Research On Design And Control Method Of Energy-saving High Performance Foam Glass Kiln

With the improvement of living standards,people’s awareness of environmental protection is constantly enhanced.Low-carbon economy has become the mainstream of the era.Waste utilization and energy conservation and emission reduction are imperative.As a new energy saving material,high-performance foam glass is made from broken glass and industrial waste slag.It has the advantages of fire protection,energy saving,corrosion resistance,low volume weight,high strength,low thermal conductivity and so on.It is widely used in building insulation,sound absorption and noise reduction,petrochemical cooling,moisture-proof and fire prevention engineering fields.The production of foam glass can not only transform waste into treasure,reduce the pollution of waste to the environment,but also replace some high energy consumption materials.However,due to the backward equipment and control technology,the production of foam glass is in a state of high cost,low quality and low yield,and its popularization is seriously hindered.The energy cost of foam glass production is high,and the kiln is the most energy consuming equipment.With the rising energy price and the emission limit of carbon dioxide gas,it is urgent to improve the kiln technology and improve the thermal efficiency of the kiln.The stability of foaming temperature of foam glass is very important to product quality and energy consumption.At present,most manufacturers adopt traditional control methods and low degree of automation,resulting in high energy consumption and low yield and low pass rate.Therefore,it is of great significance to study the new energy-saving technology of foam glass kiln,design and develop automatic production equipment and advanced and reliable control system to reduce production cost,improve product quality and reduce environmental pollution.In view of the current situation at home and abroad,in order to develop advanced energy-saving high-performance foam glass kiln and equipment,this paper has carried out a systematic and deep study from the kiln design method,complete set of automatic equipment design,fully automatic production line control system design,and they are successfully applied in practical projects.The main research work of this paper includes the following contents:(1)The numerical simulation and simulation technology of the kiln combustion process are studied,and the structure of part of the kiln is improved to increase the uniformity of temperature distribution in the kiln,so as to improve product quality and reduce heat loss.According to the structure of the kiln and the heat transfer characteristics of the air flow in the kiln,the combustion control equation and simulation geometry model of the sintering section are established.In order to reflect the overall temperature distribution in the kiln more accurately,the co-simulation simulation method of combustion process based on Fluent/Matlab is studied.The structure of the kiln is improved in view of the uneven hot air flow between the plates in the kiln.The simulation results and measured data show that the pressure,flow rate and temperature distribution of the two sides of the kiln are more uniform.(2)The optimization design of multi-layer insulation of kiln is studied.Kiln insulation is one of the most effective means to improve thermal efficiency.It is difficult to ensure the best economic benefit by expert experience to design insulation layer.In this paper,the optimization model of kiln thermal insulation is established.An optimization design method of kiln heat preservation based on improved bat algorithm is proposed.The bat algorithm is improved by introducing the historical optimal solution in the individual renewal to increase the population diversity and avoid falling into the local optimal solution.The loudness and pulse transmitting frequency are updated by dynamic inertia change to avoid oscillation around the global optimal solution.Simulation results verify the effectiveness of this method.(3)The temperature control algorithm of foaming kiln is studied.The stability of foaming temperature is the key factor of affecting product quality,but it is difficult to achieve accurate control because of its complexity and changeability.Aiming at the problems of low precision and poor anti-interference ability.Foaming temperature control algorithm based on fuzzy predictive control is studied in this paper.On the basis of studying the characteristics of foaming temperature and its influence on product quality,combining the respective characteristics of fuzzy control and predictive control,the fuzzy predictive control algorithm of foaming temperature is designed,and the algorithm is verified on the test furnace.Finally,it is applied to the actual project.The results show that the algorithm is effective,and the temperature difference in the kiln is less than ±6℃ and the temperature difference in the kiln section is less than ±3℃.Compared with the traditional control method,the temperature difference in the kiln is reduced by about 10℃,and the control accuracy and stability are greatly increased.(4)Research and design of the automatic equipment and production line automatic control system of highly efficient and energy-saving foaming kiln with independent intellectual property rights.Aiming at the problems of low output,low quality,high energy consumption,serious pollution,high labor intensity and so on,a kind of automatic roller foam kiln with a modular wide section frame structure,and the corresponding full set of automatic equipment are designed in this paper.A distributed control system of foam glass production line based on PROFIBUS-DP is designed for the complex characteristics of nonlinear and multivariable coupling in foam glass production process.The system is successfully applied to practical engineering and the product is tested.Results show that compared with the representative of the similar products abroad,the new type of kiln equipment capacity is increased about 32%,product qualified rate is increased by 3%,the unit comprehensive energy consumption is dropped about 22%,thermal efficiency is increased about 6%,and kiln section temperature difference is decreased by 3℃,with 20% reduction in carbon concentration.The other performance indexes have obvious advantages.