Application of the CatBoost Model for Stirred Reactor State Monitoring Based on Vibration Signals

Stirred reactors are key equipment in production,and unpredictable failures will result in significant economic losses and safety issues.Therefore,it is necessary to monitor its health state.To achieve this goal,in this study,five states of the stirred reactor were firstly preset:normal,shaft bending,blade eccentricity,bearing wear,and bolt looseness.Vibration signals along x,y and z axes were collected and analyzed in both the time domain and frequency domain.Secondly,93 statistical features were extracted and evaluated by ReliefF,Maximal Information Coefficient(MIC)and XGBoost.The above evaluation results were then fused by D-S evidence theory to extract the final 16 features that are most relevant to the state of the stirred reactor.Finally,the CatBoost algorithm was introduced to establish the stirred reactor health monitoring model.The validation results showed that the model achieves 100%accuracy in detecting the fault/normal state of the stirred reactor and 98%accuracy in diagnosing the type of fault.

Modeling and Control of a Continuous Stirred Tank Reactor Based on a Mixed Logical Dynamical Model

A novel control strategy for a continuous stirred tank reactor(CSTR)system,which has the typical characteristic of strongly pronounced nonlinearity,multiple operating points,and a wide operating range,is initiated from the point of hybrid systems.The proposed scheme makes full use of the modeling power of mixed logical dy- namical(MLD)systems to describe the highly nonlinear dynamics and multiple operating points in a unified framework as a hybrid system,and takes advantage of the good control quality of model predictive control(MPC) to design a controller.Thus,this approach avoids oscillation during switching between sub-systems,helps to relieve shaking in transition,and augments the stability robustness of the whole system,and finally achieves optimal(i.e. fast and smooth)transition between operating points.The simulation results demonstrate that the presented ap- proach has a satisfactory performance.

Development of Linearizing Feedback Control with a Variable Structure Observer for Continuous Stirred Tank Reactors

This paper deals with the design of an observer-based nonlinear control for continuous stirred tank reactors(CSTR).A variable structure observer is constructed to estimate the whole process state variables.This observer is basically the conventional Luenberger observer with an additional switching term used to guarantee the robustness against modeling errors.The observer is coupled with a nonlinear controller,designed based on input-output linearization for controlling the reactor temperature.The asymptotical stability of the closed-loop system is shown by the Lyapunov stability theorem.Finally,computer simulations are developed for showing the performance of the proposed approach.

Computational simulation of fluid dynamics in a tubular stirred reactor

The flow and concentration fields in a new style tubular stirred reactor were simulated by simulating the fluids dynamics(CFD),in which FLUENT software was used and the standard k-ε model and multiple reference frame(MRF) were adopted. The various values of initial rotating speed and inlet flow rate were adopted. Simulations were validated with experimental residence time distribution(RTD) determination. It is shown that the fluid flow is very turbulent and the flow pattern approaches to the plug flow. The velocity increases from shaft to the end of impeller,and the gradient is enlarged by increasing the rotating speed. Comparison between RTD curves shows that agitation can improve the performance of reactor. As the flow rate increases,the mean residence time decreases proportionally,and the variance of RTD lessens as well. When rotating speed increases to a certain value,the variance of RTD is enlarged by increasing rotating speed,but the mean residence time has no obvious change.

Modeling of organic pollutant destruction in a stirred tank reactor by ozonation

Destruction of organic contaminants in water by ozonation is a gas-liquid process which involves ozone mass transfer and fast irreversible chemical reactions. Ozonation reactor design and process optimizing require the modeling of the gas-liquid interactions within the reactor. In this paper a theoretical model combining the fluid dynamic and reaction kinetic parameters is proposed for predicting the destruction rates of organic pollutants in a semi-batch stirred-tank reactor by ozonation. A simple expression for the enhancement factor as our previous work has been applied to evaluate the chemical mass transfer coefficient in ozone absorption. 2,4-dichlorophenol (2,4-DCP) and 2,6-DCP or their mixture are chosen as the model compounds for simulating, and the predicted DCP concentrations are compared with some measured data.

