Research on dynamic characteristics of cement raw meal decomposition process based on hybrid modeling

doi:10.11949/0438-1157.20211646

Abstract

Abstract:

In order to understand the dynamic characteristics of cement precalciner, a one-dimensional hybrid model combined of reaction mechanism and neural network was constructed. Feasibility of this method was verified by comparison with industrial data. The results show that the hybrid model can accurately calculate temperature, gas concentration and other parameters in the furnace. Distribution of each parameter along the direction of flue gas flow is consistent with the actual situation. Based on the proposed model, the steady-state distribution characteristics of various state parameters in the furnace were studied. Furthermore, step response tests were carried out. Dynamic responses of temperature and NO _x concentration at furnace outlet were researched when the coal feeding rate, limestone feeding rate, ammonia injection rate and other manipulated parameters were changed respectively. The relevant dynamic characteristics obtained from the research can provide reference for the analysis, design and optimization of the control system.

Key words: cement precalciner, hybrid model, dynamic simulation, neural networks, multiphase reactor

摘要：

为掌握水泥分解炉运行过程的动态特性，采用机理建模与神经网络相结合的方法构建了水泥分解炉一维特性模型，并结合工业数据对该方法的可行性进行验证。结果表明，模型能够准确地计算炉内温度、气体浓度等参数，具有良好的泛化性能。基于所提出的模型，研究了炉内各状态参数的稳态分布特性。此外，对喷煤量、生料下料量、喷氨量以及高温风机转速等操作变量进行阶跃实验，分析上述操作变量改变时分解炉出口温度及出口NO _x 含量的动态响应情况。研究所得相关动态特性规律可以为控制系统的分析、设计和优化提供参考与依据。

关键词: 水泥分解炉, 混合模型, 动态仿真, 神经网络, 多相反应器

CLC Number:

TQ 172

Zihao QI, Wenqi ZHONG, Xi CHEN, Guanwen ZHOU, Xiaoliang ZHAO, Meijing XIN, Yi CHEN, Yongchang ZHU. Research on dynamic characteristics of cement raw meal decomposition process based on hybrid modeling[J]. CIESC Journal, 2022, 73(5): 2039-2051.

戚子豪, 钟文琪, 陈曦, 周冠文, 赵小亮, 辛美静, 陈翼, 朱永长. 基于混合建模的水泥生料分解过程动态特性研究[J]. 化工学报, 2022, 73(5): 2039-2051.

Figures/Tables 17

Fig.1 Precalciner model and division of control volume

Table 1 Parameters of calciner

名称	数值
分解炉高度/mm	78
分解炉主体直径/m	8.4
轴向长度/m	98.6
气体停留时间/s	7~8
进料量/(t/h)	360
生料温度/℃	800
分解炉喂煤量/(t/h)	11
投煤温度/℃	60
喷氨量/(kg/吨熟料)	3
氨水浓度/%	20
排烟温度/℃	880

Table 2 Parameters of fuel characteristic

元素分析/%						工业分析/%					低位发热量/(MJ/kg)
C_ad	H_ad	O_ad	S_ad	N_ad		A_ad	FC_ad	V_ad	M_ad		低位发热量/(MJ/kg)
67.73	3.89	3.59	1.03	1.41		22.34	54.32	20.21	2.11		23.93

Fig.2 Framework of hybrid model

Fig.3 Update process of neural network parameter

Fig.4 Effect of solid-gas residence time ratio

Table 3 Calculation result

预测对象	计算值	实际值
出口温度/K	1164	1160
出口压力/Pa	-900	-851
碳酸钙分解率/%	96	95
煤炭燃尽率/%	98	—
O₂含量/%	2.43	2.27
CO含量/%	0.0195	0.0217
NO _x 含量/（mg/m³）	75	66

Fig.5 Comparison of model predicted value and real value of temperature and NO x concentration

