Thread Content
“The scope of implementation for the “Research Project on Intelligent Production of Calcined Light Ash Process” includes the 6 steam rotary calciners used in the calcination process, as well as equipment such as the 6 mother liquor towers and 6 heat exchangers used in the recovery process. Due to the harsh conditions regarding processes, equipment, and instrumentation at the calcination facility, as well as the numerous interference factors and constraints, coupled with frequent adjustments to the facility’s load during production, the overall implementation of this project is extremely difficult. During the project implementation, both parties conducted thorough research and discussions on the technological characteristics of the equipment as well as the control requirements. Regular project coordination meetings were held to refine and optimize the design plans. As a result, multiple advanced control systems were developed, including programs for predicting and controlling furnace tail pressure, balancing furnace gas pressure loads, predicting alkali output temperature, implementing intelligent expert control for alkali output temperature, advanced control for the recovery process, as well as interlock protection programs for steam main pressure and vacuum main pressure, along with artificial intelligence-based intervention programs. After the project was implemented, under normal production conditions, the advance control operation rate for the calcination process reached 90%, while that for the recovery process exceeded 98%. This significantly reduced the workload on operators, and the overall automation level of the facility was greatly improved ； It improved the stability of key indicators in the light ash workshop; for instance, the variation range of core parameters such as the pressure at the end of the calcination furnace, the temperature at which alkali is produced, and the temperature of the gas exiting the recovery heat exchanger was reduced by more than 25% on average ； Furthermore, through the optimization of parameters such as the alkali outlet temperature and the exhaust gas temperature of the heat exchanger, as well as edge trimming control, the overall consumption of steam and refrigerant in the device has also been significantly reduced. The successful deployment of this project and its excellent performance have earned unanimous recognition from client executives and frontline operators.