基于节能目标的钢铁企业能源集成管理系统的研究与实现
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摘要
论文以科技部科技支撑计划项目“冶金企业氩氧精炼铁合金工艺及综合节能技术的开发与示范”的子课题“冶炼过程能耗监测与能耗系统优化”(2007BAE17B0)和吉林省科技厅社会发展重大项目“冶金行业综合节能技术与产品的开发研究”(20050414-2)为背景,并结合作者近年来参与完成的“鞍钢集团矿业公司大选厂能源信息管理系统”等科研项目,以冶金企业系统节能为研究目标,对以钢铁企业为代表的流程工业进行了生产过程的能源监测、系统优化与综合管理技术的应用研究,开发了钢铁企业生产过程能源集成管理系统,促进了企业生产过程的节能降耗。
针对以钢铁行业为代表的制造企业的生产工艺和流程进行了深入的系统分析,研究了主生产系统、辅助生产系统及能源转换系统等之间的作用机理和定量关系,进行了生产过程的能流和物流分析,并结合鞍钢集团的生产实际,介绍了能源平衡与优化模型、能源投入产出模型的具体应用。实践证明,应用这些模型的计算结果与实际生产数据误差较小,对于企业实现科学的能源分析、预测和决策具有重要的指导意义。
从系统的角度,应用改进的模糊层次分析法研究了钢铁生产流程的综合能耗问题,并结合鞍钢集团的生产实际,分析获得了各股物流因素对吨钢综合能耗影响程度大小的排序及多因素对能耗影响的量化指标,为指导企业制定科学的节能降耗措施提供了理论依据。
基于JSP+Oracle9i数据库及Tomcat5.0 WEB服务器平台,采用JSP+JavaBean开发模式开发了鞍钢集团矿业公司大孤山选矿厂能源信息集成管理系统,基于Force control V6.0工控组态技术设计了鞍钢集团矿业公司08#变电所能源计量与管理系统和大选厂生产过程监控系统,实现了能源数据采集、能耗统计与分析、能源平衡、能耗预测、自动排产及故障诊断等功能,为企业进一步实现与ERP集成奠定了基础。实际生产运行表明,本系统功能完善、运行可靠,提高了企业的能源利用率,促进了企业节能增效,具有较高的在相关流程行业推广的应用价值。
Nowdays, energy problem has become an important problem in the world while energy situation of the world is more and more serious. Iron and steel industry is high energy consumed.The energy consumption of steel industry has 10% percent in total energy consumption of China and 15-20% percent in total energy consumption of industry and 20-40% percent in the cost of iron and steel product.Because of the reason of history and objective, the amount of energy consumption of iron and steel industry in China is tremendous while comparable energy consumption per ton steel in large and medium-sized iron and steel enterprise is higher about 20% percent than the advanced levels of the world. On the other hand, the rate of energy utilization is low and energy waste phenomenon is widespread in iron and steel industry of China.So economic and social developments are restricted seriously in our country. Energy-saving is enhanced to the strategic position and the energy development strategy that economy and development simultaneously, and put the economy at first is draw up and the policy that establish a resources economy and environment friendly society is formulated as an basic national principle in China under the current critical energy situation. It put forward clearly in National Development Outline of Science and Technique in the Long-term that the first key field is energy field and the first priority topic is industry energy-saving such as power industry, metallurgical industry, iron and steel industry, petrochemical industry and so on. The goal of energy-saving and reduce discharge amount in report on the outline of the eleventh five-year plan for economic and social development in P.R. China is determined that the total energy consumption of GDP in China will reduce by 20% from which 1.22 tce in 2005 to 1 tce below in 2010.At the sametime, the total amount of water in unit industry increment value must ruduce by 30%. This is definite responsibility and duties of each industry enterprise and local governments and departments in charge.Iron and steel enterprise will suffer from pressure more and more and take primary responsibility being a major high energy consumed enterprise.The research contents of this paper is common problem with strong representative and general using in iron and steel industry and be of great significance to economic and social in China.
The relations between production process and energy consumption are made an in-depth application anslysis and theory study with theory of systematic energy-saving , technique of intelligence analysis and optimization and energy information comprehensive management based on the background of study on energy-saving and reduce energy consumption. Energy information comprehensive management system is designed. It is feneficial to the energy-saving and to reduce of production process in iron and steel enterprise. The main contributions of this paper are as follows:
1. Energy blance diagram was obtainned through analysis with energy structure and energy consumption and the second energy conversion combine with the production process in iron and steel enterprise. The important position in metallurgy industry automation of energy management center was emphasized and the basic thinking which energy management center construction was put forward. Further it established the foundation for strengthen energy management and carry out economy-saving and reduce energy consumption in iron and steel enterprise.
