Method for controlling generation of copper sulfate pentahydrate and control system

Abstract

The embodiment of the invention relates to the technical field of chemical engineering, and discloses a method for controlling generation of copper sulfate pentahydrate and a control system.The method comprises the steps that when a double decomposition reaction is conducted on a reaction kettle, the color of a solution in the reaction kettle is monitored in real time through a color matching algorithm; when it is monitored that the color of the solution in the reaction kettle is changed into the specified color, the turbidity value of the solution in the reaction kettle is monitored according to the proportional relation between the turbidity and the electric signal, and the adding speed of the acid solution and the stirring speed of stirring equipment are adjusted; when it is monitored that the turbidity value of the solution in the reaction kettle reaches a first specified threshold value and the temperature of the solution in the reaction kettle is reduced to a second specified threshold value, the cleaning time of the crystallized material is determined according to the weight of the crystallized material in the reaction kettle; and monitoring the moisture content value of the crystallized material by using a near infrared measurement method. By implementing the embodiment of the invention, the production efficiency of the copper sulfate pentahydrate can be improved.

Description

Technical Field

[0001] The invention relates to the technical field of chemical industry, and in particular to a method and a control system for controlling the generation of copper sulfate pentahydrate. Background Art

[0002] The traditional production process of copper sulfate pentahydrate (commonly known as blue vitriol or gall vitriol) mainly relies on untreated copper-containing etching waste liquid. This waste liquid usually comes from the etching process in the manufacturing process of printed circuit boards and contains high concentrations of copper ions and other impurities. When producing copper sulfate pentahydrate, the copper ions in the waste liquid are first converted into copper hydroxide precipitates through an acid-base neutralization reaction. Subsequently, the impure copper hydroxide needs to be subjected to a double decomposition reaction with concentrated sulfuric acid to produce copper sulfate pentahydrate. After the double decomposition reaction is completed, copper sulfate pentahydrate needs to be precipitated from the solution by stirring dynamic crystallization, and washed and deacidified to remove sulfuric acid and other soluble impurities attached to the surface of the product.

[0003] However, in practice, it is found that due to the lack of standardized management of reaction control nodes in the material properties, pretreatment methods and operation of each process of traditional copper sulfate pentahydrate in the production process, it is difficult to maximize the utilization of resources and fully automatic production of products, and it is highly dependent on manual operation, which not only makes product quality unstable, but also causes a lot of waste of manpower and material resources, limiting the improvement of production efficiency and product quality. Summary of the invention

[0004] The embodiment of the invention discloses a method and a control system for controlling the generation of copper sulfate pentahydrate, which can improve the production efficiency of copper sulfate pentahydrate. A first aspect of an embodiment of the present invention discloses a method for controlling the generation of copper sulfate pentahydrate, the method comprising: When the reactor is performing a double decomposition reaction, the color of the solution in the reactor is monitored in real time using a color matching algorithm; When it is detected that the color of the solution in the reactor changes to a specified color, the turbidity value of the solution in the reactor is monitored by using the proportional relationship between turbidity and the electrical signal, and the adding speed of the acidic solution and the stirring speed of the stirring device are adjusted; When it is monitored that the turbidity value of the solution in the reactor reaches a first specified threshold value and the temperature of the solution in the reactor drops to a second specified threshold value, determining a crystallization material cleaning time according to the weight of the crystallization material in the reactor; The moisture content of the crystallized material is monitored using near infrared measurement method; After monitoring that the moisture content of the crystallized material is lower than the third specified threshold, the crystallized material is packaged according to a preset packaging weight to complete the discharge of copper sulfate pentahydrate.

[0005] A second aspect of an embodiment of the present invention discloses a control system, the control system comprising: A first monitoring unit is used to monitor the color of the solution in the reactor in real time by using a color matching algorithm when the reactor is performing a double decomposition reaction; A monitoring and adjustment unit, configured to monitor the turbidity value of the solution in the reactor by using the proportional relationship between turbidity and the electrical signal, and adjust the adding speed of the acidic solution and the stirring speed of the stirring device when the first monitoring unit detects that the color of the solution in the reactor changes to a specified color; a determination unit, configured to determine a crystallization material cleaning time according to a weight of the crystallization material in the reactor when the monitoring and adjustment unit detects that the turbidity value of the solution in the reactor reaches a first specified threshold value and the temperature of the solution in the reactor drops to a second specified threshold value; The second monitoring unit is used to monitor the moisture content of the crystallization material using a near infrared measurement method; The discharging unit is used to pack the crystallized material according to a preset packing weight to complete the discharging of copper sulfate pentahydrate after the second monitoring unit monitors that the moisture content of the crystallized material is lower than a third specified threshold value.

[0006] As another optional implementation, in the second aspect of the embodiment of the present invention, the monitoring and adjusting unit includes: an adjusting subunit, configured to reduce the adding speed of the acidic solution and increase the stirring speed of the stirring device when the first monitoring unit detects that the color of the solution in the reactor changes to a specified color, so as to enter a solution reaction endpoint fine-tuning stage; A conversion subunit, configured to convert the optical signal value into an electrical signal value after receiving the optical signal value reflected by the solution in the reaction kettle; A first calculation subunit is used for pre-processing the electrical signal value and then substituting the electrical signal value into a turbidity mathematical calculation model to calculate the turbidity value of the solution in the reactor; wherein the turbidity mathematical calculation model includes a proportional relationship between turbidity and electrical signal; The stop and monitor subunit is used to stop adding the acidic solution and monitor the temperature of the solution in the reactor if the turbidity value of the solution in the reactor reaches a first specified threshold value and the color of the solution in the reactor changes to another specified color.

[0007] A third aspect of an embodiment of the present invention discloses a control system, the control system comprising: A memory storing executable program code; a processor coupled to the memory; The processor calls the executable program code stored in the memory to execute a method for controlling the generation of copper sulfate pentahydrate disclosed in the first aspect of an embodiment of the present invention.

[0008] A fourth aspect of an embodiment of the present invention discloses a computer-readable storage medium storing a computer program, wherein the computer program enables a computer to execute a method for controlling the generation of copper sulfate pentahydrate disclosed in the first aspect of an embodiment of the present invention.

[0009] A fifth aspect of an embodiment of the present invention discloses a computer program product. When the computer program product is run on a computer, the computer is enabled to execute part or all of the steps of any one of the methods for controlling the generation of copper sulfate pentahydrate in the first aspect.

[0010] A sixth aspect of an embodiment of the present invention discloses an application publishing platform, which is used to publish a computer program product, wherein when the computer program product is run on a computer, the computer executes part or all of the steps of any one of the methods for controlling the generation of copper sulfate pentahydrate in the first aspect.

[0011] Compared with the prior art, the embodiments of the present invention have the following beneficial effects: In the embodiment of the present invention, when the reactor performs double decomposition reaction, the color of the solution in the reactor is monitored in real time using a color matching algorithm; when the color of the solution in the reactor is monitored to be a specified color, the turbidity value of the solution in the reactor is monitored using the proportional relationship between turbidity and electrical signals, and the addition rate of the acidic solution and the stirring speed of the stirring device are adjusted; when the turbidity value of the solution in the reactor is monitored to reach a first specified threshold value and the temperature of the solution in the reactor is reduced to a second specified threshold value, the crystallization material cleaning time is determined according to the weight of the crystallization material in the reactor; the moisture content value of the crystallization material is monitored using a near-infrared measurement method; after the moisture content value of the crystallization material is monitored to be lower than the third specified threshold value, the crystallization material is packaged according to the preset packaging weight to complete the discharge of copper sulfate pentahydrate. It can be seen that the embodiment of the present invention can improve the production efficiency of copper sulfate pentahydrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0013] Figure 1 It is a schematic flow chart of a method for controlling the generation of copper sulfate pentahydrate disclosed in an embodiment of the present invention; Figure 2 It is a schematic flow chart of another method for controlling the generation of copper sulfate pentahydrate disclosed in an embodiment of the present invention; Figure 3 It is a structural schematic diagram of a control system disclosed in an embodiment of the present invention; Figure 4 It is a structural schematic diagram of another control system disclosed in an embodiment of the present invention; Figure 5 It is a schematic diagram of the structure of another control system disclosed in an embodiment of the present invention. DETAILED DESCRIPTION

[0014] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0015] It should be noted that the terms "first", "second", "third", "fourth", etc. in the specification and claims of the present invention are used to distinguish different objects rather than to describe a specific order. The terms "including" and "having" in the embodiments of the present invention and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device including a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0016] The embodiment of the invention discloses a method and a control system for controlling the generation of copper sulfate pentahydrate, which can improve the production efficiency of copper sulfate pentahydrate.

