Fly ash stabilization intelligent linkage automatic control method

Abstract

The embodiment of the invention discloses an intelligent linkage automatic control method for fly ash stabilization, and relates to the technical field of solid waste treatment. The method comprises the following steps: step S101, acquiring the content of heavy metals in fly ash detected in real time; step S102, based on the detection data, automatically calculating the ratio of the chelating agent stock solution to the process water / concentrated water through a preset algorithm; s103, controlling a fly ash weighing system, a solution weighing system and a mixing mill system according to the ratio of the chelating agent stock solution to the process water / concentrated water; wherein the step S102 comprises the following steps: determining a dynamic water-cement ratio; solution concentration is automatically switched according to a water source; and calculating the amount of the chelating agent stock solution and the water amount according to mass conservation. According to the embodiment of the invention, through multi-element dynamic proportioning, full-process intelligent linkage, equipment fault self-healing and unqualified product closed-loop treatment, the problems of low stabilization efficiency, agent waste and insufficient reliability in the prior art can be solved.

Description

Technical Field

[0001] The present invention relates to the technical field of solid waste treatment, and particularly to an intelligent linkage automatic control method for fly ash stabilization. Background Art

[0002] At present, the chelating agent stabilization process is commonly used for the stabilization treatment of municipal solid waste incineration fly ash. The existing control system has the following deficiencies:

[0003] 1) Coarse proportion control: The traditional system uses a fixed ratio (such as the water-to-ash ratio, the ratio of chelating agent to fly ash), without dynamically adjusting according to the real-time changes of fly ash composition, resulting in waste of reagents or insufficient stabilization effect.

[0004] 2) Frequent manual intervention: The linkage of each subsystem (such as fly ash weighing, solution preparation, and mixer operation) is poor. It needs to be manually confirmed before starting, and the degree of automation is low.

[0005] 3) Limitation of single-element control: Only the dosing range is set for the Pb element, and the co-stabilization requirements of multiple heavy metals such as Cr, Cd, and As are not solved. In actual production, the situation often occurs that a single element meets the standard while other elements exceed the standard (such as a certain batch of fly ash with Pb meeting the standard but the Cd leaching concentration exceeding the standard).

[0006] 4) Inefficient treatment of unqualified products: Unqualified fly ash needs to be manually detected and transported, and a closed-loop automatic treatment process is not formed.

[0007] The existing technology has not formed a multi-element collaborative control model, resulting in the neglect of the leaching risk of some heavy metals. There is an urgent need for a full-element dynamic ratio technology.

[0008] The invention patent application CN108593693A discloses a dosing method and system for fly ash stabilization treatment based on XRF detection. The technical key points include:

[0009] 1) Dual-threshold determination (A value / B value):

[0010] A value: The maximum XRF concentration when the original ash leaching meets the standard (for example, the A value of Pb is 1500 mg / kg, corresponding to the leaching limit of 5 mg / L);

[0011] B value: The maximum XRF concentration when the chelated ash leaching meets the standard (for example, the B value of Pb is 3800 mg / kg). If it exceeds the B value, the chelating agent dosing amount (Y%) is increased.

[0012] 2) Multi-element coverage: Detect multiple heavy metals such as Pb, Cr, Zn, Cu, As, and Cd, and dynamically adjust the reagent formula according to whether each element exceeds the standard (X > A or X > B).

[0013] This patent application has the following disadvantages:

[0014] Threshold-dependent preliminary test: The values of A and B need to be determined in advance through a large number of leaching tests, with poor adaptability to new scenarios (such as different incinerators and reagent types) and high calibration costs.

[0015] Concentration-dosage linear assumption: When X > B value, the dosage of the chelating agent increases in a fixed proportion (e.g., Y% = 2%), without considering the change of reaction kinetics at high concentrations (which may lead to waste or insufficiency of the reagent).

[0016] Lack of equipment status monitoring: It does not involve equipment fault diagnosis (such as blockage of the transfer pump and abnormality of the agitator), and the system reliability depends on manual inspection.

[0017] The invention patent application CN112756372A discloses a method for determining the dosage of chelating agent in the fly ash stabilization process. The technical key points include:

[0018] 1) Residual amount detection: Measure the residual chelating agent in the liquid after solid-liquid separation through a turbidimeter, draw a standard curve of "chelating agent residual concentration - turbidity", and calculate the appropriate dosage (actual dosage - residual amount).