2. Making intensive reserch on theories of systematic energy-saving and analyzed with function mechanism and quantitative relation of the main production system, auxiliary production system and energy conversion system.Studied for the energy flow direction and energy consumption in each production process and the influence of material flow on energy consumption in iron and steel enterprise. The mathematics models of material flow and energy flow in production process are established. It provided the theories basis for the realization of energy information management system.
3. Energy consumption target and major analysis method was introduced in iron and steel enterprise.The sequence of all kinds of material influence comprehensive energy consumption per ton steel and energy quantitative target of all factors influence energy consumption are worked out with improved fuzzy AHP(Analytic Hierarchy Process) which study of comprehensive energy consumption in typical iron and steel production process from the point of system. It has great immediate significance to guide drawing the scientific plan of economy-saving and reduce energy consumption in iron and steel enterprise.
4. Energy model and its feature and the layer structure of iron and steel enterprise were described in detail. Energy balance and comprehensive optimization model was set up further with AnGang production practice.The model calculations with data of materical flow and energy flow through taking the all practical data into the energy optimization model have shown that all constraint equations got to satisfy when the decision-variable were equal to actual value and energy consumption actually came closed to the one’s of model calculations. The fact indicated that vcalculation error was little and it was applicable to solove engineering problem.
Energy input-output model was established with AnGang energy input-output table based on material balance theories. The resonable plans of energy distribution were worked out through the functions of energy forcast and optimization. The plans were helpful to increase profit and reduce energy consumption compare with planning scheme.
5. Energy metering and management system of 08# transformer substation and production process monitoring system of Dagushan mineral separation plant of AnGang Group mining company were designed based on Force control 6.0 configuration software and energy information intergrate management system of Daxuan plant was established based on JSP+JavaBean pattern and Tamcat5.0 and Oracle9i database. It took six electricity received ports as starting points, took high pressure room,electromagnetic stations and large-medium capacity load of high and low pressure as main monitor object and took electric current/ electric voltage sensor and digital instruments as main detecting equipments.The system received energy data real time from collector at the site with 485 communication based on the star polygon network structure.Energy information transmited to the control center station through separation stations and fiber optic and inside management network by the way of ethernet and module.The management computer carried out the system energy monitoring, energy balance, forcast and analysis and intelliigence decision-making through energy information statistics and analysis. It improved the automation level of production process and information management so as to achieve the goals of economy-saving and reduce energy consumption in Daxuan plant.
针对以钢铁行业为代表的制造企业的生产工艺和流程进行了深入的系统分析,研究了主生产系统、辅助生产系统及能源转换系统等之间的作用机理和定量关系,进行了生产过程的能流和物流分析,并结合鞍钢集团的生产实际,介绍了能源平衡与优化模型、能源投入产出模型的具体应用。实践证明,应用这些模型的计算结果与实际生产数据误差较小,对于企业实现科学的能源分析、预测和决策具有重要的指导意义。
从系统的角度,应用改进的模糊层次分析法研究了钢铁生产流程的综合能耗问题,并结合鞍钢集团的生产实际,分析获得了各股物流因素对吨钢综合能耗影响程度大小的排序及多因素对能耗影响的量化指标,为指导企业制定科学的节能降耗措施提供了理论依据。
基于JSP+Oracle9i数据库及Tomcat5.0 WEB服务器平台,采用JSP+JavaBean开发模式开发了鞍钢集团矿业公司大孤山选矿厂能源信息集成管理系统,基于Force control V6.0工控组态技术设计了鞍钢集团矿业公司08#变电所能源计量与管理系统和大选厂生产过程监控系统,实现了能源数据采集、能耗统计与分析、能源平衡、能耗预测、自动排产及故障诊断等功能,为企业进一步实现与ERP集成奠定了基础。实际生产运行表明,本系统功能完善、运行可靠,提高了企业的能源利用率,促进了企业节能增效,具有较高的在相关流程行业推广的应用价值。
Nowdays, energy problem has become an important problem in the world while energy situation of the world is more and more serious. Iron and steel industry is high energy consumed.The energy consumption of steel industry has 10% percent in total energy consumption of China and 15-20% percent in total energy consumption of industry and 20-40% percent in the cost of iron and steel product.Because of the reason of history and objective, the amount of energy consumption of iron and steel industry in China is tremendous while comparable energy consumption per ton steel in large and medium-sized iron and steel enterprise is higher about 20% percent than the advanced levels of the world. On the other hand, the rate of energy utilization is low and energy waste phenomenon is widespread in iron and steel industry of China.So economic and social developments are restricted seriously in our country. Energy-saving is enhanced to the strategic position and the energy development strategy that economy and development simultaneously, and put the economy at first is draw up and the policy that establish a resources economy and environment friendly society is formulated as an basic national principle in China under the current critical energy situation. It put forward clearly in National Development Outline of Science and Technique in the Long-term that the first key field is energy field and the first priority topic is industry energy-saving such as power industry, metallurgical industry, iron and steel industry, petrochemical industry and so on. The goal of energy-saving and reduce discharge amount in report on the outline of the eleventh five-year plan for economic and social development in P.R. China is determined that the total energy consumption of GDP in China will reduce by 20% from which 1.22 tce in 2005 to 1 tce below in 2010.At the sametime, the total amount of water in unit industry increment value must ruduce by 30%. This is definite responsibility and duties of each industry enterprise and local governments and departments in charge.Iron and steel enterprise will suffer from pressure more and more and take primary responsibility being a major high energy consumed enterprise.The research contents of this paper is common problem with strong representative and general using in iron and steel industry and be of great significance to economic and social in China.
