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    燃煤锅炉干排渣系统冷却过程建模与前馈-串级控制策略

    Modeling of Cooling Process and Feedforward-cascade Control Strategy for Dry Slag Discharge System of Coal-fired Boilers

    • 摘要: 针对燃煤锅炉干排渣系统灰渣量波动大、锅炉炉底漏风严重、排渣温度不稳定等工程难题,本文以630 MW燃煤机组为对象,构建灰渣-冷却风耦合换热模型,提出前馈-串级闭环控制策略。研究采用双目视觉系统实时感知灰渣流量,设计基于退补偿机制的灰渣流量前馈模块实现渣量突变的提前响应;构建基于二次平滑衰减的输送带速度前馈补偿模块抑制速度变化引起的温度波动。以极小化时间绝对误差积分(Integral of Time-weighted Absolute Error, ITAE)为目标,采用粒子群优化(Particle Swarm Optimization, PSO)算法对关键参数进行优化。在Matlab/Simulink平台及9小时现场运行数据验证下,所提策略在设定值阶跃、渣量突变、负荷变化和负压波动工况下,排渣温度最大波动分别控制在1.3℃、1.3℃和0.2℃内,显著优于PID控制的5.1℃、3.7℃和4.8℃。现场数据显示,该策略可将排渣温度设定值由140℃提升至148℃,平均冷却风量降低14.2%,入炉冷却风温度升高4℃。本研究为解决干排渣系统运行难题提供了有效技术路径,对提升锅炉热效率与电厂经济性具有重要作用。

       

      Abstract: To address the engineering challenges of large slag flow fluctuations, severe furnace bottom air leakage, and unstable discharge temperatures in coal-fired boiler dry slag discharge systems, this study focuses on a 630 MW coal-fired unit and constructs a coupled heat transfer model between slag and cooling air. A feedforward-cascade closed-loop control strategy is proposed. The strategy integrates a binocular vision system to real-time perceive the slag mass flow on the conveyor belt, and designs a slag flow feedforward module based on a retro-compensation mechanism to proactively respond to abrupt slag flow changes. Simultaneously, a conveyor speed feedforward compensation module employing quadratic smoothing attenuation is developed to suppress temperature fluctuations induced by speed variations. To further enhance control performance, key parameters of the feedforward controller are optimized using the Particle Swarm Optimization (PSO) algorithm, with the objective of minimizing the Integral of Time-weighted Absolute Error (ITAE). The proposed strategy is validated on the Matlab/Simulink platform and through 9 hours of field operational data under multiple typical disturbances. Results show that, under setpoint step changes, the rise time of the proposed strategy is reduced by 63.5% compared to conventional PID control. Under disturbances of abrupt slag flow changes, boiler load variations, and furnace negative pressure fluctuations, the maximum slag discharge temperature deviations are limited to 1.3℃, 1.3℃, and 0.2℃, respectively—significantly lower than the 5.1℃, 3.7℃, and 4.8℃ achieved by PID control. Field data demonstrate that the slag discharge temperature setpoint is safely elevated from 140℃ to 148℃ , resulting in a 14.2% reduction in average cooling air volume and a 4℃ increase in furnace inlet air temperature. This study provides an effective technical pathway to resolve operational challenges in dry slag discharge systems, offering significant support for improving boiler thermal efficiency and power plant economic performance.

       

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