[0017] The following is a detailed description with reference to the accompanying drawings.

[0018] Embodiment 1 See also Figure 1 , Figure 1 Schematic diagram of a method for controlling the generation of copper sulfate pentahydrate disclosed in an embodiment of the present invention. Figure 1 As shown, the method for controlling the formation of copper sulfate pentahydrate may include the following steps.

[0019] 101. When the reactor is undergoing double decomposition reaction, the control system uses a color matching algorithm to monitor the color of the solution in the reactor in real time.

[0020] As an optional implementation, in an embodiment of the present invention, when a chemical reaction (particularly a double decomposition reaction) is carried out, the color of the solution may change as the reaction progresses. The control system monitors the color of the solution in the reactor in real time through a color matching algorithm (which may be based on image processing or spectral analysis). This monitoring helps to understand the progress of the reaction or whether a specific reaction stage has been reached.

[0021] As an optional implementation, in an embodiment of the present invention, the control system of the present application can capture the color change of the solution in the reactor in real time through a color matching algorithm, thereby indirectly reflecting the progress of the chemical reaction. At the same time, abnormal color changes may indicate improper reaction conditions or other problems, and real-time monitoring helps to discover and deal with them in a timely manner. And by judging the reaction stage through color changes, the reaction conditions can be optimized, and the reaction efficiency and product quality can be improved.

[0022] 102. When the control system detects that the color of the solution in the reactor changes to the specified color, it monitors the turbidity value of the solution in the reactor by using the proportional relationship between turbidity and the electrical signal, and adjusts the adding speed of the acid solution and the stirring speed of the stirring equipment.

[0023] As an optional embodiment, in an embodiment of the present invention, when the color of the solution reaches a preset specified color, this generally means that the reaction has entered a specific stage. At this point, the control system begins to monitor the turbidity of the solution, which is generally related to the number of particles or solute concentration in the solution. The control system can accurately measure the turbidity through the proportional relationship between the turbidity and the electrical signal (for example, using a turbidity sensor). Based on these measurements, the control system can adjust the addition rate of the acidic solution and the stirring speed of the stirring device to optimize the reaction conditions.

[0024] As an optional embodiment, in an embodiment of the present invention, when the solution color reaches a specified value, it indicates that the reaction has entered a specific stage, and the reaction conditions need to be adjusted to optimize the product quality. The present application can control the reaction rate and product distribution by adjusting the addition rate and stirring speed of the acidic solution, thereby improving the product quality. At the same time, precise control of the reaction conditions helps to reduce unnecessary energy consumption and waste emissions.

[0025] 103. When the control system monitors that the turbidity value of the solution in the reactor reaches a first specified threshold value and the temperature of the solution in the reactor drops to a second specified threshold value, the control system determines a crystallization material cleaning time according to the weight of the crystallization material in the reactor.

[0026] As an optional embodiment, in an embodiment of the present invention, when the turbidity reaches the first specified threshold and the temperature drops to the second specified threshold, this may mean that the reaction is close to completion and crystals begin to form. The control system will determine the cleaning time based on the weight of the crystallized material in the reactor. The cleaning time may depend on the amount and nature of the crystals to ensure effective separation and recovery.

[0027] As an optional embodiment, in the embodiment of the present invention, turbidity and temperature are important indicators for judging whether crystallization is complete. The present application can determine the best time for cleaning through these two parameters. Cleaning at the best time can ensure the quality and quantity of the crystallized material while reducing energy consumption and material loss during the cleaning process. At the same time, excessive cleaning may cause damage or loss of the crystallized material, which can be avoided by accurately controlling the cleaning time.

[0028] 104. The control system uses near infrared measurement method to monitor the moisture content of the crystallized material.

[0029] As an optional implementation, in the present invention, near infrared measurement is a non-destructive analytical method that can be used to measure the moisture content in the material. The control system uses this method to monitor the moisture content of the crystallized material, which helps to understand the dryness of the material and determine whether further drying treatment is needed.

[0030] As an optional implementation, in the embodiment of the present invention, the present application can ensure that the crystallized material reaches the required degree of dryness before packaging by real-time monitoring of the moisture content. At the same time, the degree of dryness is one of the important factors affecting product quality, and the product quality can be improved by accurately controlling the moisture content.

[0031] 105. After monitoring that the moisture content of the crystallized material is lower than the third specified threshold value, the control system packs the crystallized material according to a preset packing weight to complete the discharge of copper sulfate pentahydrate.

[0032] As an optional implementation, in the embodiment of the present invention, when the moisture content of the crystallized material is lower than the third specified threshold, it means that the material is dry enough to be packaged. The control system will then package the crystallized material according to the preset packaging weight to complete the discharging process of copper sulfate pentahydrate (or other chemicals). This process ensures the quality of the product and the standardization of packaging.

[0033] As an optional implementation, in the embodiment of the present invention, standardized packaging helps to improve the consistency and traceability of products, facilitates quality management and market sales. At the same time, by accurately controlling the packaging weight and moisture content, material waste and packaging material consumption can be reduced.

[0034] As an optional embodiment, in an embodiment of the present invention, the control system can automatically identify the full tank and non-full tank stirring modes according to the volume of the copper hydroxide slurry in the reactor to adjust the power of the agitator. When the metering pump delivers copper hydroxide slurry to the reactor, the delivery amount is automatically selected after the control system recognizes the stirring mode. After the loading is completed, the acid addition double decomposition reaction begins. Since the turbidity of the material exceeds the instrument range at the beginning, the color recognition monitoring system first intervenes in the control. When the solution color changes from weak green to ocean green, the turbidity online monitoring system is turned on, and the dual control system begins to fine-tune. The speed of adding dilute sulfuric acid slows down. When the solution color is dark green and the turbidity is less than 1NTU, the material is completely converted from copper hydroxide to copper sulfate. Stop the addition of dilute sulfuric acid, continue stirring until the solution temperature drops to 45°C, and open the discharge port for discharging. After the crystallization is completed, the material enters the gradient acid reduction washing equipment through the discharge port. The equipment washes the mother liquor and impurities on the surface of the material through a three-stage spray cycle. The washing water produced by the three-stage spray device will be classified and stored, and monitored by the copper ion concentration online monitoring equipment. When the copper content in the first-stage washing liquid exceeds 1000mg / L, it will be transported to the copper sulfate mother liquor storage tank for use as mother liquor. In the subsequent washing, the second-stage spray washing water is used as the first-stage washing water, the third-stage washing water is used as the second-stage washing water, and the clean water source is used as the new third-stage washing water, and the cycle is carried out. Improve the utilization rate of washing water and reduce the waste of water resources. The washed copper sulfate pentahydrate is transported to the drum dryer via a conveyor belt to dry the material. Through real-time monitoring by a near-infrared online moisture meter, the material is dried when the moisture content of the material in the dryer is lower than the set value. The dried material is packaged and sold by an automatic packaging machine.

