Sandy Alumina Continuous Carbonation Decomposition Process Real-time Monitoring System

As a complex production process with long time-delay, the continuous carbonation decomposition process(CCDP) has the disadvantages of unsteady work condition and unexpected technique accident. More over, it mainly depends on human's experiences to handly adjust all of the valves which is easily affected by personal factors and has great labor intensity. So how to get rid of safe incipient fault and improve the automation level of decomposition process is a key problems to be resolved urgently. The real-time monitoring software of continuous carbonation decomposition process (RMSCCDP) is developed in this paper which realized the real-time safety monitoring and decomposition-gradient optimization in decomposition process. The main research work is as follows:1. On the basis of the experiential knowledge and the mechanic characteristics of CCDP, the real-time monitor of CCDP is developed which is based on expert systems, to realize the real-time safe monitoring.2. Being very difficult to measure flow by routine apparatus, a flow soft-sensing model is present in this paper by inducing the functional relationship of the liquid level of high tank, the angle of valve and the flow.3. Based on the craft characteristic of CCDP and the technics of expert system and soft-sensing , two kinds of flow controls are proposed which named as sample control and stabilize control of first-tack. The flow hybrid control model of the first-tack is designed in this paper.4. The software of real-time monitoring system of continuous carbonation decomposition process (SRMSCCDP) has been developed by using Microsoft Visual C++6.0. The closed-cycle control of CO2 electric valve and flow electric valve is realized.Practical results show that not only the standard errors of decomposition ratio of first-tank and last-tank are respectively reduced by 12% and 7.9%, the last-tank decomposition ratio is increased by 0.9%, but also steady decomposition process, optimized decomposition gradient and high productivity are realized. At the same time, the safety of process is ensured by effective precaution of production process and the integrated management of data in the decomposition process is also realized which relives workman's labor intensity.