[0019] 2) On-site rapid determination: The operation steps are simple (pulping → separation → adding reagent → measuring turbidity), taking about 30 minutes, and it is suitable for on-site real-time adjustment.

[0020] This patent application has the following disadvantages:

[0021] Offline detection lag: Manual sampling and detection are required, and it cannot be linked with the production system in real time (such as the online mixer cannot dynamically adjust the dosage according to the residual amount).

[0022] Only focusing on the residual amount: It does not consider the influence of process parameters such as fly ash particle size and mixing efficiency on the chelation reaction, and the determination result may deviate from the actual demand.

[0023] No closed loop formed: Lack of an automatic reprocessing mechanism for unqualified products, and manual confirmation is required before re-adding, with low efficiency. Summary of the Invention

[0024] In view of this, the embodiments of the present invention provide an intelligent linkage automatic control method for fly ash stabilization to solve the problems of low stabilization efficiency, reagent waste, and insufficient reliability in the prior art.

[0025] An intelligent linkage automatic control method for fly ash stabilization includes:

[0026] Step S101: Obtain the heavy metal content in the fly ash detected in real time;

[0027] Step S102: Based on the detection data, automatically calculate the ratio of the chelating agent stock solution to process water / concentrated water through a preset algorithm;

[0028] Step S103: Control the fly ash weighing system, solution weighing system, and kneader system according to the ratio of the chelating agent stock solution to process water / concentrated water.

[0029] Among them, the said step S102 includes:

[0030] Step S1021: Determine the dynamic water-to-ash ratio.

[0031] Step S1022: Automatically switch the solution concentration according to the water source.

[0032] Step S1023: Calculate the amount of chelating agent stock solution and water volume according to the law of conservation of mass.

[0033] Preferably, in the said step S1021, the calculation formula for the dynamic water-to-ash ratio w is:

[0034] ;

[0035] Among them, w0: basic water-to-ash ratio, : heavy metal concentration correction factor, : total heavy metal concentration; C avg : average heavy metal concentration of regional fly ash, : water quality conductivity correction factor, EC: water source conductivity.

[0036] Preferably, in the said step S1022, the calculation formula for the solution concentration C is:

[0037] In the process water mode, , where W f is the moisture content of the fly ash;

[0038] In the concentrated water mode, .

[0039] Preferably, in the said step S1023, the law of conservation of mass formula is:

[0040] ,

[0041] ,

[0042] ,

[0043] Among them, M c : amount of chelating agent stock solution, M 溶液 : total liquid volume, : density of chelating agent stock solution, M w : water volume, M f : weight of fly ash to be treated.

[0044] Preferably, the step S103 includes:

[0045] Step S1031: Determine whether the weight of the fly ash weighing hopper reaches a first set value. If so, send a pre-start signal to the mixer;

[0046] Step S1032: Detect whether the liquid level of the solution weighing hopper is greater than or equal to a second set value. If so, start the mixer;

[0047] Step S1033: Automatically identify the water source type using a water quality sensor, add the water source to the required dosage according to the water source type, and perform stirring.

[0048] Preferably, the step S1032 includes:

[0049] If the liquid level of the solution weighing hopper is less than the second set value, automatically start the chelating agent preparation system.

[0050] Preferably, after the step S1033 includes:

[0051] Step S1034: After the stirring is completed, the on-line ICP-MS detector automatically analyzes whether the leaching toxicity of the wet ash meets the standard. If not, trigger the non-conforming product treatment process and transfer to the step S1031;

[0052] Among them, the non-conforming product treatment process includes:

[0053] Automatically mark the batch number, generate a unique traceability code, and associate the detection data with the treatment process;

[0054] And / or, control the lifting electric hoist to transfer the wet ash to the buffer silo, start the dust collector, the first-stage double-shaft shearing crusher and the second-stage hammer crusher in sequence, and the pulverized fly ash returns to the fly ash weighing hopper through the screw conveyor and re-enters the stabilization process.

[0055] Preferably, in the step S1034, when a certain heavy metal exceeds the standard for more than 2 consecutive times, increase the amount of chelating agent stock solution by 15% on the basis of the original calculated dosage.

[0056] Preferably, the step S1034 includes:

[0057] If the on-line ICP-MS detector automatically analyzes that the leaching toxicity of the wet ash meets the standard, open the discharge valve after 3.5 minutes, and delay for 90 seconds after discharging to reset to the standby state.