The Operating Performance of Stirred Column Reactor

A theoretical analysis of the effects of flow and mixing on the operating features of astirred column reactor(SCR)with multistage mixers and cooling partition plates was conducted.Amethod for calculating the concentration reduction for a second order chemical reaction in a SCRwas proposed.The reactants concerned were pre-mixed before feeding into the SCR.The SCR wascomposed of a number of stages with interstage backmixing.Experimental investigation with variousreaction media were carried out in order to study the effect of mixing on the operational performanceof the SCR.The experimental data were compared with the theoretical results.

Characterization of a 5 Litre Continuous Stirred Tank Reactor

Continuous Stirred Tank Reactors (CSTR) are used ubiquitously in chemical process industry for mixing, reactions and crystallizations. The purpose of this research is to study the effect of solute concentration (sodium chloride) on the stirrer speed in a CSTR. The experimental method used in this research is the stop watch and beaker method. The behavior pattern of the fluid in a CSTR can be experimentally verified as an alternative to the mathematical model. The tracer experiments were carried out. The effect of different parameters such as stirring speed, concentration at a steady time interval was analyzed. Experimental data obtained at 0.6 M and 160 rpm gave a curve that is in close agreement to that of theoretical or mathematical model. In other words, the results obtained at a concentration of 0.6 M and 160 rpm are in close agreement with that of early researchers. The paper is divided into five main sections: the first section immediately after the abstract is the introductory section that is basically a review of literature;the second section takes care of the materials and methods;the third section is the experimental procedure and this section takes the shut-down procedure and data processing into consideration;the fourth section is the discussion of experimental results and the last section is the conclusion of the paper.

A Fuzzy Logic Model to Predict the Bioleaching Efficiency of Copper Concentrates in Stirred Tank Reactors

Multiplicity of the chemical, biological, electrochemical and operational variables and nonlinear behavior of metal extraction in bioleaching environments complicate the mathematical modeling of these systems. This research was done to predict copper and iron recovery from a copper flotation concentrate in a stirred tank bioreactor using a fuzzy logic model. Experiments were carried out in the presence of a mixed culture of mesophilic bacteria at 35° C, and a mixed culture of moderately thermophilic bacteria at 50° C. Input variables were method of operation (bioleaching or electrobioleaching), the type of bacteria and time (day), while the recoveries of copper and iron were the outputs. A relationship was developed between stated inputs and the outputs by means of “if-then” rules. The resulting fuzzy model showed a satisfactory prediction of the copper and iron extraction and had a good correlation of experimental data with R-squared more than 0.97. The results of this study suggested that fuzzy logic provided a powerful and reliable tool for predicting the nonlinear and time variant bioleaching processes.

Model identification of continuous stirred tank reactor based on QKLMS algorithm

The continuous stirred tank reactor(CSTR)is one of the typical chemical processes.Aiming at its strong nonlinear characteristics,a quantized kernel least mean square(QKLMS)algorithm is proposed.The QKLMS algorithm is based on a simple online vector quantization technology instead of sparsification,which can compress the input or feature space and suppress the growth of the radial basis function(RBF)structure in the kernel learning algorithm.To verify the effectiveness of the algorithm,it is applied to the model identification of CSTR process to construct a nonlinear mapping relationship between coolant flow rate and product concentration.In additiion,the proposed algorithm is further compared with least squares support vector machine(LS-SVM),echo state network(ESN),extreme learning machine with kernels(KELM),etc.The experimental results show that the proposed algorithm has higher identification accuracy and better online learning ability under the same conditions.