[0035] As an optional implementation, in the embodiment of the present invention, the metering pump starts to feed the reactor. After double identification by the liquid level meter in the reactor and the metering pump, the system can select full tank stirring or non-full tank stirring mode. When the feeding volume exceeds the set value, it is in full tank stirring mode. The formula for calculating the power of the stirrer at this time is: stirrer power = material density × stirrer speed × container volume. After the feeding is completed, the system receives a signal and turns on the dilute sulfuric acid pump. While adding acid to the reactor, the color recognition monitor is turned on and the power of the acid pump is controlled. When the color recognition monitor recognizes that the solution in the reactor suddenly changes from weak green (color label #98FB98) to marine green (color label #2E8B57), the system controls the opening of the turbidity online monitor and reduces the power of the acid pump, reduces the acid addition speed, and enters the fine-tuning stage of the solution reaction endpoint. In the fine-tuning stage, the power of the pump is reduced, and the power of the stirrer is increased. The stirring speed is increased so that the added acid can react quickly. When the turbidity of the solution is below 1NTU and the color is dark green (color code #006400), stop adding acid, and the end point of the double decomposition reaction has been reached. After stopping the addition of acid, the solution continues to be stirred for dynamic crystallization. When the thermometer detects that the temperature of the solution in the kettle drops to 45°C, the agitator stops working and opens the discharge port for discharge. When the temperature in the reactor is lower than 45°C, the discharge valve opens, and the material enters the gradient acid reduction washing equipment for washing. After the material enters the weight-sensing conveyor belt, the current material weight is recorded. According to the conveyor belt power formula: power = material weight × friction coefficient × rotating wheel radius × transmission speed ÷ rotating wheel circumference ÷ 9550. Under the premise of fixed power, the conveyor belt transmission speed in the gradient acid reduction washing equipment can be calculated. Therefore, the material cleaning time = conveyor belt length ÷ transmission speed, thereby calculating the cleaning time of each batch of materials. The washing equipment performs three-stage spray washing on the material and recovers the washing water after washing. The copper ion concentration online monitoring equipment monitors the copper content in the washing water in real time. When the copper content in the primary washing water exceeds the set value (taking 1000 mg / L as an example), the control system recycles it and transports it to the copper sulfate mother liquor storage tank. At this time, the secondary washing water acts as the primary, the tertiary washing water acts as the secondary washing water, and the clean water source acts as the tertiary washing water, and the cycle is carried out. After completing the three-stage washing, the material enters the drum dryer through the conveyor belt at the outlet of the washing equipment. The conveyor belt is a weight-sensing conveyor belt. When the amount of material entering is close to the warning value of the dryer, the material feeding is stopped and the material conveying weight at this time is recorded. The dryer tumbles the material with hot air at 80°C. When the near-infrared online moisture meter detects that the moisture content of the material is lower than the set value (taking less than 20% as an example), the equipment stops drying and starts discharging. After the material is dried, the system opens the discharge port and sends it to the baler through the conveyor belt for packaging and sale. After each discharge, the conveyor belt will record the discharge weight and feedback to the control system. The control system collects and summarizes the data, and adjusts the drying temperature and duration according to the summarized data to further achieve energy-saving effects.The automatic baler weighs and packs each bag of product according to the preset packing weight. When the weight of the remaining material in the equipment is less than one bag, the baling will stop and the baling will start again after the next batch of materials is dried.

[0036] exist Figure 1 In the method for controlling the generation of copper sulfate pentahydrate, the control system is used as an example to describe the execution subject. It should be noted that, Figure 1 The execution subject of the method for controlling the generation of copper sulfate pentahydrate may also be an independent device associated with the control system, which is not limited in the embodiment of the present invention.

[0037] It can be seen that implementation Figure 1 The disclosed method for controlling the generation of copper sulfate pentahydrate can improve the production efficiency of copper sulfate pentahydrate.

[0038] In addition, implementation Figure 1 A method for controlling the formation of copper sulfate pentahydrate is described, which helps to improve product quality and reduce production costs.

[0039] Embodiment 2 See also Figure 2 , Figure 2 FIG. 2 is a flow chart of another method for controlling the generation of copper sulfate pentahydrate disclosed in an embodiment of the present invention. Figure 2 , the method for controlling the generation of copper sulfate pentahydrate may comprise the following steps: 201. If it is detected that the liquid level in the dilute sulfuric acid storage tank is lower than the alarm line, the control system calculates the current required volume of concentrated sulfuric acid and the current volume of water required to be added based on the current required dilute sulfuric acid concentration, the current required volume of dilute sulfuric acid and the current concentrated sulfuric acid concentration.

[0040] As an optional implementation, in an embodiment of the present invention, the present application can calculate the current required volume of concentrated sulfuric acid and the current required volume of water to be added according to the following formula: the current required volume of concentrated sulfuric acid = (the current required concentration of dilute sulfuric acid × the current required volume of dilute sulfuric acid) / the current concentration of concentrated sulfuric acid, the current required volume of water to be added = the current required volume of dilute sulfuric acid - the current required volume of concentrated sulfuric acid, respectively. For example, assuming that 40m³ of dilute sulfuric acid with a concentration of 70% needs to be prepared, and the concentration of concentrated sulfuric acid is 98%, it can be calculated that the current required volume of concentrated sulfuric acid = 70*40 / 98≈28.57 m³ (to simplify the calculation, two decimal places are taken here, and more digits may need to be taken according to the accuracy requirements in the actual calculation), and then the current required volume of water to be added can be calculated = 40m³-28.57 m³=11.43 m³.

[0041] 202. The control system controls the metering pump to quantitatively deliver the currently required volume of concentrated sulfuric acid and the currently required volume of water to be added to the sulfuric acid dilution cooler through the delivery pipeline.

[0042] 203. The control system obtains the density of dilute sulfuric acid measured by an online density hydrometer in the conveying pipeline.

[0043] 204. The control system matches the dilute sulfuric acid control concentration value corresponding to the dilute sulfuric acid density from a preset dilute sulfuric acid concentration specific gravity table according to the dilute sulfuric acid density, and executes step 205 or step 206.

[0044] 205. If the dilute sulfuric acid control concentration value does not match the currently required dilute sulfuric acid concentration, the control system recalculates the amount of concentrated sulfuric acid and water to be added and executes steps 207 to 215.

[0045] As an optional embodiment, in an embodiment of the present invention, during the preparation of dilute sulfuric acid, the present application can determine whether the concentration of dilute sulfuric acid is accurate by comparing the measured density value with the concentration specific gravity table in the system. For example, assuming that the density measured by the online density specific gravity meter is ρ, the concentration specific gravity table in the system gives the corresponding relationship between density and concentration. Then, the concentration value C corresponding to the measured density ρ can be found by a lookup table or interpolation method. If C does not match the expected concentration value, it is necessary to adjust the amount of sulfuric acid or water according to the difference between C and the expected concentration value to ensure that the final concentration of dilute sulfuric acid is accurate.

[0046] 206. If the dilute sulfuric acid control concentration value matches the currently required dilute sulfuric acid concentration, the control system transports the liquid in the sulfuric acid dilution cooler to the dilute sulfuric acid storage tank through the delivery pipeline when the temperature in the sulfuric acid dilution cooler reaches the specified temperature, and releases the liquid level alarm, and executes steps 207 to 215.

[0047] As an optional implementation mode, in the embodiment of the present invention, the present application can ensure that the concentration and volume of dilute sulfuric acid meet the production requirements, avoiding waste and shortage. At the same time, through accurate calculation and delivery, the production efficiency is improved and the energy consumption is reduced. Moreover, real-time monitoring and adjustment are performed to ensure the stable quality of dilute sulfuric acid, providing reliable raw materials for subsequent reactions.

[0048] When the reactor is performing double decomposition reaction, the control system calculates the cosine similarity between the color characteristics of the solution in the reactor and the specified color characteristics in real time.

[0049] 208. When the cosine similarity is greater than a fourth specified threshold, the control system determines that the color of the solution in the reaction kettle changes to a specified color.

[0050] As an optional implementation, in an embodiment of the present invention, first, the color information captured by the system is usually presented in the form of RGB (red, green, blue) color space. However, in order to perform color matching more accurately, the system can convert the RGB color space into other color spaces, such as HSV (hue, saturation, brightness) or Lab color space. These color spaces have better performance in some aspects (such as hue distinction, color perception consistency, etc.). After the color space conversion, the system can extract color features. These features may include hue, saturation, brightness, etc. (in HSV color space), or brightness, a and b components (in Lab color space). These features are used to describe the basic properties of color and serve as input for subsequent matching processes. In the system, a color label library is usually preset. This library contains various possible color labels and their corresponding color feature values. These color labels are determined according to actual application requirements. For example, in this example, they may include weak green (#98FB98), ocean green (#2E8B57) and dark green (#006400). Next, the algorithm uses a matching strategy to compare the color features captured by the sensor with the color features in the preset color label library. Common matching strategies include: Euclidean distance: Calculate the Euclidean distance between the color features captured by the sensor and each color feature in the preset color label library, and select the color label with the smallest distance as the matching result. Cosine similarity: Treat the color features as vectors, calculate the cosine similarity between the color features captured by the sensor and each color feature in the preset color label library, and select the color label with the highest similarity as the matching result. Threshold matching: Set a threshold range for each color feature. If the color features captured by the sensor fall within the threshold range of a color label, select the color label as the matching result. Finally, the system can output the matching result. This is usually a color label or color name, indicating which color in the preset color label library is closest to the color captured by the sensor.

