氧化铝连续碳酸化分解过程多重大时滞系统控制若干问题研究
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摘要
氧化铝连续碳酸化分解过程(简称碳分过程)由六个分解槽串联组成,通过控制各槽的二氧化碳气体通入量,实现末槽的分解率要求,以生产出满足一定质量指标的氢氧化铝。由于六个分解槽地域跨度大,每个槽控制点到末槽的距离不同,物料传质所需的时间不同,导致每个槽控制量输出到末槽分解率改变需要几十分钟甚至数个小时,时间长且各不相同,呈现出多重大时滞特性。多重大时滞的存在,造成末槽分解率信息无法实时准确的反馈给控制器,难以实现生产指标的闭环控制。并且多个控制点的设置形成多个回路,不同控制回路间存在关联耦合。当矿源改变或外界干扰引起生产过程稳态工作点改变时,由工人调节到新的稳态工作点需较长时间。长时间的工矿不稳造成生产指标波动大,产品质量不合格。因此,研究碳分过程的解耦控制、时滞参数辨识、时间对应参数自调整控制方法等问题,对企业增产增效,提高企业经济效益具有重要意义。
论文在深入分析碳分过程工艺和反应机理的基础上,建立了碳分过程多重时滞动态模型,提出了一种多变量时滞过程的解耦Smith控制方法,基于改进互相关函数和基于时效关联分析矩阵的多重时滞参数辨识方法。在此基础上,针对多重大时滞系统难以闭环稳定控制的问题,提出了时间对应参数自调整控制方法和基于工艺指标分解的分散控制策略,并将其应用到碳分过程实际生产中,取得了较好的效果。论文主要研究工作及创新性成果如下：
(1)建立了碳分过程的多重时滞动态反应模型。在分析碳分过程运行机理和生产工艺的基础上,根据工业过程中连续搅拌反应釜的建模方法,基于物料平衡原理建立碳分过程的动态模型,该模型体现了碳分过程关联、多重时滞、非线性的特点。
(2)针对实际工业生产中常见的多输入多输出时滞系统,用传递函数矩阵表示输入、输出之间的耦合关系,提出一种基于伴随矩阵的解耦器设计方法。通过对解耦后对象的幅频和相频特性分析,获得对象的简化一阶数学模型。在此基础上,结合Smith预估控制结构闭环特征方程的特点,提出基于Butterworth滤波器极点配置原理的PI控制器设计方法。考虑被控过程参数和执行机构等不确定性,分析了系统保证鲁棒稳定性的充要条件。最后通过仿真验证了所提方法的有效性并分析了该方法应用于碳分过程的可行性。
(3)为了解决碳分过程的多重时滞辨识难题,分别提出了基于改进互相关函数和基于时效关联分析矩阵的多重时滞参数辨识方法。对于工业过程中受控制信号影响的多个变量,选择一个参考变量,考虑其它各变量和参考变量之间的相关性,基于有固定采样周期的工业现场数据,通过计算两个变量的数据组在不同相对时延对应的互相关矩阵的奇异值,其最大奇异值对应的相对时延即为所求时滞。另一方面,从多重时滞序列的角度出发,考虑由多个变量之间的不同时滞组成的时滞序列对应的数据矩阵,定义时效关联分析矩阵,并用其H。范数定量地描述数据矩阵内部的关联关系,其最大H∞范数对应的时滞序列即为所求多重时滞。比较分析两种多重时滞辨识方法,将其分别应用于碳分过程多重时滞辨识,在此基础上计算了碳分过程模型参数并校验了时滞辨识结果。
(4)针对大时滞系统闭环稳定控制困难的问题,提出了一种时间对应参数自调整控制策略。首先讨论了几类传统方法对滞后时间长达几十分钟系统的控制效果,分析其难以闭环稳定控制的根本原因是时滞很大导致控制量和输出反馈量在时间上严重不对应。通过引入大时滞系统的脉冲响应等效系统,协调控制量和反馈量间正确的时间对应关系,再用脉冲响应等效系统的输出反馈量和设定值之间的偏差修正脉冲响应系数和PID控制器参数以实现在线调整。最后分析了该控制方法的稳定性并仿真对比证明了所提方法的优越性。
(5)针对碳分过程多重大时滞系统的控制问题,提出了基于工艺指标分解的分散控制策略。将末槽分解率工艺指标分解为各槽的分解率梯度,以二氧化碳气体通入量为优化目标,采用遗传算法求解动态约束优化问题以获得分解率梯度优化设定值,从而将碳分过程多重大时滞系统控制分解为每个槽的大时滞对象控制。运用时间对应参数自调整控制方法对碳分过程各槽大时滞系统进行分散控制,仿真和工业应用结果表明所提方法能较好地解决碳分过程的控制问题。
Alumina continuous carbonation decomposition process (ACCDP) is composed of six series decomposers, in which the aeration amount of the dioxide carbon is controlled to ensure the process index of last resolution ratio and the quality of aluminum hydroxide. Because of large geographical span of the six decomposers, the distances between each decomposer control point and last resolution ratio check point are different, which causes the time between control signale output and last resolution ratio change reach from tens of minutes to several hours. So the delay times are long and multiple, it is difficult to realize production targets closed-loop control because the feedback information of last resolution ratio is not real-time. Multiple control points form muti-loops, in which correlative coupling is existed. When the steady state operating point is changed causing by ore source change or external interference, a long time is needed to adjust the process to a new state operating point. The production index fluctuation caused by unstable condition leads to poor product quality. Therefore, some researches on ACCDP decoupling control, delay time identification, closed-loop stable control strategy have an important and practical significance for improving product quality and industrial economic profits.