Effect of Temperature on Gas Hold-up in Aerated Stirred Tanks

Gas holdups in ambient gassed and hot sparged systems with multiple modern impellers and the effect of temperature on gas holdup are reported. The operating temperature has a great impact on gas holdup though the gas dispersion regime in the hot sparged system is similar to the ambient gassed condition. The gas holdup under the elevated temperature and the ambient gassed operation is successfully correlated. With the same total gas flow rate and power input, the gas holdup in the hot sparged system (say near the boiling point) is only about half of that in the ambient system. The results imply that almost all existing hot sparged reactors have been designed on the basis of incorrect estimates of the gas holdup during operation.

Influence of impeller diameter on overall gas dispersion properties in a sparged multi-impeller stirred tank

The impeller configuration with a six parabolic blade disk turbine below two down-pumping hydrofoil propellers, identified as PDT + 2CBY, was used in this study. The effect of the impeller diameter D, ranging from0.30 T to 0.40T(T as the tank diameter), on gas dispersion in a stirred tank of 0.48 m diameter was investigated by experimental and CFD simulation methods. Power consumption and total gas holdup were measured for the same impeller configuration PDT + 2CBY with four different D/T. Results show that with D/T increases from 0.30 to 0.40, the relative power demand(RPD) in a gas–liquid system decreases slightly. At low superficial gas velocity VSof 0.0078 m·s-1, the gas holdup increases evidently with the increase of D/T. However, at high superficial gas velocity, the system with D/T = 0.33 gets a good balance between the gas recirculation and liquid shearing rate, which resulted in the highest gas holdup among four different D/T. CFD simulation based on the two-fluid model along with the Population Balance Model(PBM) was used to investigate the effect of impeller diameter on the gas dispersion. The power consumption and total gas holdup predicted by CFD simulation were in reasonable agreement with the experimental data.

Gas dispersion and solid suspension in a three-phase stirred tank with triple impellers

The hydrodynamics is still not fully understood in the three-phase stirred tank equipped with multi-impeller due to the intensive interaction between phases.In this work,the solid critical suspension speed(NJSG),relative power demand(RPD)and overall gas holdup(ε_G)were measured in an air–water–glass beads stirred tank equipped with multi-impeller,which consists of a parabolic blade disk turbine below two down-pumping hydrofoils.Results show that either the NJSGor the specific power consumption increases when increasing the volumetric solid concentration or superficial gas velocity.RPD changes less than 10%when solid volumetric concentration ranges from 0 to 15%.ε_G decreases with the increase of solid concentration,and increases with the increase of both superficial gas velocity and the total specific power consumption.The quantitative correlations of NJSG,RPD andεGwere regressed as the function of superficial gas velocity,specific power consumption,Froude number and gas flow number,in order to provide the reference in the design of such three-phase stirred tank with similar multi-impellers.

基于一般化内模结构的反应釜自抗扰控制

连续反应器搅拌系统具有连续进料、充分反应的特点,已经成为我国当前能源利用的重要组成部分。然而,当反应器充分反应时,常常具有大滞后、强耦合和多扰动等特点,这使得系统控制滞后时间长、容易受到外部扰动的影响。为此,提出一种基于新型自抗扰控制的釜温控制方法,用以削弱大滞后和多扰动的负面影响,并补偿系统使其尽快稳定。

下层桨叶结构对搅拌反应器内部流场的影响

搅拌反应器可以对物料进行均匀的搅拌及混合,极大提高了工艺物料的处理效率。利用CFD技术对搅拌反应器内的流场特性进行数值分析,研究下层桨叶结构对流体流速的影响。研究结果表明,桨叶数目增加时搅拌效率增大,搅拌核心区域的流速较大,旋转域内部的流速增大;桨叶角度增加时桨叶搅拌区域的流速增大,但在旋转域的下部流速反而减小。