[0051] 209. When the control system detects that the color of the solution in the reactor has changed to the specified color, it reduces the rate of adding the acid solution and increases the stirring speed of the stirring device to enter the stage of fine-tuning the solution reaction endpoint.

[0052] As an optional implementation, in an embodiment of the present invention, when the reactor is performing a double decomposition reaction, the control system monitors the color characteristics of the solution in the reactor in real time and compares it with the preset specified color characteristics (by calculating the cosine similarity). When the color characteristic matching degree reaches a preset threshold, the control system adjusts the addition speed and stirring speed of the acidic solution to enter the reaction endpoint fine-tuning stage.

[0053] 210. After receiving the light signal value reflected by the solution in the reaction kettle, the control system converts the light signal value into an electrical signal value.

[0054] 211. After preprocessing the electrical signal value, the control system substitutes the electrical signal value into the turbidity mathematical calculation model to calculate the turbidity value of the solution in the reactor; wherein the turbidity mathematical calculation model includes the proportional relationship between turbidity and electrical signal.

[0055] As an optional implementation, in the embodiment of the present invention, the control system can receive the light signal reflected by the solution in the reactor and convert it into an electrical signal. After preprocessing, these electrical signals will be substituted into the turbidity mathematical calculation model to calculate the turbidity value of the solution.

[0056] 212. If the turbidity value of the solution in the reactor reaches a first specified threshold value and the color of the solution in the reactor changes to another specified color, the control system stops adding the acidic solution and monitors the temperature of the solution in the reactor.

[0057] As an optional implementation, in an embodiment of the present invention, when light passes through a solution, it will be scattered by particles in the solution (such as suspended matter, colloids, etc.). The system can evaluate turbidity by measuring the intensity of the scattered light. The intensity of the scattered light is related to the number, size and distribution of particles in the solution. After the light passes through the solution, part of the light will be absorbed or scattered, and the remaining light will continue to propagate. The system can evaluate turbidity by measuring the intensity of the transmitted light. The intensity of the transmitted light is inversely proportional to the clarity of the solution, that is, the higher the turbidity, the lower the intensity of the transmitted light.

[0058] As an optional embodiment, in an embodiment of the present invention, after receiving the electrical signal output by the detector, first, the system can pre-process the received electrical signal to eliminate noise and interference. This includes steps such as filtering, amplification and calibration. Subsequently, based on the principle of scattered light or transmitted light, a mathematical model is established to describe the relationship between turbidity and electrical signals. This model usually includes some parameters, such as light source intensity, detector sensitivity, characteristics of optical components, etc. Before formal use, the system needs to be calibrated. This is usually done by measuring a series of solutions with known turbidity and adjusting the parameters in the mathematical model so that the calculated turbidity value is consistent with the actual value. After the calibration is completed, verification is required to ensure the accuracy and reliability of the measurement results. During normal operation, the system receives the electrical signal output by the detector in real time, and uses the calibrated mathematical model for calculation to obtain a real-time turbidity value. The control system can trigger corresponding control logic according to the size of the turbidity value, such as stopping acid addition, adjusting the stirring speed, etc.

[0059] 213. When it is monitored that the turbidity value of the solution in the reactor reaches the first specified threshold value and the temperature of the solution in the reactor drops to the second specified threshold value, the control system uses the conveyor belt speed adjustment calculation formula and substitutes the weight of the crystallized material in the reactor to calculate the current conveyor belt transmission speed.

[0060] In this embodiment, the conveyor belt speed adjustment calculation formula is the product of the conveyor belt power and the circumference of the conveyor belt rotating wheel divided by the product of the weight of the crystal material, the friction coefficient of the conveyor belt and the radius of the conveyor belt rotating wheel. When the power is fixed, the present application can adapt to different material weights by adjusting the transmission speed, that is, the control system can automatically calculate and adjust the transmission speed of the conveyor belt according to the reading of the material weight sensor. For example, if the material weight is doubled, the transmission speed needs to be reduced to half of the original to keep the power unchanged. For example, assuming that the material weight is 1000kg, the friction coefficient is 0.3, the rotating wheel radius is 0.2m, the transmission speed is V (unit: m / s), and the rotating wheel circumference is π×0.4m (assuming that the rotating wheel is circular), the power formula becomes: P=1000×0.3×0.2×V÷(π×0.4)÷9550.

[0061] As an optional implementation, in the embodiment of the present invention, when the turbidity value and color characteristics of the solution reach the preset conditions, the control system stops adding the acid solution and starts monitoring the temperature of the solution. When the temperature and turbidity both meet specific conditions, the control system uses the conveyor belt speed adjustment calculation formula to calculate the current conveyor belt transmission speed.

[0062] 214. The control system divides the current conveyor belt length by the current conveyor belt driving speed to calculate the crystallized material cleaning time.

[0063] As an optional embodiment, in an embodiment of the present invention, the present application can monitor the reaction process in real time to ensure that the reaction is carried out under optimal conditions and improve product quality and yield. At the same time, by adjusting the reaction conditions and parameters, accurate control of the reaction process is achieved, reducing energy consumption and waste generation. In addition, the conveyor belt speed adjustment calculation formula and cleaning time calculation are used to optimize the processing flow of the crystallized material and improve production efficiency.

[0064] 215. After the control system performs three gradient acid reduction washings on the crystallized material in the reactor according to the crystallized material cleaning time, it detects whether the copper content in the primary washing liquid exceeds the set value. If so, execute steps 216 to 220; if not, execute steps 218 to 220.

[0065] 216. The control system recycles the primary washing liquid into the copper sulfate mother liquor storage tank.

[0066] 217. The control system sets the secondary washing liquid to the new primary washing liquid, the tertiary washing liquid to the new secondary washing liquid, and the clean water source to the new tertiary washing liquid.

[0067] 218. When the control system starts the drying equipment to dry the crystallized material that has reached the dry weight standard, it receives the infrared reflection signal of the crystallized material.

[0068] 219. The control system substitutes the infrared reflection signal of the crystallized material into the infrared moisture calibration curve to determine the moisture content value of the crystallized material; wherein the infrared moisture calibration curve includes the corresponding relationship between the infrared reflection signal intensity of the material and the moisture content.

[0069] As an optional implementation, in an embodiment of the present invention, the present application can detect the moisture content of the material by emitting near infrared rays and receiving the signal reflected by the material. For example, when the moisture content of the material is 25%, the system will receive a specific reflected signal intensity. The moisture content of the material can be calculated through the pre-established correspondence between the reflected signal intensity and the moisture content (i.e., the calibration curve). When the moisture content of the material is detected to be lower than the set value (such as 20%), the equipment will stop drying and start discharging.

[0070] As an optional implementation, in the embodiment of the present invention, the present application effectively removes impurities and excess acid in the crystallized material through gradient acid reduction washing to improve the purity of the product. At the same time, the washing liquid is recycled to the copper sulfate mother liquor storage tank to achieve resource recycling and reduce waste. And the infrared moisture calibration curve is used to monitor the moisture content of the crystallized material in real time to ensure that the drying effect meets the requirements.

[0071] 220. After monitoring that the moisture content of the crystallized material is lower than the third specified threshold value, the control system packages the crystallized material according to the preset packaging weight to complete the discharging of copper sulfate pentahydrate, thereby ending this process.

[0072] As an optional implementation, in an embodiment of the present invention, the present application can be packaged according to a preset packaging weight to achieve standardization and normalization of the product for easy storage and sales.

[0073] As an optional embodiment, in an embodiment of the present invention, the purpose of recording the discharge weight in this application is to collect data and analyze it so as to adjust and optimize the parameters in the production process. For example, if it is found through data analysis that the drying temperature of a batch of materials is high and the duration is long, but the moisture content is still high, then the control system can automatically adjust the drying temperature and duration of the next batch to reduce energy consumption and improve drying efficiency. Specifically, if the drying temperature of the previous batch of materials is 85°C and the duration is 2 hours, but the moisture content is still higher than 20%, the control system can reduce the drying temperature of the next batch to 80°C and shorten the duration to 1.5 hours, and observe the effect. If the effect is good, you can continue to maintain this parameter; if the effect is not good, continue to adjust.