On the basis of our research findings into the carbonation decomposition process and reaction mechanism, the multiple time-delays dynamic reaction model is established. The decoupling Smith control method is presented for multi-input-multi-output system with time delays. Multiple time-delays identification methods based on improved cross-correlation function and time-correlation analysis matrix are proposed. Time correspondence and parameters self-adjustment (TCPSA) control strategy for multiple long time-delay system is derived. ACCDP decentralized control strategy based on process index decomposition is researched. All these methods are applied to the ACCDP, and some good performances are achieved, the main content and some innovative achievements are depicted as follows:
(1) The multiple time-delays dynamic reaction model of ACCDP is established. Based on the analysis for operational mechanism and production technology of ACCDP, dynamic differential equations derived from material balance principle are constructed according to the modeling method of continuous stirred-tank reactor. The model reflects ACCDP characteristics of association, multiple time-delays, and nonlinear.
(2) The decoupling Smith control method is presented for multi-input-multi-output system with time delays often encountered in practical engineering. A new design method of decoupler based on the adjoint matrix of the multivariable system model with time delays is proposed. By analyzing the amplitude-frequency and phase-frequency characteristics, the models decoupled are reduced to first-order plus time delay models. According to the closed-loop characteristic equation of Smith predictor structure, PI controllers are obtained using the principle of pole assignment for Butterworth filter. At the same time, sufficient and necessary conditions for robust stability are analyzed with adaptive and multiplicative uncertainties which encountered frequently in practice. Simulation example results show the superiority of the proposed method. At last, the feasibility of applying the proposed method to ACCDP is analyzed by simulation in the condition of model mismatch.
(3) The improved cross-correlation function method and time-correlation analysis matrix method are proposed for the problem of multiple time-delay parameters identification of ACCDP. For all the process variables effected by control signals, the reference variable is selected to be considered the correlation with the other variables respectively. For the considered variable, a set of data in a continuous time segment is selected as identification object, and the cross-correlation matrix of the data sets are calculated. By comparing the singular values of cross-correlation matrix, the delay corresponding to the maximun singular value is the required delay. On the other hand, from the perspective of multiple time-delay sequence, time-correlation analysis matrix of the data matrix related to different time-delay sequence is defined. The delay sequence corresponding to the maximun H infinity norm of time-correlation analysis matrix is the required value. The proposed methods are applied to identify the multiple time-delays of ACCDP using the field data. And the comparative analysis of the two methods is given to show the superiority of time-correlation analysis matrix method. At last, the ACCDP model parameters are calculated, and the accuracy of identified time-delays is verified.
(4) Aiming at the problem of the stable closed-loop control for long time-delay system, TCPSA control strategy is proposed. The control effect of traditional time delay control methods for the system which delay time up to tens of minutes is discussed. The basic reason for control difficulties result from long time-delay is analyzed. On this basis, the pulse response equivalent system is introduced to coordinate the time corresponding relationship of control variable and output feedback variable. The parameters of pulse response equivalent system and PID controller are adjusted based on the deviation of pulse response equivalent system output and set value. Simulation results comparing the control effect of proposed method and other time delay methods show the superiority of TCPSA control strategy.