[0058] Preferably, the method further includes:

[0059] When the vibration amplitude, temperature or flow rate of each device exceeds the normal range, it automatically switches to the standby device, and uses acoustic and optical alarms to indicate the fault location. At the same time, it records the fault data for later maintenance. Among them, each device includes a rotary feeder, a transfer pump or a stirrer.

[0060] The present invention has the following beneficial effects:

[0061] (1) Multi-element collaborative dynamic ratio technology

[0062] Technical breakthrough: Break through the limitations of traditional single-element control, construct a dynamic dosing model, and synchronously respond to changes in the concentrations of multiple metals such as Pb, Cr, Cd, and As. For example, when the Pb concentration exceeds 1.5 times the limit value, the dosing amount of the chelating agent is automatically increased by 2% to ensure the balanced stabilization effect of multiple elements.

[0063] Beneficial effect: Compared with the fixed ratio dosing, the chemical consumption is reduced by 8%-12%, avoiding the problem that other elements exceed the standard while a single element meets the standard. The comprehensive compliance rate of leaching toxicity is increased from 91.6% to 97.2%.

[0064] (2) Three-level intelligent linkage control mechanism

[0065] Technical innovation: Design a "weighing trigger - stirring linkage - quality feedback" closed-loop process to achieve seamless connection of subsystems:

[0066] After weighing is completed, the internal mixer is automatically pre-started (with a 30s delay to prevent impact), and the chemical reserve status is intelligently judged, and automatic feeding is carried out;

[0067] The solution concentration is switched in real time according to the water quality (12% for process water / 48% for concentrated water), and the dosing accuracy is controlled within ±1.5%, solving the problem of lag in traditional manual switching;

[0068] When the wet ash test is unqualified, the batch is automatically marked and double-stage crushing and reprocessing is triggered, forming a "detection - processing - re-detection" closed-loop, and the processing efficiency is increased by 60%.

[0069] (3) Real-time monitoring of equipment status and self-healing ability

[0070] Technical advantage: Integrate the data of vibration, temperature, and flow rate sensors to establish a three-dimensional monitoring model of the equipment operation status. When the flow rate of the transfer pump is lower than 80% of the threshold value or the vibration amplitude exceeds the limit by ±10%, the standby device is automatically switched within 10s, and at the same time, acoustic and optical alarms are given and the fault data is recorded. Compared with the prior art that relies on manual inspection, the continuous operation time of the system is increased by 90%, and the fault handling response speed is increased by 80%.

[0071] (4) Automated closed-loop processing process for non-conforming products

[0072] Engineering innovation: By enhancing the linkage control of electric hoists (load capacity of 500 kg), double-shaft shear crushers (primary screen mesh of 10 mm), and hammer crushers (secondary screen mesh of 5 mm), precise control of the crushing particle size of unqualified fly ash (≤5 mm) is achieved. Additionally, based on historical unqualified data, the chemical agent dosage is automatically increased by 15%, solving the problem of low efficiency in traditional manual transfer. The reprocessing cycle is shortened to 1 / 3 of the original process.

[0073] (5) Water quality adaptive solution concentration algorithm

[0074] Process optimization: Considering the characteristics of process water and concentrated water, a differential concentration adjustment formula is designed. This algorithm stabilizes the moisture content of wet ash in the optimal range of 20% - 25% and improves the mixing uniformity by 30%.

[0075] Through the above innovations, the present invention constructs a full-process intelligent control closed-loop of "detection - calculation - execution - feedback", significantly enhancing the intelligent level, reliability, and economy of fly ash stabilization treatment. BRIEF DESCRIPTION OF THE DRAWINGS

[0076] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0077] Figure 1 It is a flow chart of the intelligent linkage automatic control method for fly ash stabilization of the present invention;

[0078] Figure 2 It is a system architecture diagram of the intelligent linkage automatic control method for fly ash stabilization of the present invention, which hierarchically shows the core modules of the system and the flow of data / materials, reflecting the closed-loop integration of detection, control, execution, and feedback;

[0079] Figure 3 It is a flow chart of the dynamic ratio control algorithm in the present invention;

[0080] Figure 4 It is a flow chart of the three-level intelligent linkage control in the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0081] The following will describe the embodiments of the present invention in detail with reference to the drawings.