[0074] As an optional implementation, in the embodiment of the present invention, the control system collects data through sensors and instruments, such as discharge weight, drying temperature, drying time, etc. These data will be stored in the database of the control system and can be summarized and displayed in the form of reports or charts.

[0075] It can be seen that implementation Figure 2 Another method for controlling the formation of copper sulfate pentahydrate is described, which can improve the production efficiency of copper sulfate pentahydrate. In addition, implementation Figure 2 Another method for controlling the generation of copper sulfate pentahydrate described herein can monitor and adjust the conditions and parameters of each production link in real time to improve the quality and output of the product.

[0076] Embodiment 3 See also Figure 3 , Figure 3 Schematic diagram of a control system disclosed in an embodiment of the present invention. Figure 3 The control system 300 may include a first monitoring unit 301, a monitoring and adjusting unit 302, a determining unit 303, a second monitoring unit 304 and a discharging unit 305, wherein: The first monitoring unit 301 is used to monitor the color of the solution in the reactor in real time by using a color matching algorithm when the reactor is performing a double decomposition reaction.

[0077] The monitoring and adjustment unit 302 is used to monitor the turbidity value of the solution in the reactor and adjust the addition speed of the acidic solution and the stirring speed of the stirring device by using the proportional relationship between turbidity and the electrical signal when the first monitoring unit 301 detects that the color of the solution in the reactor changes to a specified color.

[0078] The determination unit 303 is used to determine the crystallization material cleaning time according to the weight of the crystallization material in the reactor when the monitoring and adjustment unit 302 monitors that the turbidity value of the solution in the reactor reaches the first specified threshold and the temperature of the solution in the reactor drops to the second specified threshold.

[0079] The second monitoring unit 304 is used to monitor the moisture content of the crystallization material using a near infrared measurement method.

[0080] The discharging unit 305 is used to pack the crystallized material according to a preset packing weight to complete the discharging of copper sulfate pentahydrate after the second monitoring unit 304 detects that the moisture content of the crystallized material is lower than the third specified threshold value.

[0081] As an optional implementation, in the embodiment of the present invention, when a chemical reaction (particularly a double decomposition reaction) is carried out, the color of the solution may change as the reaction progresses. The first monitoring unit 301 monitors the color of the solution in the reactor in real time through a color matching algorithm (possibly based on image processing or spectral analysis). This monitoring helps to understand the progress of the reaction or whether a specific reaction stage has been reached.

[0082] As an optional implementation, in the embodiment of the present invention, the first monitoring unit 301 can capture the color change of the solution in the reactor in real time through a color matching algorithm, thereby indirectly reflecting the progress of the chemical reaction. At the same time, abnormal color changes may indicate improper reaction conditions or other problems, and real-time monitoring helps to discover and deal with them in a timely manner. And judging the reaction stage through color changes can optimize the reaction conditions and improve the reaction efficiency and product quality.

[0083] As an optional embodiment, in an embodiment of the present invention, when the solution color reaches a preset specified color, this generally means that the reaction has entered a specific stage. At this time, the monitoring and adjustment unit 302 begins to monitor the turbidity of the solution, which is generally related to the number of particles or solute concentration in the solution. The monitoring and adjustment unit 302 can accurately measure the turbidity through the proportional relationship between the turbidity and the electrical signal (for example, using a turbidity sensor). Based on these measurements, the monitoring and adjustment unit 302 can adjust the addition rate of the acidic solution and the stirring speed of the stirring device to optimize the reaction conditions.

[0084] As an optional implementation, in the embodiment of the present invention, when the solution color reaches a specified value, it indicates that the reaction has entered a specific stage, and the reaction conditions need to be adjusted to optimize the product quality. The monitoring and adjustment unit 302 can control the reaction rate and product distribution by adjusting the addition speed and stirring speed of the acidic solution, thereby improving the product quality. At the same time, precise control of the reaction conditions helps to reduce unnecessary energy consumption and waste emissions.

[0085] As an optional implementation, in the embodiment of the present invention, when the turbidity reaches the first specified threshold and the temperature drops to the second specified threshold, this may mean that the reaction is nearly complete and crystals begin to form. The determination unit 303 will determine the cleaning time according to the weight of the crystallized material in the reactor. The cleaning time may depend on the amount and nature of the crystals to ensure effective separation and recovery.

[0086] As an optional implementation, in the embodiment of the present invention, turbidity and temperature are important indicators for determining whether crystallization is complete, and the determination unit 303 can determine the best cleaning time through these two parameters. Cleaning at the best time can ensure the quality and quantity of the crystallized material, while reducing energy consumption and material loss during the cleaning process. At the same time, excessive cleaning may cause damage or loss of the crystallized material, which can be avoided by accurately controlling the cleaning time.

[0087] As an optional implementation, in the embodiment of the present invention, near infrared measurement is a non-destructive analysis method that can be used to measure the moisture content in the material. The second monitoring unit 304 uses this method to monitor the moisture content of the crystallized material, which helps to understand the dryness of the material and determine whether further drying treatment is needed.

[0088] As an optional implementation, in the embodiment of the present invention, the second monitoring unit 304 can ensure that the crystallized material reaches the required degree of dryness before packaging by real-time monitoring of the moisture content. At the same time, the degree of dryness is one of the important factors affecting product quality, and the product quality can be improved by accurately controlling the moisture content.

[0089] As an optional implementation, in the embodiment of the present invention, when the moisture content of the crystallized material is lower than the third specified threshold, it means that the material is dry enough and can be packaged. The discharging unit 305 will now package the crystallized material according to the preset packaging weight to complete the discharging process of copper sulfate pentahydrate (or other chemicals). This process ensures the quality of the product and the standardization of packaging.

[0090] As an optional implementation, in the embodiment of the present invention, standardized packaging helps to improve the consistency and traceability of products, facilitates quality management and market sales. At the same time, by accurately controlling the packaging weight and moisture content, material waste and packaging material consumption can be reduced.

[0091] As an optional implementation, in the embodiment of the present invention, the metering pump starts to feed the reactor. After double identification by the liquid level meter in the reactor and the metering pump, the system can select full tank stirring or non-full tank stirring mode. When the feeding volume exceeds the set value, it is in full tank stirring mode. The formula for calculating the power of the stirrer at this time is: stirrer power = material density × stirrer speed × container volume. After the feeding is completed, the system receives a signal and turns on the dilute sulfuric acid pump. While adding acid to the reactor, the color recognition monitor is turned on and the power of the acid pump is controlled. When the color recognition monitor recognizes that the solution in the reactor suddenly changes from weak green (color label #98FB98) to marine green (color label #2E8B57), the system controls the opening of the turbidity online monitor and reduces the power of the acid pump, reduces the acid addition speed, and enters the fine-tuning stage of the solution reaction endpoint. In the fine-tuning stage, the power of the pump is reduced, and the power of the stirrer is increased. The stirring speed is increased so that the added acid can react quickly. When the turbidity of the solution is below 1NTU and the color is dark green (color code #006400), stop adding acid, and the end point of the double decomposition reaction has been reached. After stopping the addition of acid, the solution continues to be stirred for dynamic crystallization. When the thermometer detects that the temperature of the solution in the kettle drops to 45°C, the agitator stops working and opens the discharge port for discharge. When the temperature in the reactor is lower than 45°C, the discharge valve opens, and the material enters the gradient acid reduction washing equipment for washing. After the material enters the weight-sensing conveyor belt, the current material weight is recorded. According to the conveyor belt power formula: power = material weight × friction coefficient × rotating wheel radius × transmission speed ÷ rotating wheel circumference ÷ 9550. Under the premise of fixed power, the conveyor belt transmission speed in the gradient acid reduction washing equipment can be calculated. Therefore, the material cleaning time = conveyor belt length ÷ transmission speed, thereby calculating the cleaning time of each batch of materials. The washing equipment performs three-stage spray washing on the material and recovers the washing water after washing. The copper ion concentration online monitoring equipment monitors the copper content in the washing water in real time. When the copper content in the primary washing water exceeds the set value (taking 1000 mg / L as an example), the control system recycles it and transports it to the copper sulfate mother liquor storage tank. At this time, the secondary washing water acts as the primary, the tertiary washing water acts as the secondary washing water, and the clean water source acts as the tertiary washing water, and the cycle is carried out. After completing the three-stage washing, the material enters the drum dryer through the conveyor belt at the outlet of the washing equipment. The conveyor belt is a weight-sensing conveyor belt. When the amount of material entering is close to the warning value of the dryer, the material feeding is stopped and the material conveying weight at this time is recorded. The dryer tumbles the material with hot air at 80°C. When the near-infrared online moisture meter detects that the moisture content of the material is lower than the set value (taking less than 20% as an example), the equipment stops drying and starts discharging. After the material is dried, the system opens the discharge port and sends it to the baler through the conveyor belt for packaging and sale. After each discharge, the conveyor belt will record the discharge weight and feedback to the control system. The control system collects and summarizes the data, and adjusts the drying temperature and duration according to the summarized data to further achieve energy-saving effects.The automatic baler weighs and packs each bag of product according to the preset packing weight. When the weight of the remaining material in the equipment is less than one bag, the baling will stop and the baling will start again after the next batch of materials is dried.

