention has been described in detail with reference to the foregoing embodiments, it should be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit and scope of the present invention. Furthermore, those skilled in the art will appreciate that while some embodiments described herein include some features included in other embodiments, rather than other features, combinations of features of different embodiments are meant to be within the scope of the invention and form different embodiments. For example, any of the claimed embodiments may be used in any combination. The information disclosed in this background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information constitutes prior art already known to a person skilled in the art.
Claims (9)
1. An advanced process control system is used for a coal-to-methanol conversion and synthesis device, and is characterized in that the coal-to-methanol conversion and synthesis device comprises a conversion mechanism, a synthesis mechanism and an adjusting component, wherein the adjusting component is arranged on the conversion mechanism and the synthesis mechanism;
the advanced process control system comprises a distributed control device and an advanced control device, wherein the distributed control device comprises a detector assembly and a distributed controller assembly which are in communication connection; the advanced control device comprises a dynamic data memory, a model memory, a variation trend arithmetic unit and an optimization control component which are mutually communicated and connected; the model memory stores transformation mechanism model data and synthesis mechanism model data;
the dynamic data storage and the optimization control component are both in communication connection with the distributed controller component; the detector assembly respectively acquires dynamic data of controlled variables of the transformation mechanism and the synthesis mechanism, and transmits and stores the dynamic data to the dynamic data memory; historical data is stored in the dynamic data memory;
the change trend calculator can predict the change trend of the controlled variable within a preset time according to the transformation mechanism model data, the synthesis mechanism model data, the dynamic data and the historical data;
the optimization control component can calculate an optimal regulating quantity for the regulating component according to the change trend and a preset expected value and transmit the optimal regulating quantity to the distributed controller component;
and the distributed controller component regulates the regulating component according to the optimal regulating quantity so that the controlled variable works at the preset expected value.
2. The apc system of claim 1, wherein said apc apparatus further comprises a feedback corrector;
the feedback corrector is respectively in communication connection with the dynamic data memory, the model memory, the change trend calculator and the optimization control component;
and the feedback corrector corrects the transformation mechanism model data and the synthesis mechanism model data according to the dynamic data and the change trend.
3. The APC system according to claim 1,
the detector assembly comprises a first detector assembly and a second detector assembly;
the first detector assembly can acquire first dynamic data of a first controlled variable of the transformation mechanism, and transmit and store the first dynamic data to the dynamic data memory;
the second detector assembly is capable of acquiring second dynamic data of a second controlled variable of the combining mechanism and transmitting and storing the second dynamic data to the dynamic data memory.
4. The APC system according to claim 3,
the optimization control component comprises a transformation controller and a synthesis controller;
the adjusting assembly comprises a first adjusting assembly arranged on the transformation mechanism and a second adjusting assembly arranged on the synthesis mechanism;
the change trend calculator can predict a first change trend of the first controlled variable within the preset time length according to the first dynamic data, the transformation mechanism model data and the historical data; the conversion controller is capable of calculating a first optimal adjustment amount for the first adjustment assembly according to the first trend of change and the predetermined desired value;
the change trend calculator is also capable of predicting a second change trend of the second controlled variable within the preset time length according to the second dynamic data, the synthetic mechanism model data and the historical data; the synthesizing controller is capable of calculating a second optimum adjustment amount for the second adjustment component based on the second tendency of change and the predetermined desired value.
5. The APC system according to claim 4,
the first adjusting component comprises a first water separator outlet temperature adjusting part, a shift reactor inlet temperature adjusting part, a shift reactor second bed layer temperature adjusting valve, a first water separator outlet temperature adjusting part, a shift reactor second bed layer temperature adjusting valve, a shift outlet CO content adjusting valve, a purified fresh air flow adjusting valve, a synthesis compressor inlet flow adjusting valve and a synthesis compressor rotating speed adjuster;
the first detector assembly comprises a shift reactor upper temperature sensor, a shift reactor hot spot temperature sensor, a fresh gas hydrogen-carbon ratio detection piece, a low-temperature methanol washing absorption tower pressure sensor, a synthesis reactor pressure drop sensor and a synthesis circulating gas quantity detection piece;
the conversion mechanism model data is control model data of a set value of the first adjustment module to a detected value of the first detector module.
6. The APC system according to claim 4,
the second regulating component comprises a non-permeable gas discharge valve, a synthetic steam drum pressure regulating valve, a non-permeable gas discharge valve, a hydrogen compressor primary air inlet pressure regulating valve, a synthetic compressor rotating speed regulator and a synthetic steam drum medium sub-steam flow regulating valve;
the second detector component comprises a synthesis reactor inlet inert gas content detection piece, a synthesis reactor hot spot temperature sensor, a synthesis reactor inlet pressure sensor, a membrane recovery inlet flowmeter, a membrane recovery permeate gas pressure difference detection piece, a membrane recovery permeate gas pressure difference sensor, a turbine guide vane opening degree detection piece, a synthesis gas compressor inlet pressure sensor and a superheater fuel gas valve position detection piece;
the synthetic mechanism model data is control model data of a set value of the second adjusting component to a detection value of the second detector component.
7. The apc system of claim 1, wherein the hub controller component further comprises a hub controller, a command input component, and a results display component;
the instruction input assembly and the result display assembly are connected with the distributed controller; the instruction input component is used for inputting the threshold value of the regulating quantity and the threshold value of the controlled variable by an operator; and the result display assembly is used for data monitoring of operators.
8. The apc system of claim 1, further comprising an OPC server, a first gateway, and a second gateway:
the distributed control appliance component communicates with the OPC server through the first gateway and the optimization control component communicates with the OPC server through the second gateway.
9. A coal-to-methanol conversion and synthesis system comprising a coal-to-methanol conversion and synthesis apparatus and the apc system of any of claims 1-8.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113025390A (en) * | 2021-03-22 | 2021-06-25 | 万华化学集团股份有限公司 | Control method, storage medium and system for automatic load distribution of gasification device |
| CN116283487A (en) * | 2023-02-23 | 2023-06-23 | 中国平煤神马控股集团有限公司 | Control method and device applied to methanol preparation, electronic equipment and readable medium |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113025390A (en) * | 2021-03-22 | 2021-06-25 | 万华化学集团股份有限公司 | Control method, storage medium and system for automatic load distribution of gasification device |
| CN116283487A (en) * | 2023-02-23 | 2023-06-23 | 中国平煤神马控股集团有限公司 | Control method and device applied to methanol preparation, electronic equipment and readable medium |
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