CN-122020943-A - Construction and operation method of dry cement production process digital factory

CN122020943ACN 122020943 ACN122020943 ACN 122020943ACN-122020943-A

Abstract

The invention provides a construction and operation method of a digital factory of a dry cement production process, which comprises the steps of constructing a refined model of the dry cement production process to form the digital factory, adopting a multi-scale real-time simulation system to obtain simulation data, preprocessing the simulation data and adopting a rendering algorithm to process the simulation data, providing a method for exploring three-dimensional space internal data of the simulation data according to a real-time section of the digital factory, and carrying out three-dimensional visualization and dynamic interaction on the digital factory and the processed simulation data to comprehensively display the production flow of the digital factory of the dry cement production process. According to the invention, three-dimensional modeling is carried out on the production environment and process equipment of the whole flow of the dry cement production process, and the data are preprocessed and rendered through multi-scale simulation calculation of the main equipment preheater, the decomposing furnace and the rotary kiln, so that three-dimensional visualization and dynamic interaction of various attribute information in the simulation data of the dry cement process core equipment are realized.

Inventors

JI XIAO
YE JIAYUAN
XIA ZHAOJIE
LIU SIYUAN
XU JI
GAO LIN
SHUI PEI

Assignees

中国建材集团有限公司
中国建筑材料科学研究总院有限公司
中国科学院过程工程研究所
合肥水泥研究设计院有限公司

Dates

Publication Date: 20260512
Application Date: 20241224
Priority Date: 20241111

Claims (10)

1. A method of constructing and operating a dry cement production process digital plant, the method comprising the steps of: (1) Constructing a refined model of a dry cement production process to form a digital factory; (2) Obtaining simulation data by adopting a multi-scale real-time simulation system, and preprocessing the simulation data; (3) Processing the analog data preprocessed in the step (2) by adopting a rendering algorithm; (4) Providing a method for exploring three-dimensional space internal data of analog data according to the real-time section of the digital factory; (5) And carrying out three-dimensional visualization and dynamic interaction on the digital factory and the processed analog data, and displaying the production flow of the digital factory in the dry cement production process in an omnibearing manner.
2. The method according to claim 1, wherein the construction of the refinement model in the step (1) is a step-by-step visualization of the dry cement production process from the device, the equipment to the pipeline, and clearly and completely reveals the plant environment of the whole dry cement production, and forms a digital plant; Preferably, the refined model has the characteristics of proportion reduction, model disassembly data hooking, ground-to-ground accurate butt joint and model weight reduction in the dry cement production process; preferably, the proportional reduction comprises an equal proportional reduction, a scale-up reduction or a scale-down reduction; Preferably, the ratio reduction is multiplied by 1:50-50:1.
3. The method according to claim 1 or 2, wherein the dry cement production process in step (1) is performed by a dry cement production plant, a model file of the dry cement production plant is converted into a 3D engine file format, the 3D engine file format is imported into the 3D engine, and an immersive three-dimensional virtual environment of the digital plant of the dry cement production process is built; Preferably, the dry cement production plant comprises an integral scene of the dry cement production plant and production equipment, wherein a model file of the plant scene is a file in a max format, and a model file of the production equipment is a file in a stl format; Preferably, the format of the 3D engine file includes fbx format; Preferably, the max-format factory scene file is converted into the fbx-format file through a Blender, and a production factory basic model is obtained after the 3D engine is imported; Preferably, the stl-format equipment model file is converted into the fbx-format file, a static grid map asset is obtained after the fbx-format file is imported into a 3D engine, an equipment cluster of the cement production process after equal scaling and coordinate transformation is built, and a map and materials are provided for the equipment model.
4. A method according to any one of claims 1 to 3, wherein the simulation data generated by the multi-scale real-time simulation system of step (2) comprises particle data and flow field data; Preferably, the number of particles is in the order of hundred million, the number of flow field grids is in the order of million, and corresponding particle data and flow field data contain massive three-dimensional space information; Preferably, the types of the simulation data include mass composition of raw materials and products in the preheater, the decomposing furnace, the rotary kiln equipment, temperature, pressure, gas composition, particle size of raw materials and cement clinker; preferably, the pretreatment in the step (2) is a digital factory adopting a pretreatment algorithm to adapt the pretreatment to a dry cement production process; preferably, the preprocessing algorithm is a conversion of file format, converting collected vtu types of data into glTF format data that can be used in the 3D engine.
5. The method of any one of claims 1-4, wherein the simulated data of step (3) is rendered and visualized, including rendering of particle data and visualization of flow field data; Preferably, the rendering step of the particle data comprises the steps of importing the point cache data into a 3D engine, creating a rendering system in the 3D engine, initializing module parameters of the point cache data in the rendering system, setting attributes in a name space for each particle when the particle is generated, and finally updating the attributes in the name space through a point cache updating module; preferably, the format of the point cache data includes hjson format or hbjson format; Preferably, the module parameters include rendering sphere attributes and GPU rendering visible ranges; Preferably, the attributes in the namespace include a location attribute, a lifetime attribute, a speed attribute, and a color attribute; Preferably, the point cache update module includes a Houdini point cache update module.
6. The method of claim 5, wherein the visualization of the flow field data adopts a multithreading technology, the flow field simulation data is asynchronously loaded during operation, the main thread completes the flow field rendering task, and the sub-thread asynchronously loads the flow field data in glTF format for the main thread; Preferably, the rendering algorithm includes information interchange of R and B channels of the simulation result image, RGB image rendering, and depth setting.
7. The method according to any one of claims 1 to 6, wherein the digital factory in the step (4) has a real-time section function, and includes three detection modules for detecting a state of entering a section, whether a bounding box is displayed when the section is detected, and a section according to a preset angle; Preferably, the state of entering the cross section refers to the flow field distribution and particle distribution of the cross section observed through the cross section function; Preferably, the bounding box refers to an auxiliary tool actually used when executing the section function, so as to better realize the section function; Preferably, the preset direction of the section comprises an axial direction and a radial direction, and the preset angle is 0-90 degrees.
8. The method according to any one of claims 1-7, wherein the digital plant is provided with a virtual measurement function, the virtual measurement being performed from a cross-sectional view of the digital plant, the virtual measurement being performed on a cross-sectional rendered image of the cross-sectional view; preferably, the virtual measurement only needs to provide coordinate values of an X-Z plane, and the Y value is determined by the Y value of the center point coordinate of the cross section; Preferably, during the virtual measurement, the measured attribute value and the image of the corresponding frame are bound and transmitted, and a specific number of attributes are added into the corresponding image data structure, so that the measurement point information is ensured to be consistent with the image information of the current frame.
9. The method according to any one of claims 1-8, wherein the three-dimensional visualization of step (5) is aimed at combining the simulation data of the equipment model and the particles and the flow field in the dry cement production process digital factory, so as to realize the coupling rendering of the simulation data and the equipment model to provide the visualization and the interactive analysis of the particles and the flow field; Preferably, the three-dimensional visualization and dynamic interaction can be free roaming in a virtual scene by using an interaction tool; Preferably, the interactive tool comprises a mouse and/or a handle.
10. The method according to any one of claims 1-9, wherein the digital factory of step (5) is provided with a perspective function for perspective viewing of the equipment internals in a virtual environment; preferably, the perspective function is realized by switching the material of the object to a transparent material, and the transparent material is realized by setting the self-luminous color and the transparency of the material; preferably, when the three-dimensional visualization and the dynamic interaction are performed, a user can click different attributes of the simulation data, and view evolution conditions of physical fields in the preheater, the decomposing furnace and the rotary kiln in a three-dimensional scene in real time, so that 3D visual display and interactive operation of the preheater, the decomposing furnace and the rotary kiln are realized; Preferably, the physical field comprises a physical field of temperature, pressure and composition parameters.