[0092] It can be seen that implementation Figure 3 The control system described can improve the production efficiency of copper sulfate pentahydrate. In addition, implementation Figure 3 The control system described helps to improve product quality and reduce production costs. Embodiment 4 See also Figure 4 , Figure 4 is a schematic diagram of the structure of another control system disclosed in an embodiment of the present invention. Figure 4 The control system is composed of Figure 3 The control system is optimized. Figure 3 Compared with the control system, Figure 4 The monitoring and adjusting unit 302 includes: The adjusting subunit 3021 is used to reduce the adding speed of the acid solution and increase the stirring speed of the stirring device when the first monitoring unit detects that the color of the solution in the reactor changes to a specified color, so as to enter the fine-tuning stage of the solution reaction endpoint.

[0093] As an optional implementation, in the embodiment of the present invention, when the reactor performs a double decomposition reaction, the adjustment subunit 3021 monitors the color characteristics of the solution in the reactor in real time and compares it with the preset specified color characteristics (by calculating the cosine similarity). When the color characteristic matching degree reaches the preset threshold, the adjustment subunit 3021 adjusts the addition speed and stirring speed of the acidic solution to enter the reaction endpoint fine-tuning stage.

[0094] The conversion subunit 3022 is used to convert the light signal value into an electrical signal value after receiving the light signal value reflected by the solution in the reaction kettle.

[0095] The first calculation subunit 3023 is used to substitute the electrical signal value into the turbidity mathematical calculation model after preprocessing the electrical signal value to calculate the turbidity value of the solution in the reactor; wherein the turbidity mathematical calculation model includes the proportional relationship between turbidity and electrical signal.

[0096] As an optional implementation, in the embodiment of the present invention, the conversion subunit 3022 can receive the light signal reflected by the solution in the reactor and convert it into an electrical signal. After preprocessing, these electrical signals will be substituted into the turbidity mathematical calculation model, and the first calculation subunit 3023 will calculate the turbidity value of the solution.

[0097] The stop and monitor subunit 3024 is used to stop adding the acid solution and monitor the temperature of the solution in the reactor if the turbidity value of the solution in the reactor reaches a first specified threshold value and the color of the solution in the reactor changes to another specified color.

[0098] As an optional implementation, in an embodiment of the present invention, when light passes through a solution, it will be scattered by particles (such as suspended matter, colloids, etc.) in the solution. The first calculation subunit 3023 can evaluate turbidity by measuring the intensity of scattered light. The intensity of scattered light is related to the number, size and distribution of particles in the solution. After the light passes through the solution, part of the light will be absorbed or scattered, and the remaining light will continue to propagate. The first calculation subunit 3023 can evaluate turbidity by measuring the intensity of transmitted light. The intensity of transmitted light is inversely proportional to the clarity of the solution, that is, the higher the turbidity, the lower the intensity of transmitted light.

[0099] As an optional embodiment, in an embodiment of the present invention, after receiving the electrical signal output by the detector, first, the conversion subunit 3022 can pre-process the received electrical signal to eliminate noise and interference. This includes steps such as filtering, amplification and calibration. Subsequently, based on the principle of scattered light or transmitted light, a mathematical model is established to describe the relationship between turbidity and electrical signals. This model usually includes some parameters, such as light source intensity, detector sensitivity, characteristics of optical components, etc. Before formal use, the system needs to be calibrated. This is usually done by measuring a series of solutions with known turbidity and adjusting the parameters in the mathematical model so that the calculated turbidity value is consistent with the actual value. After the calibration is completed, verification is also required to ensure the accuracy and reliability of the measurement results. During normal operation, the first calculation subunit 3023 receives the electrical signal output by the detector in real time, and uses the calibrated mathematical model for calculation to obtain a real-time turbidity value. The stop and monitor subunit 3024 can trigger corresponding control logic according to the size of the turbidity value, such as stopping acid addition, adjusting the stirring speed, etc.

[0100] and Figure 3 Compared with the control system, Figure 4 The first monitoring unit 301 comprises: The second calculation subunit 3011 is used to calculate the cosine similarity between the color feature of the solution in the reactor and the specified color feature in real time when the reactor performs double decomposition reaction.

[0101] The first determining subunit 3012 is configured to determine that the color of the solution in the reaction kettle changes to a specified color when the cosine similarity is greater than a fourth specified threshold.

[0102] As an optional implementation, in an embodiment of the present invention, first, the color information captured by the system is usually presented in the form of RGB (red, green, blue) color space. However, in order to perform color matching more accurately, the system can convert the RGB color space into other color spaces, such as HSV (hue, saturation, brightness) or Lab color space. These color spaces have better performance in some aspects (such as hue distinction, color perception consistency, etc.). After the color space conversion, the system can extract color features. These features may include hue, saturation, brightness, etc. (in HSV color space), or brightness, a and b components (in Lab color space). These features are used to describe the basic properties of color and serve as input for subsequent matching processes. In the system, a color label library is usually preset. This library contains various possible color labels and their corresponding color feature values. These color labels are determined according to actual application requirements. For example, in this example, they may include weak green (#98FB98), ocean green (#2E8B57) and dark green (#006400). Next, the algorithm uses a matching strategy to compare the color features captured by the sensor with the color features in the preset color label library. Common matching strategies include: Euclidean distance: Calculate the Euclidean distance between the color features captured by the sensor and each color feature in the preset color label library, and select the color label with the smallest distance as the matching result. Cosine similarity: Treat the color features as vectors, calculate the cosine similarity between the color features captured by the sensor and each color feature in the preset color label library, and select the color label with the highest similarity as the matching result. Threshold matching: Set a threshold range for each color feature. If the color features captured by the sensor fall within the threshold range of a color label, select the color label as the matching result. Finally, the system can output the matching result. This is usually a color label or color name, indicating which color in the preset color label library is closest to the color captured by the sensor.

[0103] and Figure 3 Compared with the control system, Figure 4 The determining unit 303 includes: The third calculation subunit 3031 is used to use the conveyor belt speed adjustment calculation formula to substitute the weight of the crystallized material in the reactor to calculate the current conveyor belt transmission speed; wherein the conveyor belt speed adjustment calculation formula is the product of the conveyor belt power and the circumference of the conveyor belt rotating wheel divided by the product of the weight of the crystallized material, the conveyor belt friction coefficient and the conveyor belt rotating wheel radius.

[0104] In this embodiment, the conveyor belt speed adjustment calculation formula is the product of the conveyor belt power and the circumference of the conveyor belt rotating wheel divided by the product of the weight of the crystal material, the friction coefficient of the conveyor belt and the radius of the conveyor belt rotating wheel. When the power is fixed, the third calculation subunit 3031 can adapt to different material weights by adjusting the transmission speed, that is, the control system can automatically calculate and adjust the transmission speed of the conveyor belt according to the reading of the material weight sensor. For example, if the material weight is doubled, the transmission speed needs to be reduced to half of the original to keep the power unchanged. For example, if the material weight is 1000kg, the friction coefficient is 0.3, the rotating wheel radius is 0.2m, the transmission speed is V (unit: m / s), and the rotating wheel circumference is π×0.4m (assuming that the rotating wheel is circular), the power formula becomes: P=1000×0.3×0.2×V÷(π×0.4)÷9550.

[0105] As an optional implementation, in the embodiment of the present invention, when the turbidity value and color characteristics of the solution reach the preset conditions, the control system stops adding the acid solution and starts monitoring the temperature of the solution. When the temperature and turbidity both meet specific conditions, the control system uses the conveyor belt speed adjustment calculation formula to calculate the current conveyor belt transmission speed.