(5) In view of the control problem of ACCDP multiple long time-delay system, decentralized control strategy based on process index decomposition is proposed. Decompose the last resolution ratio to optimal resolution ratio gradient of front five decomposers by using genetic algorithm to solve dynamic constrain optimization of aeration amount of the dioxide carbon. So the multiple long time-delay system control problem of ACCDP is decomposed to decentralized control problem of each decomposer. Using the TCPSA method for long time-delay system of each decomposer, simulation and applictioan results show the effectiveness of TCPSA method for ACCDP.
论文在深入分析碳分过程工艺和反应机理的基础上,建立了碳分过程多重时滞动态模型,提出了一种多变量时滞过程的解耦Smith控制方法,基于改进互相关函数和基于时效关联分析矩阵的多重时滞参数辨识方法。在此基础上,针对多重大时滞系统难以闭环稳定控制的问题,提出了时间对应参数自调整控制方法和基于工艺指标分解的分散控制策略,并将其应用到碳分过程实际生产中,取得了较好的效果。论文主要研究工作及创新性成果如下：
(1)建立了碳分过程的多重时滞动态反应模型。在分析碳分过程运行机理和生产工艺的基础上,根据工业过程中连续搅拌反应釜的建模方法,基于物料平衡原理建立碳分过程的动态模型,该模型体现了碳分过程关联、多重时滞、非线性的特点。
(2)针对实际工业生产中常见的多输入多输出时滞系统,用传递函数矩阵表示输入、输出之间的耦合关系,提出一种基于伴随矩阵的解耦器设计方法。通过对解耦后对象的幅频和相频特性分析,获得对象的简化一阶数学模型。在此基础上,结合Smith预估控制结构闭环特征方程的特点,提出基于Butterworth滤波器极点配置原理的PI控制器设计方法。考虑被控过程参数和执行机构等不确定性,分析了系统保证鲁棒稳定性的充要条件。最后通过仿真验证了所提方法的有效性并分析了该方法应用于碳分过程的可行性。
(3)为了解决碳分过程的多重时滞辨识难题,分别提出了基于改进互相关函数和基于时效关联分析矩阵的多重时滞参数辨识方法。对于工业过程中受控制信号影响的多个变量,选择一个参考变量,考虑其它各变量和参考变量之间的相关性,基于有固定采样周期的工业现场数据,通过计算两个变量的数据组在不同相对时延对应的互相关矩阵的奇异值,其最大奇异值对应的相对时延即为所求时滞。另一方面,从多重时滞序列的角度出发,考虑由多个变量之间的不同时滞组成的时滞序列对应的数据矩阵,定义时效关联分析矩阵,并用其H。范数定量地描述数据矩阵内部的关联关系,其最大H∞范数对应的时滞序列即为所求多重时滞。比较分析两种多重时滞辨识方法,将其分别应用于碳分过程多重时滞辨识,在此基础上计算了碳分过程模型参数并校验了时滞辨识结果。
(4)针对大时滞系统闭环稳定控制困难的问题,提出了一种时间对应参数自调整控制策略。首先讨论了几类传统方法对滞后时间长达几十分钟系统的控制效果,分析其难以闭环稳定控制的根本原因是时滞很大导致控制量和输出反馈量在时间上严重不对应。通过引入大时滞系统的脉冲响应等效系统,协调控制量和反馈量间正确的时间对应关系,再用脉冲响应等效系统的输出反馈量和设定值之间的偏差修正脉冲响应系数和PID控制器参数以实现在线调整。最后分析了该控制方法的稳定性并仿真对比证明了所提方法的优越性。
(5)针对碳分过程多重大时滞系统的控制问题,提出了基于工艺指标分解的分散控制策略。将末槽分解率工艺指标分解为各槽的分解率梯度,以二氧化碳气体通入量为优化目标,采用遗传算法求解动态约束优化问题以获得分解率梯度优化设定值,从而将碳分过程多重大时滞系统控制分解为每个槽的大时滞对象控制。运用时间对应参数自调整控制方法对碳分过程各槽大时滞系统进行分散控制,仿真和工业应用结果表明所提方法能较好地解决碳分过程的控制问题。
Alumina continuous carbonation decomposition process (ACCDP) is composed of six series decomposers, in which the aeration amount of the dioxide carbon is controlled to ensure the process index of last resolution ratio and the quality of aluminum hydroxide. Because of large geographical span of the six decomposers, the distances between each decomposer control point and last resolution ratio check point are different, which causes the time between control signale output and last resolution ratio change reach from tens of minutes to several hours. So the delay times are long and multiple, it is difficult to realize production targets closed-loop control because the feedback information of last resolution ratio is not real-time. Multiple control points form muti-loops, in which correlative coupling is existed. When the steady state operating point is changed causing by ore source change or external interference, a long time is needed to adjust the process to a new state operating point. The production index fluctuation caused by unstable condition leads to poor product quality. Therefore, some researches on ACCDP decoupling control, delay time identification, closed-loop stable control strategy have an important and practical significance for improving product quality and industrial economic profits.