Fig.6 Error distribution

Table 4 Comparison of training error and test error

项目	训练集		测试集
项目	RMSE	MAPE	RMSE	MAPE
温度	4.06 K	0.34%	6.72 K	0.50%
NO _x 浓度	6.22 mg/m³	7.27%	7.35 mg/m³	9.01%

Fig.7 Comparison of model predicted value and real value

Fig.8 Step change of coal feed

Fig.9 Step change of limestone

Fig.10 Step change of ammonia injection

Fig.11 Step change of high temperature fan speed

Appendix 1　Calculation formulas for volatile matter， coke combustion and calcium carbonate decomposition

	变量名称	方程		变量名称	方程
挥发分析出	挥发分析出量	$\{\begin{array}{l} V_{v o l} = X_{V M} - A - B \\ A = e x p (26.41 - 3.691 l n T + 1.15 X_{V M}) \\ B = 0.2 (X_{V M} - 10.9) \end{array}$	焦炭燃烧	氧气扩散系数	$D_{g} (T, P) = D_{g} (T_{0}, P_{0}) {(\frac{T}{T_{0}})}^{1.75} (\frac{P_{0}}{P})$
				Reynolds 数	$R e_{T} = \frac{A r ε^{4.75}}{18 + 0.61 {(A r ε^{4.74})}^{0.5}}$
				Schmidt 数	$S c = \frac{μ_{g}}{ρ_{g} D_{g}}$
	挥发分含量	$\begin{matrix} Y_{C H_{4}} = 0.201 - 0.469 X_{V M} + 0.241 X_{V M}^{2} \\ Y_{H_{2}} = 0.157 - 0.868 X_{V M} + 1.388 X_{V M}^{2} \\ Y_{C O_{2}} = 0.135 - 0.900 X_{V M} + 1.906 X_{V M}^{2} \\ Y_{C O} = 0.428 - 2.653 X_{V M} + 4.845 X_{V M}^{2} \\ Y_{H_{2} O} = 0.409 - 2.389 X_{V M} + 4.554 X_{V M}^{2} \\ Y_{t a r} = - 0.325 + 7.279 X_{V M} - 12.880 X_{V M}^{2} \end{matrix}$		Schmidt 数	$S c = \frac{μ_{g}}{ρ_{g} D_{g}}$
				Archimedes 数	$A r = \frac{g d_{p}^{3} ρ_{g} (ρ_{p} - ρ_{g})}{μ}$
			碳酸钙分解	分解速率	$k_{C a C O_{3}} = {(\frac{1}{k_{p h}} + \frac{1}{η k_{c h}})}^{- 1}$