[0082] It should be clear that the described embodiments are only a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0083] An embodiment of the present invention provides an intelligent linkage automatic control method for fly ash stabilization, as Figures 1-4 shown, including:

[0084] Step S101: Obtain the heavy metal content in the fly ash detected in real time;

[0085] This step can be implemented by a dynamic ratio control module, which may include an X-ray fluorescence spectrometer (XRF) and / or an on-line fly ash composition detector for detecting the heavy metal content in the fly ash in real time. Let the content of heavy metal i in the fly ash be Ci (i = 1, 2,..., n, representing different types of heavy metals, such as lead (Pb), cadmium (Cd), arsenic (As), chromium (Cr), etc.).

[0086] Step S102: Based on the detection data, automatically calculate the ratio of the chelating agent stock solution to process water / concentrated water through a preset algorithm;

[0087] This step can be executed by the Figure 2 central controller therein.

[0088] Among them, the step S102 includes:

[0089] Step S1021: Determine the dynamic water-to-ash ratio;

[0090] As another alternative embodiment, in the step S1021, the calculation formula of the dynamic water-to-ash ratio w is:

[0091] ;

[0092] wherein, w0 = 25% (basic water-to-ash ratio, determined by standard mixing tests);

[0093] : heavy metal concentration correction factor (value range 0.01 - 0.03, slightly increasing water demand at higher concentrations to promote reaction uniformity);

[0094] : total concentration of heavy metals such as Pb, Cd, As, etc. (mg / kg);

[0095] C avg = 2000 mg / kg (average heavy metal concentration of regional fly ash, can be calibrated);

[0096] : water quality conductivity correction factor (process water = 0.05, concentrated water = 0.1, reducing the amount of free water used at high conductivity);

[0097] EC: conductivity of the water source ( (the process water is usually < 500, and the concentrated water is 1000 - 3000).

[0098] This formula indicates that: the higher the heavy metal concentration, the slightly increased amount of dispersion medium (water) required for the chelation reaction ( item). When the conductivity of the concentrated water is high, the activity of free water decreases, and the theoretical water consumption needs to be reduced ( negatively correlated).

[0099] Step S1022: Automatically switch the solution concentration according to the water source;

[0100] As another optional embodiment, in the step S1022, the calculation formula for the solution concentration C is:

[0101] In the process water mode, , where W f is the moisture content of the fly ash. At this time, the higher the moisture content, the slightly decreased solution concentration to avoid over - wetness, and it is dynamically adjusted according to the moisture content to avoid dust or adhesion caused by over - wetness;

[0102] In the concentrated water mode, , at this time, the higher the conductivity, the slightly decreased concentration to prevent salting - out, and it is automatically compensated according to the conductivity to prevent the chelation effect from being affected by salting - out.

[0103] Step S1023: Calculate the amount of chelating agent stock solution and the amount of water (i.e., the process water / concentrated water amount) according to the law of conservation of mass.

[0104] As yet another optional embodiment, in the step S1023, the law of conservation of mass formula is:

[0105] ,

[0106] ,

[0107] ,

[0108] where M c : the amount of chelating agent stock solution (kg);

[0109] M 溶液 : the total liquid amount (kg), determined by the dynamic water - to - ash ratio w.

[0110] = 1.1t / m 3 (the density of the chelating agent stock solution, which can be calibrated according to the chemical agent model);

[0111] M w : the amount of water (kg);

[0112] M f : the weight of fly ash to be treated (kg);

[0113] This formula explicitly correlates the solution concentration C with the water source type. Through mass conservation calculations, it ensures that the total amount of water and chelating agent meets the requirements of the mixing process for the moisture content of the materials (such as the moisture content of wet ash being 20% - 25%).

[0114] Such as Figure 3 As shown, through the above steps S1021 - S1023, the dynamic ratio control algorithm can be completed. This algorithm is based on the fly ash component detection data and calculates the dosing ratio of the chelating agent and water through a multi - element dynamic model. It includes heavy metal concentration response, water quality adaptive adjustment, and mass conservation calculation, focusing on the real - time calculation of multi - element concentration and water quality to solve the deficiencies of traditional fixed ratios.