Description

Construction and operation method of dry cement production process digital factory Technical Field The invention belongs to the technical field of industrial digitization and engineering simulation software, and relates to a construction and operation method of a dry cement production process digital factory. Background In the dry cement production process, a new process of external kiln decomposition is adopted to produce cement, and the production process takes a suspension preheater and an external kiln decomposition technology as cores, adopts novel raw material, fuel homogenization and energy-saving grinding technologies and equipment, adopts computer distributed control on the whole line, and realizes automation, high efficiency, high quality, low consumption and environmental protection of the cement production process. The main flow of the production process comprises the following steps: 1) Crushing and pre-homogenizing, wherein most raw materials are crushed in the cement production process, such as limestone, clay, iron ore, coal and the like, and the pre-homogenizing technology is to use a scientific stacking and taking technology to realize the primary homogenization of the raw materials in the raw material storage process, so that the raw material storage yard has the functions of storage and homogenization; 2) In the cement production process, at least 3 tons of materials are ground, so that grinding equipment and process flow are reasonably selected, technological parameters are optimized, operation is standardized, operation system is controlled, and the method has great significance for ensuring product quality and reducing energy consumption; 3) Preheating and decomposing, namely preheating and partial decomposing of raw materials are completed by a preheater, partial functions of a rotary kiln can be replaced, the effect of shortening the length of the rotary kiln is achieved, meanwhile, the gas-material heat exchange process carried out in a piled state in the kiln is moved to the preheater to be carried out in a suspended state, so that the raw materials can be fully mixed with hot gas exhausted from the rotary kiln, the contact area of the gas materials is increased, the heat transfer speed is high, the heat exchange efficiency is high, and the purposes of improving the production efficiency of a rotary kiln system and reducing the sintering heat consumption of clinker are achieved; 4) The method comprises the steps of (1) sintering cement clinker, namely, after preheating and pre-decomposition of raw materials in a preheater, entering a rotary kiln to perform clinker sintering, further decomposing carbonate in the rotary kiln and generating a series of solid-phase reactions to generate cement clinker, after sintering the clinker, reducing the temperature, and finally cooling the high-temperature clinker to the temperature which can be borne by downstream conveying, storage and a cement mill by a cement clinker cooler, and simultaneously recovering sensible heat of the high-temperature clinker to improve the thermal efficiency and clinker quality of a system; 5) The cement grinding is the final process of cement manufacture and the process with the greatest power consumption, and has the main functions of grinding cement clinker, gelatinizing agent, performance regulating material and the like to proper granularity to form certain grain size, increase the hydration area, accelerate the hydration speed and meet the requirements of cement paste coagulation and hardening. Based on the complex multi-physical process of the novel dry cement production process, key equipment mainly comprises a preheater, a decomposing furnace, a rotary kiln, a grate cooler and the like, each equipment is a multi-physical field coupling process, in order to improve parameters of the cement production process, predict maintenance requirements, optimize production flow, design a digital production line, construct a digital factory and realize the intellectualization of the production process. The CN 113343414A discloses a cement curing body production line operation simulation and digital twin system, which comprises a three-dimensional-based digital factory modeling module, a virtual production line simulation module, a value data evaluation module and a field production management system MES, wherein the three-dimensional-based digital factory modeling module is used for constructing a GIS map engine and three-dimensional model data processing of a cement curing production line, simulating, analyzing and optimizing each production link by constructing a multi-resolution map engine, the virtual production line simulation module is used for quickly establishing an object model library of the cement curing manufacturing line based on an object parameterized production line model library establishing technology, and the value data evaluation module is used for carrying out statistical analysis processing on prod