焦炭燃烧	焦炭燃烧化学机械因子	$? = \{\begin{array}{l} \frac{2 K_{r} + 2}{K_{r} + 2} & d_{p} < 0.05 m m \\ 2 K_{r} + 2 - \frac{K_{r}}{0.095} (d_{p} - 0.005) & 0.05 m m < d_{p} \leq 1 m m \\ K_{r} + 2 & d_{p} > 1.0 m m \end{array}$		孔隙效率因子	$η = t a n h (\frac{d}{6} \sqrt[]{\frac{{\overset{?}{k}}_{c h}}{? D}}) / (\frac{d}{6} \sqrt[]{\frac{{\overset{?}{k}}_{c h}}{? D}})$
	焦炭燃烧化学机械因子			分子扩散系数	$D = {(\frac{1}{D_{b i n}} + \frac{1}{D_{k n u}})}^{- 1}$
	CO/CO₂浓度生成比	$K_{r} = 2515 e x p (- \frac{5.19 \times 10^{4}}{R_{g} T_{c}})$			$D_{b i n} = \frac{0.0266 T^{1.5}}{p M_{A B}^{0.5} σ_{A B}^{2} ω_{d}}$
	颗粒表面温度	$T_{c} = T + 6.6 \times 10^{4} C_{O_{2}}$			$D_{k n u} = \frac{d_{p o r e}}{3} {(\frac{8 R_{C O_{2}} T}{π})}^{0.5}$
	单个焦炭颗粒反应速率	$r_{c} = π d_{c}^{2} k_{c} C_{O_{2}}$		扩散系数校正因子	$? = \frac{ε_{p}}{τ_{p}^{2}}$
	焦炭燃烧反应速率	$k_{c} = 1 / (\frac{1}{? k_{c d}} + \frac{1}{k_{c s}})$		CO₂平衡分压	$p_{e q} = 4.137 \times 10^{12} e x p (- \frac{20474}{T})$
	化学反应速率	$k_{c s} = 8710 e x p (- \frac{- 1.4947 \times 10^{8}}{R T_{c}})$		化学反应速率	$k_{c h} = \frac{k_{D} (p_{e q} - p_{C O_{2}}) M_{C a C O_{3}}}{1000}$ $k_{D} = 1.22 \times 10^{- 5} e x p (- \frac{4026}{T})$
	扩散反应速率	$k_{c d} = \frac{S h D_{g}}{d_{c}}$		扩散反应速率	$k_{p h} = \frac{12 D S h}{R_{C O_{2}} d_{C a C O_{3}} T} p_{r e f}$
	Sherwood 数	$S h = 2 + 0.6 R e_{T}^{0.5} S c^{0.33}$		碳酸钙质量变化速率	$\frac{d m_{C a C O_{3}}}{d t} = - k_{C a C O_{3}} π d_{C a C O_{3}}^{2}$