On the basis of our research findings into the carbonation decomposition process and reaction mechanism, the multiple time-delays dynamic reaction model is established. The decoupling Smith control method is presented for multi-input-multi-output system with time delays. Multiple time-delays identification methods based on improved cross-correlation function and time-correlation analysis matrix are proposed. Time correspondence and parameters self-adjustment (TCPSA) control strategy for multiple long time-delay system is derived. ACCDP decentralized control strategy based on process index decomposition is researched. All these methods are applied to the ACCDP, and some good performances are achieved, the main content and some innovative achievements are depicted as follows:
(1) The multiple time-delays dynamic reaction model of ACCDP is established. Based on the analysis for operational mechanism and production technology of ACCDP, dynamic differential equations derived from material balance principle are constructed according to the modeling method of continuous stirred-tank reactor. The model reflects ACCDP characteristics of association, multiple time-delays, and nonlinear.
(2) The decoupling Smith control method is presented for multi-input-multi-output system with time delays often encountered in practical engineering. A new design method of decoupler based on the adjoint matrix of the multivariable system model with time delays is proposed. By analyzing the amplitude-frequency and phase-frequency characteristics, the models decoupled are reduced to first-order plus time delay models. According to the closed-loop characteristic equation of Smith predictor structure, PI controllers are obtained using the principle of pole assignment for Butterworth filter. At the same time, sufficient and necessary conditions for robust stability are analyzed with adaptive and multiplicative uncertainties which encountered frequently in practice. Simulation example results show the superiority of the proposed method. At last, the feasibility of applying the proposed method to ACCDP is analyzed by simulation in the condition of model mismatch.
(3) The improved cross-correlation function method and time-correlation analysis matrix method are proposed for the problem of multiple time-delay parameters identification of ACCDP. For all the process variables effected by control signals, the reference variable is selected to be considered the correlation with the other variables respectively. For the considered variable, a set of data in a continuous time segment is selected as identification object, and the cross-correlation matrix of the data sets are calculated. By comparing the singular values of cross-correlation matrix, the delay corresponding to the maximun singular value is the required delay. On the other hand, from the perspective of multiple time-delay sequence, time-correlation analysis matrix of the data matrix related to different time-delay sequence is defined. The delay sequence corresponding to the maximun H infinity norm of time-correlation analysis matrix is the required value. The proposed methods are applied to identify the multiple time-delays of ACCDP using the field data. And the comparative analysis of the two methods is given to show the superiority of time-correlation analysis matrix method. At last, the ACCDP model parameters are calculated, and the accuracy of identified time-delays is verified.
(4) Aiming at the problem of the stable closed-loop control for long time-delay system, TCPSA control strategy is proposed. The control effect of traditional time delay control methods for the system which delay time up to tens of minutes is discussed. The basic reason for control difficulties result from long time-delay is analyzed. On this basis, the pulse response equivalent system is introduced to coordinate the time corresponding relationship of control variable and output feedback variable. The parameters of pulse response equivalent system and PID controller are adjusted based on the deviation of pulse response equivalent system output and set value. Simulation results comparing the control effect of proposed method and other time delay methods show the superiority of TCPSA control strategy.
(5) In view of the control problem of ACCDP multiple long time-delay system, decentralized control strategy based on process index decomposition is proposed. Decompose the last resolution ratio to optimal resolution ratio gradient of front five decomposers by using genetic algorithm to solve dynamic constrain optimization of aeration amount of the dioxide carbon. So the multiple long time-delay system control problem of ACCDP is decomposed to decentralized control problem of each decomposer. Using the TCPSA method for long time-delay system of each decomposer, simulation and applictioan results show the effectiveness of TCPSA method for ACCDP.
引文
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