[0115] Step S103: Control the fly ash weighing system, solution weighing system, and mixing machine system according to the ratio of the chelating agent stock solution to process water / concentrated water;

[0116] This step can be realized through the full - process intelligent linkage module. This module includes three - level linkage control units for the fly ash weighing system, solution weighing system, and mixing machine system, realizing three - level signal interaction of weighing trigger, stirring linkage, and quality feedback. The process can be as follows:

[0117] Weighing trigger: The fly ash weighing hopper reaches the standard → Pre - start the mixing machine (with a 30 - second delay);

[0118] Stirring linkage: Automatically switch the solution concentration according to the water quality, and the flowmeter accuracy is controlled within ±1.5%;

[0119] Quality feedback: Discharge after the wet ash detection reaches the standard, and trigger the automatic re - processing process if it does not meet the standard.

[0120] As an alternative embodiment, such as Figure 4 As shown, step S103 includes:

[0121] Step S1031: Determine whether the weight of the fly ash weighing hopper reaches the first set value. If so, send a pre - start signal to the mixing machine;

[0122] This step corresponds to the weighing trigger in the above process. Specifically, when the weight of the fly ash weighing hopper reaches the first set value (the first set value can be flexibly set according to requirements), the system sends a pre - start signal to the mixing machine and starts with a 30 - second delay to avoid impact load.

[0123] Step S1032: Detect whether the liquid level of the solution weighing hopper is greater than or equal to the second set value. If so, start the mixing machine;

[0124] Preferably, step S1032 includes:

[0125] If the liquid level in the solution weighing bucket is less than the second set value (the second set value can be flexibly set according to demand, such as 10%, 20%, 30%, etc.), the chelating agent (stock solution) preparation system is automatically started (preparation time ≤ 8 minutes).

[0126] Step S1033: Use the water quality sensor to automatically identify the type of water source, add water to the required amount according to the type of water source, and stir.

[0127] This step corresponds to the stirring linkage in the above process, and mainly realizes stirring and proportioning control. When implemented specifically, it may include:

[0128] Process water mode: Open the pneumatic valve and control the dosage through the electromagnetic flowmeter (accuracy ±1.5%);

[0129] Concentrated water mode: Activate the concentrated water flow meter, which will automatically shut down when the preset threshold is reached, and simultaneously switch the chelating agent solution concentration to 48%±3%.

[0130] Through steps S1031 to S1033, the fly ash weighing system, the solution weighing system and the mixer system can be linked to achieve three-level linkage control (that is, engineering realization of intelligent linkage process).

[0131] As another optional embodiment, the step S1033 includes:

[0132] Step S1034: After the stirring is completed, the online ICP-MS detector automatically analyzes whether the wet ash leaching toxicity meets the standard. If not, the unqualified product (closed loop) processing flow is triggered and the process goes to step S1031;

[0133] This step mainly implements quality inspection and feedback.

[0134] The defective product handling process includes:

[0135] Automatically mark batch numbers, generate unique traceability codes, and associate test data with processing procedures;

[0136] And / or, control the lifting electric hoist to transfer the wet ash to the buffer silo, start the dust collector, the first-stage double-shaft shear crusher and the second-stage hammer crusher in sequence, and the crushed fly ash returns to the fly ash weighing hopper through the screw conveyor and re-enters the stabilization process.

[0137] This step can be implemented by the unqualified fly ash closed-loop treatment module, which may include an unqualified fly ash automatic recognition unit (based on the heavy metal leaching toxicity test results). Assume that the qualified standard for heavy metal leaching toxicity is L0. When the detected heavy metal leaching toxicity L > L0, it is determined as unqualified fly ash. Improve the full-automatic linkage control unit of the electric hoist, crusher, and screw conveyor to realize the full-process automation of unqualified fly ash from detection, crushing, and recycling to re-stabilization treatment without manual intervention.

[0138] Preferably, if the leaching toxicity of wet ash does not meet the standard, the system automatically adjusts the dosage of the chelating agent according to historical unqualified data (such as the type of heavy metal exceeding the standard, the multiple of exceeding the standard, and the historical treatment records) of this batch. The specific rule is: when a certain heavy metal exceeds the standard for more than 2 consecutive times, increase the amount of the chelating agent stock solution by 15% (i.e., M c new =M c ×1.15) on the basis of the originally calculated dosage to strengthen the stabilization reaction.

[0139] As yet another alternative embodiment, the step S1034 includes:

[0140] If the on-line ICP-MS detector automatically analyzes that the leaching toxicity of wet ash meets the standard, the discharge valve is opened after 3.5 minutes, and after discharging, it is reset to the standby state after a delay of 90 seconds.