Appendix 1　Calculation formulas for volatile matter， coke combustion and calcium carbonate decomposition

	变量名称	方程		变量名称	方程
挥发分析出	挥发分析出量	$\{\begin{array}{l} V_{v o l} = X_{V M} - A - B \\ A = e x p (26.41 - 3.691 l n T + 1.15 X_{V M}) \\ B = 0.2 (X_{V M} - 10.9) \end{array}$	焦炭燃烧	氧气扩散系数	$D_{g} (T, P) = D_{g} (T_{0}, P_{0}) {(\frac{T}{T_{0}})}^{1.75} (\frac{P_{0}}{P})$
				Reynolds 数	$R e_{T} = \frac{A r ε^{4.75}}{18 + 0.61 {(A r ε^{4.74})}^{0.5}}$
				Schmidt 数	$S c = \frac{μ_{g}}{ρ_{g} D_{g}}$
	挥发分含量	$\begin{matrix} Y_{C H_{4}} = 0.201 - 0.469 X_{V M} + 0.241 X_{V M}^{2} \\ Y_{H_{2}} = 0.157 - 0.868 X_{V M} + 1.388 X_{V M}^{2} \\ Y_{C O_{2}} = 0.135 - 0.900 X_{V M} + 1.906 X_{V M}^{2} \\ Y_{C O} = 0.428 - 2.653 X_{V M} + 4.845 X_{V M}^{2} \\ Y_{H_{2} O} = 0.409 - 2.389 X_{V M} + 4.554 X_{V M}^{2} \\ Y_{t a r} = - 0.325 + 7.279 X_{V M} - 12.880 X_{V M}^{2} \end{matrix}$		Schmidt 数	$S c = \frac{μ_{g}}{ρ_{g} D_{g}}$
				Archimedes 数	$A r = \frac{g d_{p}^{3} ρ_{g} (ρ_{p} - ρ_{g})}{μ}$
			碳酸钙分解	分解速率	$k_{C a C O_{3}} = {(\frac{1}{k_{p h}} + \frac{1}{η k_{c h}})}^{- 1}$
焦炭燃烧	焦炭燃烧化学机械因子	$? = \{\begin{array}{l} \frac{2 K_{r} + 2}{K_{r} + 2} & d_{p} < 0.05 m m \\ 2 K_{r} + 2 - \frac{K_{r}}{0.095} (d_{p} - 0.005) & 0.05 m m < d_{p} \leq 1 m m \\ K_{r} + 2 & d_{p} > 1.0 m m \end{array}$		孔隙效率因子	$η = t a n h (\frac{d}{6} \sqrt[]{\frac{{\overset{?}{k}}_{c h}}{? D}}) / (\frac{d}{6} \sqrt[]{\frac{{\overset{?}{k}}_{c h}}{? D}})$
	焦炭燃烧化学机械因子			分子扩散系数	$D = {(\frac{1}{D_{b i n}} + \frac{1}{D_{k n u}})}^{- 1}$
	CO/CO₂浓度生成比	$K_{r} = 2515 e x p (- \frac{5.19 \times 10^{4}}{R_{g} T_{c}})$			$D_{b i n} = \frac{0.0266 T^{1.5}}{p M_{A B}^{0.5} σ_{A B}^{2} ω_{d}}$
	颗粒表面温度	$T_{c} = T + 6.6 \times 10^{4} C_{O_{2}}$			$D_{k n u} = \frac{d_{p o r e}}{3} {(\frac{8 R_{C O_{2}} T}{π})}^{0.5}$
	单个焦炭颗粒反应速率	$r_{c} = π d_{c}^{2} k_{c} C_{O_{2}}$		扩散系数校正因子	$? = \frac{ε_{p}}{τ_{p}^{2}}$
	焦炭燃烧反应速率	$k_{c} = 1 / (\frac{1}{? k_{c d}} + \frac{1}{k_{c s}})$		CO₂平衡分压	$p_{e q} = 4.137 \times 10^{12} e x p (- \frac{20474}{T})$
	化学反应速率	$k_{c s} = 8710 e x p (- \frac{- 1.4947 \times 10^{8}}{R T_{c}})$		化学反应速率	$k_{c h} = \frac{k_{D} (p_{e q} - p_{C O_{2}}) M_{C a C O_{3}}}{1000}$ $k_{D} = 1.22 \times 10^{- 5} e x p (- \frac{4026}{T})$
	扩散反应速率	$k_{c d} = \frac{S h D_{g}}{d_{c}}$		扩散反应速率	$k_{p h} = \frac{12 D S h}{R_{C O_{2}} d_{C a C O_{3}} T} p_{r e f}$
	Sherwood 数	$S h = 2 + 0.6 R e_{T}^{0.5} S c^{0.33}$		碳酸钙质量变化速率	$\frac{d m_{C a C O_{3}}}{d t} = - k_{C a C O_{3}} π d_{C a C O_{3}}^{2}$