基于格子玻尔兹曼法的连续式搅拌反应釜流场数值模拟

为探究高含固厨余垃圾条件下连续式搅拌反应釜(continuousstirred-tankreactor,CSTR)的流场特性,课题组采用一种新颖的计算流体动力学方法格子玻尔兹曼法(latticeBoltzmannmethod,LBM)进行研究。模拟了3种桨型的流场特性,并通过对比不同转速下的扭矩实验值与模拟值,评估了该方法的可靠性,结果表明在低转速时实验值与模拟值的相对偏差均小于5%;随后考察了不同搅拌桨的速度分布、扭矩以及死区占比的变化情况。模拟结果显示:在处理含固体积分数为20%的厨余垃圾时,螺带式搅拌桨几乎带动整个反应釜内物料运动,并且其死区占比相对较小;使用螺带式搅拌桨时,随着转速的增加,反应釜中死区占比会有所下降。因此,综合考虑反应釜内的速度分布、扭矩及死区占比,用于搅拌高含固的厨余垃圾的连续式搅拌反应釜的最佳搅拌条件是转速为40r/min的螺带式搅拌桨。课题组所提出的格子玻尔兹曼法方法可用于模拟低转速条件下高含固厨余垃圾的流动特性。

氨/氢/柴油三燃料燃烧机理构建及研究

使用Chemkin软件中的Reaction Workbench模块,构建了由70种物种和392步基元反应组成的氨/氢/柴油(ammonia/hydrogen/diesel, AHD)三燃料燃烧机理。利用Chemkin软件对AHD机理进行化学动力学验证,同时通过将AHD机理与计算流体力学(computational fluid dynamics, CFD)模型耦合的方法,对发动机不同燃料燃烧模式下的燃烧过程和排放进行对比验证。结果表明,AHD机理对氨、氢、柴油的点火延迟时间、层流火焰传播速度、射流搅拌反应器(jet stirred reactor, JSR)氧化关键组分浓度变化的预测值与试验结果吻合较好,平均误差均在一个数量级内;通过CFD模型与AHD机理耦合,在纯柴油、氨/柴油、氨/氢/柴油三种燃烧模式下,发动机缸内压力和放热率的模拟值与试验结果的变化趋势一致,最大误差均在10%以内。在标定工况(1 800 r/min)下,随着氢能比增大,点火延迟期缩短,燃烧速率加快,CO和碳氢化合物排放逐渐下降,NOx排放呈上升趋势。

基于射频波强化的试验型水热反应器研究

针对水热提取反应目前主要依靠微波强化,存在穿透深度小、加热均匀性差的问题,利用加热均匀性更好的射频波为热源,基于常见的水平式平行极板射频加热系统设计了一套适用于射频强化的水热反应器。该水热反应器主要由双层反应釜、压力调节装置、光纤测温计和气动磁力搅拌器4部分构成,首先对整机结构及工作原理进行阐述,然后基于内压薄壁圆筒应力分析理论和磁力耦合传动理论对双层反应釜和气动磁力搅拌器的关键零部件进行设计,并完成了压力调节装置和测温方式的设计和选型,最后完成射频强化水热反应试验平台的搭建,并选取搅拌转速、液固比和射频极板间距对水热反应器的搅拌和升温性能进行了测试。结果表明:当液固比大于20 mL/g时,搅拌转速与对照样品纯水无显著差异(p>0.05),此时液固比不再是影响搅拌转速的主要因素;当液固比小于40 mL/g、搅拌转速大于150 r/min时,极板间距是影响物料升温速率的主要因素,随着极板间距的减小,升温速率不断加快,当极板间距为130 mm时,升温速率可达到8~10℃/min。