[0141] As yet another alternative embodiment, the method further includes:

[0142] When it is detected that the vibration amplitude, temperature, or flow rate of each device exceeds the normal range, it is automatically switched to the standby device, and the fault location is prompted through an audible and visual alarm. At the same time, the fault data is recorded for later maintenance, where each device includes a rotary feeder, a transfer pump, or a stirrer.

[0143] This step is a fault diagnosis and self-healing mechanism, which can be implemented by the fault diagnosis and self-healing module. This module may include vibration sensors, temperature sensors, and flow sensors of each device (rotary feeder, transfer pump, stirrer) to monitor the operation status of the device in real time. When the parameters exceed the normal range, it is switched to the standby device within 10 seconds, and the fault is recorded.

[0144] Specifically, during implementation, assume that the normal vibration amplitude range of the device is [A1, A2], the normal temperature range is [T1, T2], and the normal flow rate range is [Q1, Q2]. When it is detected that the vibration amplitude A, temperature T, or flow rate Q of the device exceeds the normal range, that is or or , the system automatically switches to the standby device (automatic switching of the main and standby pumps), and the fault location is prompted through an audible and visual alarm. At the same time, the fault data is recorded for later maintenance.

[0145] As shown Figure 4 in the figure above, after the above steps S1031 - S1034, the full - process linkage of fly ash weighing, mixer startup, solution dosing, and quality inspection can be achieved, including a three - stage trigger logic and equipment interlock, forming a quality control closed - loop.

[0146] Implementation case:

[0147] (1) Input parameters (corresponding to step S101):

[0148] Fly ash batch: 620 kg, water content 18%, XRF test values: Pb = 1800 mg / kg (GB18598 limit 1.2 mg / L), Cd = 300 mg / kg (limit 0.6 mg / L), As = 100 mg / kg (limit 1.2 mg / L);

[0149] Water source: concentrated water ( ), with a set water - to - ash ratio of 28%.

[0150] (2) Dynamic ratio calculation (corresponding to step S102):

[0151] Since Pb exceeds the limit by 1.5 times, the calculation is as follows:

[0152] Concentrated water mode: ;

[0153] Total liquid volume: ;

[0154] Chelating agent stock solution volume: ;

[0155] Concentrated water volume: .

[0156] Through the dynamic water - to - ash ratio and solution concentration algorithm, the system realizes automatic increase of chelating agent dosing amount for high - concentration fly ash to ensure sufficient multi - element stabilization reaction; automatically reduces the solution concentration in the case of high conductivity of concentrated water to prevent reagent failure; and through mass conservation calculation, strictly controls the water content of wet ash within the process requirements range, improving the mixing uniformity and stabilization effect.

[0157] (3) Engineering implementation of intelligent linkage process (corresponding to step S103):

[0158] The fly ash weighing system, solution weighing system, and mixer system operate in linkage, performing three - level linkage control:

[0159] Weighing trigger: When the weight of the fly ash weighing hopper reaches 620 kg (the first set value is 620 kg at this time), the system sends a pre-start signal to the mixer and starts after a 30s delay to avoid impact load; meanwhile, the liquid level of the solution weighing hopper is detected. If it is <20%, the chelating agent preparation system is automatically started (preparation time ≤ 8 min).

[0160] Stirring and ratio control: After the mixer is started, the water quality sensor automatically identifies the water source type:

[0161] Process water mode: Open the pneumatic valve and control the dosing amount through the electromagnetic flowmeter (accuracy ±1.5%). For example, if the target for a single batch is 155 kg, the actual dosing amount is 155 ± 2.3 kg;

[0162] Concentrated water mode: Activate the concentrated water flowmeter and automatically close it when it reaches 116 kg ± 1.7 kg. Synchronously switch the concentration of the chelating agent solution to 48% ± 3%.

[0163] Quality detection and feedback: After stirring is completed, the on-line ICP-MS detector automatically analyzes the leaching toxicity of the wet ash:

[0164] Up to standard: Open the discharge valve after 3.5 min, and reset to the standby state after a 90s delay after discharging;

[0165] Not up to standard: The system automatically marks the batch number (such as "20250510-001"), triggers the lifting electric hoist to transfer it to the buffer silo, starts the crusher (primary crushing to <10 mm, secondary crushing to <5 mm), and the fly ash after crushing returns to the weighing system for reprocessing. The secondary dosing amount increases dynamically by 10% - 20% according to historical data.