The relations between production process and energy consumption are made an in-depth application anslysis and theory study with theory of systematic energy-saving , technique of intelligence analysis and optimization and energy information comprehensive management based on the background of study on energy-saving and reduce energy consumption. Energy information comprehensive management system is designed. It is feneficial to the energy-saving and to reduce of production process in iron and steel enterprise. The main contributions of this paper are as follows:
1. Energy blance diagram was obtainned through analysis with energy structure and energy consumption and the second energy conversion combine with the production process in iron and steel enterprise. The important position in metallurgy industry automation of energy management center was emphasized and the basic thinking which energy management center construction was put forward. Further it established the foundation for strengthen energy management and carry out economy-saving and reduce energy consumption in iron and steel enterprise.
2. Making intensive reserch on theories of systematic energy-saving and analyzed with function mechanism and quantitative relation of the main production system, auxiliary production system and energy conversion system.Studied for the energy flow direction and energy consumption in each production process and the influence of material flow on energy consumption in iron and steel enterprise. The mathematics models of material flow and energy flow in production process are established. It provided the theories basis for the realization of energy information management system.
3. Energy consumption target and major analysis method was introduced in iron and steel enterprise.The sequence of all kinds of material influence comprehensive energy consumption per ton steel and energy quantitative target of all factors influence energy consumption are worked out with improved fuzzy AHP(Analytic Hierarchy Process) which study of comprehensive energy consumption in typical iron and steel production process from the point of system. It has great immediate significance to guide drawing the scientific plan of economy-saving and reduce energy consumption in iron and steel enterprise.
4. Energy model and its feature and the layer structure of iron and steel enterprise were described in detail. Energy balance and comprehensive optimization model was set up further with AnGang production practice.The model calculations with data of materical flow and energy flow through taking the all practical data into the energy optimization model have shown that all constraint equations got to satisfy when the decision-variable were equal to actual value and energy consumption actually came closed to the one’s of model calculations. The fact indicated that vcalculation error was little and it was applicable to solove engineering problem.
Energy input-output model was established with AnGang energy input-output table based on material balance theories. The resonable plans of energy distribution were worked out through the functions of energy forcast and optimization. The plans were helpful to increase profit and reduce energy consumption compare with planning scheme.
5. Energy metering and management system of 08# transformer substation and production process monitoring system of Dagushan mineral separation plant of AnGang Group mining company were designed based on Force control 6.0 configuration software and energy information intergrate management system of Daxuan plant was established based on JSP+JavaBean pattern and Tamcat5.0 and Oracle9i database. It took six electricity received ports as starting points, took high pressure room,electromagnetic stations and large-medium capacity load of high and low pressure as main monitor object and took electric current/ electric voltage sensor and digital instruments as main detecting equipments.The system received energy data real time from collector at the site with 485 communication based on the star polygon network structure.Energy information transmited to the control center station through separation stations and fiber optic and inside management network by the way of ethernet and module.The management computer carried out the system energy monitoring, energy balance, forcast and analysis and intelliigence decision-making through energy information statistics and analysis. It improved the automation level of production process and information management so as to achieve the goals of economy-saving and reduce energy consumption in Daxuan plant.
引文
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