Appendix 2　Homogeneous reaction rate in the furnace

化学反应	催化剂	反应速率
（1） $2 H_{2} + O_{2} \overset{}{\to} 2 H_{2} O$	—	$r_{1} = k_{1} C_{H_{2}}^{1.5} C_{O_{2}}$	$k_{1} = 1.63 \times 10^{9} T^{1.5} e x p (- \frac{3420}{T})$
（2） $C H_{4} + \frac{3}{2} O_{2} \overset{}{\to} C O + H_{2} O$	—	$r_{2} = k_{2} C_{C H_{4}}^{0.7} C_{O_{2}}^{0.8}$	$k_{2} = 1.585 \times 10^{10} e x p (- \frac{24157}{T})$
（3） $C O + \frac{1}{2} O_{2} \overset{}{\to} C O_{2}$	—	$r_{3} = k_{3} C_{C O} C_{H_{2} O}^{0.5} C_{O_{2}}^{0.3}$	$k_{3} = 1.9 \times 10^{6} e x p (- \frac{8050}{T})$
（4） $t a r + 7.5 O_{2} \overset{}{\to} 6 C O_{2} + H_{2} O$	—	$r_{4} = k_{4} C_{t a r} C_{O_{2}}$	$k_{4} = 3.8 \times 10^{7} e x p (- \frac{0.555 \times 10^{8}}{T})$
（5） $N H_{3} + N O + \frac{1}{4} O_{2} \overset{}{\to} N_{2} + \frac{3}{2} H_{2} O$	—	$r_{5} = k_{5} C_{N H_{3}} C_{N O}$	$k_{5} = 2.45 \times 10^{17} e x p (- \frac{29400}{T})$
	CaO	$r_{5}^{'} = k_{5}^{'} C_{N H_{3}}$	$k_{5}^{'} = 0.73 \times 10^{6} e x p (- \frac{7000}{T})$
（6） $N H_{3} + \frac{5}{4} O_{2} \overset{}{\to} N O + \frac{3}{2} H_{2} O$	—	$r_{6} = k_{6} C_{N H_{3}}$	$k_{6} = 2.21 \times 10^{14} e x p (- \frac{38160}{T})$
	char	$r_{6}^{'} = k_{6}^{'} C_{N H_{3}} C_{O_{2}}$	$k_{6}^{'} = 4.95 \times 10^{12} e x p (- \frac{15000}{T})$
	CaO	$r_{6}^{″} = k_{6}^{″} C_{N H_{3}} C_{O_{2}}$	$k_{6}^{″} = 2.67 \times 10^{10} e x p (- \frac{10000}{T})$
（7） $2 N H_{3} + \frac{3}{2} O_{2} \overset{}{\to} N_{2} + 3 H_{2} O$	char	$r_{7} = k_{7} C_{N H_{3}} C_{O_{2}}$	$k_{7} = 1.58 \times 10^{13} e x p (- \frac{15000}{T})$
	CaO	$r_{7}^{'} = k_{7}^{'} C_{N H_{3}} C_{O_{2}}$	$k_{7}^{'} = 6.65 \times 10^{9} e x p (- \frac{10000}{T})$
（8） $N O + C O \overset{}{\to} C O_{2} + \frac{1}{2} N_{2}$	char	$r_{8} = \frac{k_{8} p_{N O} (k_{81} p_{N O} + k_{82})}{k_{8} p_{N O} + k_{81} p_{N O} + k_{82}}$	$k_{8} = 2.1 \times 10^{- 6} e x p (- \frac{13000}{T})$
			$k_{81} = 7.3 \times 10^{- 9} e x p (- \frac{9560}{T})$
			$k_{82} = 0.015 e x p (- \frac{20100}{T})$
	CaO	$r_{8}^{'} = k_{8}^{'} C_{N O} C_{C O}$	$k_{8}^{'} = 1.58 \times 10^{8} e x p (- \frac{8920}{T})$
（9） $N O + H_{2} \overset{}{\to} H_{2} O + \frac{1}{2} N_{2}$	Char	$r_{9} = k_{9} C_{N O} C_{H_{2}}$	$k_{9} = 4.6 T e x p (- \frac{12120}{T})$
	CaO	$r_{9}^{'} = k_{9}^{'} C_{N O} C_{H_{2}}$	$k_{9}^{'} = 7 \times 10^{10} e x p (- \frac{9320}{T})$
（10） $H C N + O_{2} \overset{}{\to} N O + C O$	—	$r_{10} = k_{10} ρ C_{O_{2}}^{b} C_{H C N}$	$k_{10} = 10^{11} e x p (- \frac{33700}{T})$