[0166] (4)Fault diagnosis and self-healing mechanism:

[0167] When the detection value Q of the flow sensor of the chelating agent delivery pump is 40 L / min, which is lower than the lower limit Q1 = 50 L / min of the normal range, the system determines it as "flow anomaly" and automatically executes:

[0168] a) Stop the current pump and switch to the standby pump (switching time ≤ 10 s);

[0169] b) A red alarm pops up on the operation interface, showing "Delivery pump blocked (pump number: P-001)", and records the fault time and type;

[0170] c) After the maintenance personnel clean the filter screen, manually reset the equipment, and the system resumes automatic operation.

[0171] (5)Closed-loop processing flow for non-conforming products (corresponding to step S1034):

[0172] When the wet ash detection determines non-conformity (such as heavy metal leaching concentration L > L0), the system automatically executes:

[0173] a) Marking batches: Generate a unique traceability code (such as "RE-20250510-001") and associate the detection data with the processing flow;

[0174] b) Transfer and pulverization: Control the lifting electric hoist to transfer the wet ash to the buffer silo (with a capacity of 500 kg), and sequentially start the dust collector (air volume 1000 m³ / h), the first-stage double-shaft shear crusher (screen aperture 10 mm), and the second-stage hammer crusher (screen aperture 5 mm);

[0175] c) Return processing: The pulverized fly ash returns to the fly ash weighing hopper through a screw conveyor (conveying speed 0.5 m / s) and re-enters the stabilization process.

[0176] In summary, the intelligent linkage automatic control method for fly ash stabilization of the present invention processes fly ash through multi-element dynamic ratio, full-process intelligent linkage, equipment fault self-healing, and closed-loop processing of non-conforming products, solving the problems of low stabilization efficiency, reagent waste, and insufficient reliability in the prior art. The present invention is specifically an automatic control method for fly ash stabilization based on dynamic ratio and full-process intelligent linkage, and is particularly suitable for the chelating stabilization treatment of municipal solid waste incineration fly ash. The present invention has the following beneficial effects:

[0177] (1) Multi-element collaborative dynamic ratio technology

[0178] Technical breakthrough: Break through the limitation of traditional single-element control, construct a dynamic dosing model, and synchronously respond to the changes in the concentrations of multiple heavy metals such as Pb, Cr, Cd, and As. For example, when the Pb concentration exceeds 1.5 times the limit value, the chelating agent dosing amount is automatically increased by 2% to ensure the balanced stabilization effect of multiple elements.

[0179] Beneficial effect: Compared with the fixed ratio dosing, the reagent consumption is reduced by 8%-12%, avoiding the problem that other elements exceed the standard while a single element meets the standard, and the comprehensive compliance rate of leaching toxicity is increased from 91.6% to 97.2%.

[0180] (2) Three-level intelligent linkage control mechanism

[0181] Technical innovation: Design a "weighing trigger - stirring linkage - quality feedback" closed-loop process to achieve seamless connection of subsystems:

[0182] After weighing is completed, the mixer is automatically pre-started (with a 30 s delay to prevent impact), and the reagent reserve status is intelligently judged and automatic feeding is carried out;

[0183] According to the water quality, the solution concentration is switched in real time (process water 12% / concentrated water 48%), and the dosing accuracy is controlled within ±1.5%, solving the problem of lag in traditional manual switching;

[0184] When the wet ash detection is unqualified, the batch is automatically marked and double-stage crushing reprocessing is triggered, forming a closed loop of "detection - processing - re-detection", and the processing efficiency is increased by 60%.

[0185] (3)Real-time monitoring and self-healing ability of equipment status

[0186] Technical advantages: Integrate the data of vibration, temperature, and flow sensors to establish a three-dimensional monitoring model of the equipment operation status. When the flow rate of the transfer pump is lower than 80% of the threshold or the vibration amplitude exceeds the limit by ±10%, the standby equipment is automatically switched within 10 seconds, and at the same time, an audible and visual alarm is given and the fault data is recorded. Compared with the existing technology that relies on manual inspection, the continuous operation time of the system is increased by 90%, and the fault handling response speed is increased by 80%.

