基于时序对比学习与自适应门控TCN-GRU的水泥熟料f-CaO预测

Prediction of Cement Clinker f-CaO Based on Temporal Contrastive Learning and Adaptive Gated TCN-GRU

  • 摘要: 水泥熟料煅烧是水泥生产的核心环节,其中游离氧化钙f-CaO含量是衡量熟料质量与生产能耗的关键指标。针对目前离线化验反馈滞后、工业现场标注样本稀缺及长时序特征提取困难等挑战,本文提出一种基于自适应门控融合时序卷积网络TCN与门控循环单元GRU的双层时序对比回归模型AGTC-TCN-GRU。模型首先采用矩阵窗口化策略对原始工艺数据进行结构化重构,以有标签样本为锚点,截取其与前一有标签样本间的无标签数据,构造二维时序数据块作为后续特征提取单元的输入。在特征提取阶段,模型构建层级化建模架构,先利用时序卷积网络提取各数据块内部的局部时序特征,将每个数据块经全局平均池化压缩映射为局部特征向量,再利用门控循环单元对局部特征向量进行时序建模。为增强对复杂扰动的适应性,引入自适应门控模块动态调节局部与全局特征的融合权重,并结合基于指数衰减权重的时序对比学习机制,在特征空间引入时间邻近样本一致性约束以降低随机噪声干扰。实验结果显示,该模型在真实数据集上的决定系数为0.7970,均方根误差与平均绝对误差分别为0.1480和0.1153,预测精度优于对比模型,为水泥生产自动控制提供了技术支撑。

     

    Abstract: The calcination of cement clinker is the fundamental stage of the entire cement manufacturing process, where the concentration level of free calcium oxide f-CaO is universally recognized as the most critical parameter for assessing clinker quality and controlling energy efficiency. However, in current industrial practice, the measurement of f-CaO primarily depends on manual sampling and off-line laboratory analysis, which introduces a substantial feedback delay typically ranging from one to two hours. This feedback latency makes it impossible to satisfy the strict requirements for real-time closed-loop control, often resulting in quality fluctuations and increased fuel consumption. To overcome these limitations, this paper proposes a dual-layer temporal contrastive regression model, termed AGTC-TCN-GRU, which combines an adaptive gated fusion mechanism with Temporal Convolutional Networks TCN and Gated Recurrent Units GRU. To resolve the conflict between the vast amount of unannotated process data and the scarcity of quality labels, a matrix-based structuring technique is first introduced. This technique utilizes a matrix windowing strategy to transform raw process data into two-dimensional structured blocks, allowing the model to incorporate latent process information from unlabeled data to enrich the feature representation. The proposed architecture adopts a hierarchical modeling approach to distinguish between intra-block local features and inter-block global dependencies. Specifically, a TCN layer—incorporating causal convolutions, dilated convolutions, and residual blocks—is implemented to extract high-dimensional temporal features within each data block. The TCN consists of two layers with 48 and 24 channels respectively, and a kernel size of 3. A global average pooling operation is then applied along the temporal dimension to compress each data block into a fixed-dimensional local feature vector. Subsequently, a GRU layer is applied to the sequence of these feature vectors to model the long-term dynamic evolution and the substantial thermal inertia inherent in the continuous calcination process, thereby bridging the temporal gaps introduced by discrete data slicing. The GRU hidden size is set to 56. To enhance robustness under fluctuating operating conditions, an adaptive gated fusion module is designed. This module dynamically adjusts the fusion weights between local information and global trends based on the real-time input status, ensuring stable output during process disturbances. Furthermore, the framework integrates a temporal weighted contrastive learning mechanism that enforces a distance constraint in the feature space. By applying an exponential time-decay function to maintain feature consistency between temporally adjacent samples, the model suppresses high-frequency sensor noise and enhances representation stability. This soft weighting strategy avoids hard binary partitioning of samples and effectively preserves the continuity of operating condition transitions. Comprehensive experimental evaluations using a real-world industrial dataset from a cement production line confirm the performance of the AGTC-TCN-GRU model. The model achieves a determination coefficient R2 of 0.7970, a Root Mean Square Error RMSE of 0.1480, and a Mean Absolute Error MAE of 0.1153. These results demonstrate that the proposed method outperforms conventional models such as Support Vector Regression SVR and LightGBM, as well as several advanced deep learning architectures. This research provides a reliable technical foundation for real-time quality monitoring and energy-efficient control in cement clinker production.

     

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