[0106] The fourth calculation subunit 3032 is used to divide the current conveyor belt length by the current conveyor belt transmission speed to calculate the crystal material cleaning time.

[0107] As an optional embodiment, in an embodiment of the present invention, the present application can monitor the reaction process in real time to ensure that the reaction is carried out under optimal conditions and improve product quality and yield. At the same time, by adjusting the reaction conditions and parameters, accurate control of the reaction process is achieved, reducing energy consumption and waste generation. In addition, the conveyor belt speed adjustment calculation formula and cleaning time calculation are used to optimize the processing flow of the crystallized material and improve production efficiency.

[0108] and Figure 3 Compared with the control system, Figure 4 The second monitoring unit 304 includes: The receiving subunit 3041 is used to receive the infrared reflection signal of the crystallized material when the drying device is started to dry the crystallized material that reaches the dry weight standard.

[0109] The second determination subunit 3042 is used to substitute the infrared reflection signal of the crystallized material into the infrared moisture calibration curve to determine the moisture content value of the crystallized material; wherein the infrared moisture calibration curve includes the corresponding relationship between the infrared reflection signal intensity of the material and the moisture content.

[0110] As an optional implementation, in an embodiment of the present invention, the present application can detect the moisture content of the material by emitting near infrared rays and receiving the signal reflected by the material. For example, when the moisture content of the material is 25%, the receiving subunit 3041 will receive a specific reflected signal intensity. Through the pre-established correspondence between the reflected signal intensity and the moisture content (i.e., the calibration curve), the second determination subunit 3042 can calculate the moisture content of the material. When it is detected that the moisture content of the material is lower than the set value (such as 20%), the equipment will stop drying and start discharging.

[0111] As an optional implementation, in the embodiment of the present invention, the present application effectively removes impurities and excess acid in the crystallized material through gradient acid reduction washing to improve the purity of the product. At the same time, the washing liquid is recycled to the copper sulfate mother liquor storage tank to achieve resource recycling and reduce waste. And the infrared moisture calibration curve is used to monitor the moisture content of the crystallized material in real time to ensure that the drying effect meets the requirements.

[0112] and Figure 3 Compared with the control system, Figure 4 The control system includes: The detection unit 306 is used to detect whether the copper content in the first-level washing liquid exceeds the set value after the crystallization material in the reactor is subjected to three gradient acid reduction washings in accordance with the crystallization material cleaning time, after the determination unit 303 determines the crystallization material cleaning time according to the weight of the crystallization material in the reactor, and before the second monitoring unit 304 monitors the moisture content of the crystallization material using a near-infrared measurement method.

[0113] The recovery unit 307 is used to recover the primary washing liquid to the copper sulfate mother liquor storage tank when the detection unit 306 detects that the copper content in the primary washing liquid exceeds the set value.

[0114] The setting unit 308 is used to set the secondary washing liquid as the new primary washing liquid, the tertiary washing liquid as the new secondary washing liquid, and the clean water source as the new tertiary washing liquid.

[0115] and Figure 3 Compared with the control system, Figure 4 The control system includes: The calculation unit 309 is used before the first monitoring unit 301 uses the color matching algorithm to monitor the color of the solution in the reactor in real time. If it is detected that the liquid level in the dilute sulfuric acid storage tank is lower than the alarm line, the current required concentrated sulfuric acid volume and the current required water volume to be added are calculated according to the current required dilute sulfuric acid concentration, the current required dilute sulfuric acid volume and the current concentrated sulfuric acid concentration.

[0116] As an optional implementation, in an embodiment of the present invention, the calculation unit 309 can calculate the current required volume of concentrated sulfuric acid and the current required volume of water to be added according to the following formula: the current required volume of concentrated sulfuric acid = (the current required dilute sulfuric acid concentration × the current required volume of dilute sulfuric acid) / the current concentrated sulfuric acid concentration, the current required volume of water to be added = the current required volume of dilute sulfuric acid - the current required volume of concentrated sulfuric acid, respectively. For example, assuming that 40m³ of dilute sulfuric acid with a concentration of 70% needs to be prepared, and the concentration of concentrated sulfuric acid is 98%, it can be calculated that the current required volume of concentrated sulfuric acid = 70*40 / 98≈28.57 m³ (to simplify the calculation, two decimal places are taken here, and more digits may need to be taken according to the accuracy requirements in the actual calculation), and then the current required volume of water to be added = 40m³-28.57 m³=11.43 m³ can be calculated.

[0117] The control unit 310 is used to control the metering pump to quantitatively deliver the currently required volume of concentrated sulfuric acid and the currently required volume of water to be added to the sulfuric acid dilution cooler through the delivery pipeline.

[0118] The acquisition unit 311 is used to acquire the density of dilute sulfuric acid measured by an online density hydrometer in the delivery pipeline.

[0119] The matching unit 312 is used to match the dilute sulfuric acid control concentration value corresponding to the dilute sulfuric acid density from a preset dilute sulfuric acid concentration specific gravity table according to the dilute sulfuric acid density.

[0120] The recalculation unit 313 is used to recalculate the addition amount of concentrated sulfuric acid and water if the dilute sulfuric acid control concentration value does not match the currently required dilute sulfuric acid concentration.

[0121] As an optional implementation, in an embodiment of the present invention, during the preparation of dilute sulfuric acid, the matching unit 312 can determine whether the concentration of the dilute sulfuric acid is accurate by comparing the measured density value with the concentration specific gravity table in the system. For example, assuming that the density measured by the online density specific gravity meter is ρ, the concentration specific gravity table in the system gives the corresponding relationship between density and concentration. Then, the concentration value C corresponding to the measured density ρ can be found by a lookup table or interpolation method. If C does not match the expected concentration value, the recalculation unit 313 needs to adjust the amount of sulfuric acid or water according to the difference between C and the expected concentration value to ensure that the final concentration of the dilute sulfuric acid is accurate.

[0122] The conveying and releasing unit 314 is used to convey the liquid in the sulfuric acid dilution cooler to the dilute sulfuric acid storage tank through the conveying pipeline and release the liquid level alarm if the dilute sulfuric acid control concentration value matches the currently required dilute sulfuric acid concentration and the temperature in the sulfuric acid dilution cooler reaches a specified temperature.

[0123] As an optional implementation mode, in the embodiment of the present invention, the present application can ensure that the concentration and volume of dilute sulfuric acid meet the production requirements, avoiding waste and shortage. At the same time, through accurate calculation and delivery, the production efficiency is improved and the energy consumption is reduced. Moreover, real-time monitoring and adjustment are performed to ensure the stable quality of dilute sulfuric acid, providing reliable raw materials for subsequent reactions.

[0124] It can be seen that the implementation Figure 4 Another control system described can improve the production efficiency of copper sulfate pentahydrate. In addition, implementation Figure 4 The control system described can monitor and adjust the conditions and parameters of each production link in real time to improve the quality and output of the product. Embodiment 5 See also Figure 5 , Figure 5 FIG. 1 is a schematic diagram of another control system disclosed in an embodiment of the present invention. Figure 5 , the control system may include: A memory 501 storing executable program codes; a processor 502 coupled to the memory 501; The processor 502 calls the executable program code stored in the memory 501 to execute Figure 1~Figure 2 Any method of controlling the formation of copper sulfate pentahydrate.

[0125] The embodiment of the present invention discloses a computer-readable storage medium storing a computer program, wherein the computer program enables a computer to execute Figure 1~Figure 2 Any method of controlling the formation of copper sulfate pentahydrate.

[0126] The embodiments of the present invention further disclose a computer program product, wherein when the computer program product is run on a computer, the computer is enabled to execute part or all of the steps of the methods in the above method embodiments.

[0127] A person of ordinary skill in the art can understand that all or part of the steps in the various methods of the above embodiments can be completed by instructing related hardware through a program, and the program can be stored in a computer-readable storage medium, and the storage medium includes a read-only memory (ROM), a random access memory (RAM), a programmable read-only memory (PROM), an erasable programmable read-only memory (EPROM), a one-time programmable read-only memory (OTPROM), an electronically erasable programmable read-only memory (EEPROM), a compact disc (CD-ROM) or other optical disc storage, magnetic disk storage, magnetic tape storage, or any other computer-readable medium that can be used to carry or store data.