基于量子化学计算的正己烷热解反应动力学模拟

为研究正己烷(n-C_(6)H_(14))的常压热解特性,提出了正己烷热解(NHP)模型,该模型使用基于误差传播的直接关系图(DRGEP)简化方法和色散校正密度泛函理论的B2PLYP/def2-tzvp方法,得到了一个包含33种物种和134个基元反应的简化机理。利用该模型计算了n-C_(6)H_(14)在不同温度下主要热解产物乙烯(C_(2)H_(4))、丙烯(C3H6)和丁炔(C4H6)的相对摩尔分数,并对n-C_(6)H_(14)的热解过程进行了反应路径分析。利用同步辐射真空紫外光电离质谱法(SVUV-PIMS)结合射流搅拌反应器(JSR)在温度为673~1103K、压力为1atm条件下对n-C_(6)H_(14)进行了热解实验,并与NHP模型进行了对比分析。结果表明:n-C_(6)H_(14)热解过程中最主要的产物是C_(2)H_(4),促使C_(2)H_(4)生成较为重要的两个反应的指前因子分别为6.01×10^(13)s^(-1)和2.18×10^(13)s^(-1)。在673~1023K温度范围内,结合量子化学计算得到的NHP模型对n-C_(6)H_(14)主要热解产物的相对摩尔分数进行了预测,与JetSurF 2.0模型相比,C_(2)H_(4)和C4H6的最大误差分别减小了27.9%和47.9%。反应路径分析表明,C_(2)H_(4)主要来源于己基的一系列β位断裂。

基于多智能体深度强化学习的解耦控制方法

[目的]在现代工业生产过程中,实现复杂非线性多输入多输出系统的解耦控制对于生产过程的操作和优化都具有至关重要的意义.[方法]本文基于多智能体深度确定性策略梯度(MADDPG)算法,提出了一种解决复杂非线性多输入多输出系统解耦控制问题的设计方案,并通过连续搅拌反应过程的解耦控制仿真计算,验证了设计方案的有效性.[结果]验证结果表明:本文所提出的方案能够同时对连续搅拌反应过程中反应温度、产物摩尔流量两个被控量的设定控制目标进行跟踪调节,且在同样的控制目标下,该设计方案比单智能体方案和PID(proportional-integral-derivative control)控制方案都具有更好的稳定性与更小的稳态控制误差.[结论]仿真结果表明:针对复杂非线性多输入多输出系统的解耦控制问题,多智能体强化学习算法能够在不依赖于过程模型的基础上,实现复杂非线性多输入多输出系统的解耦控制,并保证较好的控制性能.

连续式咸淡水混合搅拌反应器混合性能研究

为合理开发利用咸水资源,优化农田灌溉设施前端连续式咸淡水混合搅拌反应器结构和运行参数,探究了搅拌转速和桨叶宽度对不同类型搅拌器咸淡水混合性能的影响。以直径为290 mm的双层桨叶搅拌器为研究对象,采用Realizable k-ε模型和欧拉多相流模型进行数值模拟并利用试验结果对其进行验证。系统分析不同搅拌器结构在不同搅拌转速和桨叶宽度下的湍动能、速度流场、咸水体积分数分布、混合均匀所需时间及搅拌器功耗,发现随着搅拌转速和桨叶宽度增加,三叶开启式搅拌器与组合锚式搅拌器湍动能和液体流速均增加,反应釜内咸水体积分数也随之发生显著变化,到达混合均匀状态所需时间缩短,出口处咸水均匀度和搅拌器功率均呈上升趋势。整体来说,转速对上述指标的影响较桨叶宽度更为显著,另外,2种搅拌器类型中相关指标受转速和桨叶宽度变化的影响差异明显。与三叶开启式搅拌器相比,组合锚式搅拌器达到完全混合均匀状态所需时间最小值虽然低6.8%,但其搅拌功耗却高10%左右。综合考虑灌溉作物水量需求、混合效率和设备能耗等因素,推荐采用较低转速(90 r/min)、宽桨叶(50 mm)的三叶开启式搅拌器,该配置在咸淡水混合过程中能够有效保障混合效率,并在连续混合设备中有效控制能耗的同时满足实际应用需求。研究结果可为连续式咸淡水混合搅拌反应器设计优化提供参考。