Appendix 2　Homogeneous reaction rate in the furnace

化学反应	催化剂	反应速率
（1） $2 H_{2} + O_{2} \overset{}{\to} 2 H_{2} O$	—	$r_{1} = k_{1} C_{H_{2}}^{1.5} C_{O_{2}}$	$k_{1} = 1.63 \times 10^{9} T^{1.5} e x p (- \frac{3420}{T})$
（2） $C H_{4} + \frac{3}{2} O_{2} \overset{}{\to} C O + H_{2} O$	—	$r_{2} = k_{2} C_{C H_{4}}^{0.7} C_{O_{2}}^{0.8}$	$k_{2} = 1.585 \times 10^{10} e x p (- \frac{24157}{T})$
（3） $C O + \frac{1}{2} O_{2} \overset{}{\to} C O_{2}$	—	$r_{3} = k_{3} C_{C O} C_{H_{2} O}^{0.5} C_{O_{2}}^{0.3}$	$k_{3} = 1.9 \times 10^{6} e x p (- \frac{8050}{T})$
（4） $t a r + 7.5 O_{2} \overset{}{\to} 6 C O_{2} + H_{2} O$	—	$r_{4} = k_{4} C_{t a r} C_{O_{2}}$	$k_{4} = 3.8 \times 10^{7} e x p (- \frac{0.555 \times 10^{8}}{T})$
（5） $N H_{3} + N O + \frac{1}{4} O_{2} \overset{}{\to} N_{2} + \frac{3}{2} H_{2} O$	—	$r_{5} = k_{5} C_{N H_{3}} C_{N O}$	$k_{5} = 2.45 \times 10^{17} e x p (- \frac{29400}{T})$
	CaO	$r_{5}^{'} = k_{5}^{'} C_{N H_{3}}$	$k_{5}^{'} = 0.73 \times 10^{6} e x p (- \frac{7000}{T})$
（6） $N H_{3} + \frac{5}{4} O_{2} \overset{}{\to} N O + \frac{3}{2} H_{2} O$	—	$r_{6} = k_{6} C_{N H_{3}}$	$k_{6} = 2.21 \times 10^{14} e x p (- \frac{38160}{T})$
	char	$r_{6}^{'} = k_{6}^{'} C_{N H_{3}} C_{O_{2}}$	$k_{6}^{'} = 4.95 \times 10^{12} e x p (- \frac{15000}{T})$
	CaO	$r_{6}^{″} = k_{6}^{″} C_{N H_{3}} C_{O_{2}}$	$k_{6}^{″} = 2.67 \times 10^{10} e x p (- \frac{10000}{T})$
（7） $2 N H_{3} + \frac{3}{2} O_{2} \overset{}{\to} N_{2} + 3 H_{2} O$	char	$r_{7} = k_{7} C_{N H_{3}} C_{O_{2}}$	$k_{7} = 1.58 \times 10^{13} e x p (- \frac{15000}{T})$
	CaO	$r_{7}^{'} = k_{7}^{'} C_{N H_{3}} C_{O_{2}}$	$k_{7}^{'} = 6.65 \times 10^{9} e x p (- \frac{10000}{T})$
（8） $N O + C O \overset{}{\to} C O_{2} + \frac{1}{2} N_{2}$	char	$r_{8} = \frac{k_{8} p_{N O} (k_{81} p_{N O} + k_{82})}{k_{8} p_{N O} + k_{81} p_{N O} + k_{82}}$	$k_{8} = 2.1 \times 10^{- 6} e x p (- \frac{13000}{T})$
			$k_{81} = 7.3 \times 10^{- 9} e x p (- \frac{9560}{T})$
			$k_{82} = 0.015 e x p (- \frac{20100}{T})$
	CaO	$r_{8}^{'} = k_{8}^{'} C_{N O} C_{C O}$	$k_{8}^{'} = 1.58 \times 10^{8} e x p (- \frac{8920}{T})$
（9） $N O + H_{2} \overset{}{\to} H_{2} O + \frac{1}{2} N_{2}$	Char	$r_{9} = k_{9} C_{N O} C_{H_{2}}$	$k_{9} = 4.6 T e x p (- \frac{12120}{T})$
	CaO	$r_{9}^{'} = k_{9}^{'} C_{N O} C_{H_{2}}$	$k_{9}^{'} = 7 \times 10^{10} e x p (- \frac{9320}{T})$
（10） $H C N + O_{2} \overset{}{\to} N O + C O$	—	$r_{10} = k_{10} ρ C_{O_{2}}^{b} C_{H C N}$	$k_{10} = 10^{11} e x p (- \frac{33700}{T})$

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