[0128] The above is a detailed introduction to a method and control system for controlling the generation of copper sulfate pentahydrate disclosed in an embodiment of the present invention. Specific examples are used herein to illustrate the principle and implementation mode of the present invention. The description of the above embodiments is only used to help understand the method of the present invention and its core idea. At the same time, for those skilled in the art, according to the idea of ​​the present invention, there will be changes in the specific implementation mode and application scope. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. A method for controlling the generation of copper sulfate pentahydrate, characterized in that: include: When the reactor is performing a double decomposition reaction, the color of the solution in the reactor is monitored in real time using a color matching algorithm; When it is detected that the color of the solution in the reactor changes to a specified color, the turbidity value of the solution in the reactor is monitored by using the proportional relationship between turbidity and the electrical signal, and the adding speed of the acidic solution and the stirring speed of the stirring device are adjusted; When it is monitored that the turbidity value of the solution in the reactor reaches a first specified threshold value and the temperature of the solution in the reactor drops to a second specified threshold value, determining a crystallization material cleaning time according to the weight of the crystallization material in the reactor; The moisture content of the crystallized material is monitored using near infrared measurement method; After monitoring that the moisture content of the crystallized material is lower than the third specified threshold, the crystallized material is packaged according to a preset packaging weight to complete the discharge of copper sulfate pentahydrate.

2. A method for controlling the generation of copper sulfate pentahydrate according to claim 1, characterized in that: When the color of the solution in the reactor is detected to be a specified color, the turbidity value of the solution in the reactor is monitored by using the proportional relationship between the turbidity and the electrical signal, and the adding speed of the acid solution and the stirring speed of the stirring device are adjusted, including: When it is monitored that the color of the solution in the reactor changes to a specified color, the adding speed of the acidic solution is reduced, and the stirring speed of the stirring device is increased to enter the solution reaction endpoint fine-tuning stage; After receiving the light signal value reflected by the solution in the reaction kettle, converting the light signal value into an electrical signal value; After preprocessing the electrical signal value, the electrical signal value is substituted into a turbidity mathematical calculation model to calculate the turbidity value of the solution in the reactor; wherein the turbidity mathematical calculation model includes a proportional relationship between turbidity and electrical signal; If the turbidity value of the solution in the reactor reaches a first specified threshold value and the color of the solution in the reactor changes to another specified color, the addition of the acidic solution is stopped, and the temperature of the solution in the reactor is monitored.

3. A method for controlling the generation of copper sulfate pentahydrate according to claim 1, characterized in that: The method of using a color matching algorithm to monitor the color of the solution in the reactor in real time includes: Calculating in real time the cosine similarity between the color feature of the solution in the reactor and the specified color feature; When the cosine similarity is greater than a fourth specified threshold, it is determined that the color of the solution in the reaction kettle becomes a specified color.

4. A method for controlling the generation of copper sulfate pentahydrate according to claim 1, characterized in that: The step of determining the crystallization material cleaning time according to the weight of the crystallization material in the reactor comprises: The weight of the crystallized material in the reactor is substituted into the conveyor belt speed adjustment calculation formula to calculate the current conveyor belt transmission speed; wherein the conveyor belt speed adjustment calculation formula is the product of the conveyor belt power and the circumference of the conveyor belt rotating wheel divided by the product of the weight of the crystallized material, the conveyor belt friction coefficient and the conveyor belt rotating wheel radius; The current conveyor belt length is divided by the current conveyor belt transmission speed to calculate the crystal material cleaning time.

5. A method for controlling the formation of copper sulfate pentahydrate according to claim 1, characterized in that: The method of monitoring the moisture content of the crystallized material by using a near infrared measurement method comprises: When the drying equipment is started to dry the crystallized material that has reached the dry weight standard, an infrared reflection signal of the crystallized material is received; Substituting the infrared reflection signal of the crystallized material into the infrared moisture calibration curve, the moisture content value of the crystallized material is determined; wherein the infrared moisture calibration curve includes the corresponding relationship between the infrared reflection signal intensity of the material and the moisture content.

6. A method for controlling the generation of copper sulfate pentahydrate according to claim 1, characterized in that: After determining the crystallization material cleaning time according to the weight of the crystallization material in the reactor and before monitoring the moisture content of the crystallization material by using the near infrared measurement method, the method further includes: After the crystallized material in the reactor is subjected to three gradient acid reduction washings in sequence according to the crystallized material washing time, detecting whether the copper content in the primary washing liquid exceeds the set value; if so, recovering the primary washing liquid to the copper sulfate mother liquor storage tank; The secondary washing liquid is set as the new primary washing liquid, the tertiary washing liquid is set as the new secondary washing liquid, and the clean water source is set as the new tertiary washing liquid.

7. A method for controlling the generation of copper sulfate pentahydrate according to any one of claims 1 to 6, characterized in that: Before using the color matching algorithm to monitor the color of the solution in the reactor in real time, the method further includes: If the liquid level in the dilute sulfuric acid storage tank is detected to be lower than the alarm line, the current required volume of concentrated sulfuric acid and the current volume of water to be added are calculated according to the current required concentration of dilute sulfuric acid, the current required volume of dilute sulfuric acid and the current concentration of concentrated sulfuric acid; Controlling the metering pump to quantitatively deliver the currently required volume of concentrated sulfuric acid and the currently required volume of water to be added to the sulfuric acid dilution cooler through the delivery pipeline; Obtaining the density of dilute sulfuric acid measured by an online density hydrometer in the delivery pipeline; According to the density of the dilute sulfuric acid, a dilute sulfuric acid control concentration value corresponding to the density of the dilute sulfuric acid is matched from a preset dilute sulfuric acid concentration specific gravity table; If the dilute sulfuric acid control concentration value does not match the currently required dilute sulfuric acid concentration, recalculate the amount of concentrated sulfuric acid and water to be added; If the dilute sulfuric acid control concentration value matches the currently required dilute sulfuric acid concentration, when the temperature in the sulfuric acid dilution cooler reaches the specified temperature, the liquid in the sulfuric acid dilution cooler is transported to the dilute sulfuric acid storage tank through a delivery pipeline, and the liquid level alarm is released.

8. A control system, characterized in that: The control system comprises: A first monitoring unit is used to monitor the color of the solution in the reactor in real time by using a color matching algorithm when the reactor is performing a double decomposition reaction; A monitoring and adjustment unit, configured to monitor the turbidity value of the solution in the reactor by using the proportional relationship between turbidity and the electrical signal, and adjust the adding speed of the acidic solution and the stirring speed of the stirring device when the first monitoring unit detects that the color of the solution in the reactor changes to a specified color; a determination unit, configured to determine a crystallization material cleaning time according to a weight of the crystallization material in the reactor when the monitoring and adjustment unit detects that the turbidity value of the solution in the reactor reaches a first specified threshold value and the temperature of the solution in the reactor drops to a second specified threshold value; The second monitoring unit is used to monitor the moisture content of the crystallization material using a near infrared measurement method; The discharging unit is used to pack the crystallized material according to a preset packing weight to complete the discharging of copper sulfate pentahydrate after the second monitoring unit monitors that the moisture content of the crystallized material is lower than a third specified threshold value.

9. The control system according to claim 8, characterized in that: The monitoring and adjusting unit comprises: an adjusting subunit, configured to reduce the adding speed of the acidic solution and increase the stirring speed of the stirring device when the first monitoring unit detects that the color of the solution in the reactor changes to a specified color, so as to enter a solution reaction endpoint fine-tuning stage; A conversion subunit, configured to convert the optical signal value into an electrical signal value after receiving the optical signal value reflected by the solution in the reaction kettle; A first calculation subunit is used for pre-processing the electrical signal value and then substituting the electrical signal value into a turbidity mathematical calculation model to calculate the turbidity value of the solution in the reactor; wherein the turbidity mathematical calculation model includes a proportional relationship between turbidity and electrical signal; The stop and monitor subunit is used to stop adding the acidic solution and monitor the temperature of the solution in the reactor if the turbidity value of the solution in the reactor reaches a first specified threshold value and the color of the solution in the reactor changes to another specified color.

10. The control system according to claim 8, characterized in that: The control system comprises: A memory storing executable program code; a processor coupled to the memory; The processor calls the executable program code stored in the memory to execute the method for controlling the generation of copper sulfate pentahydrate according to any one of claims 1 to 7.

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