[0187] (4)Automated closed-loop processing flow for non-conforming products

[0188] Engineering innovation: By improving the linkage control of the electric hoist (load 500 kg), double-shaft shear crusher (primary screen 10 mm), and hammer crusher (secondary screen 5 mm), precise control of the crushing particle size of non-conforming fly ash (≤5 mm) is achieved, and the chemical agent dosage is automatically increased by 15% according to historical non-conforming data, solving the problem of low efficiency in traditional manual transfer. The reprocessing cycle is shortened to 1 / 3 of the original process.

[0189] (5)Water quality adaptive solution concentration algorithm

[0190] Process optimization: Design differential concentration adjustment formulas for the characteristics of process water and concentrated water. This algorithm stabilizes the moisture content of wet ash in the optimal range of 20% - 25%, and the stirring uniformity is increased by 30%.

[0191] Through the above innovations, the present invention constructs a full-process intelligent control closed loop of "detection - calculation - execution - feedback", significantly improving the intelligent level, reliability, and economy of fly ash stabilization treatment.

[0192] The above is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention should be covered by the protection scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims.

Claims

1. An intelligent linkage automatic control method for fly ash stabilization, characterized in that Including: Step S101: Obtain the heavy metal content in fly ash detected in real time; Step S102: Based on the detection data, automatically calculate the ratio of the chelating agent stock solution to process water / concentrated water through a preset algorithm; Step S103: Control the fly ash weighing system, solution weighing system, and kneader system according to the ratio of the chelating agent stock solution to process water / concentrated water; Among them, the said Step S102 includes: Step S1021: Determine the dynamic water-to-ash ratio; Step S1022: Automatically switch the solution concentration according to the water source; Step S1023: Calculate the amount of chelating agent stock solution and water amount according to the law of conservation of mass.

2. The intelligent linkage automatic control method for fly ash stabilization according to claim 1, wherein In the said Step S1021, the calculation formula for the dynamic water-to-ash ratio w is: ； where, w0: basic water-cement ratio, : heavy metal concentration correction factor, : total sum of heavy metal concentrations; C avg : average heavy metal concentration of regional fly ash, : water quality conductivity correction factor, EC: conductivity of water source.

3. The intelligent linkage automatic control method for fly ash stabilization according to claim 2, wherein In the said Step S1022, the calculation formula for the solution concentration C is: In the process water mode, , where W f is the moisture content of fly ash; In the concentrated water mode, .

4. The intelligent linkage automatic control method for fly ash stabilization according to claim 3, wherein In the said Step S1023, the law of conservation of mass formula is: ， ， ， Among them, M c : The amount of chelating agent stock solution, M 溶液 : The total liquid volume, : The density of chelating agent stock solution, M w : The amount of water, M f : The weight of fly ash to be treated.

5. The intelligent linkage automatic control method for fly ash stabilization according to any one of claims 1-4, characterized in that The said Step S103 includes: Step S1031: Judge whether the weight of the fly ash weighing hopper reaches the first set value. If so, send a pre-start signal to the kneader; Step S1032: Detect whether the liquid level of the solution weighing hopper is greater than or equal to the second set value. If so, start the kneader; Step S1033: Automatically identify the water source type by using a water quality sensor, add the water source to the required dosage according to the water source type, and perform stirring.

6. The intelligent linkage automatic control method for fly ash stabilization according to claim 5, wherein The said Step S1032 includes: If the liquid level of the solution weighing hopper is less than the second set value, automatically start the chelating agent preparation system.

7. The intelligent linkage automatic control method for fly ash stabilization according to claim 5, wherein After the said Step S1033 includes: Step S1034: After stirring is completed, the on-line ICP-MS detector automatically analyzes whether the leaching toxicity of the wet ash meets the standard. If not, trigger the non-conforming product handling process and transfer to the said Step S1031; Among them, the said non-conforming product handling process includes: Automatically mark the batch number, generate a unique traceability code, and associate the detection data with the handling process; And / or, control the lifting electric hoist to transfer the wet ash to the buffer silo, sequentially start the dust collector, the first-stage double-shaft shear crusher, and the second-stage hammer crusher. The pulverized fly ash returns to the fly ash weighing hopper through the screw conveyor and re-enters the stabilization process.

8. The intelligent linkage automatic control method for fly ash stabilization according to claim 7, characterized in that, In the said Step S1034, when a certain heavy metal exceeds the standard for more than 2 consecutive times, increase the amount of chelating agent stock solution by 15% on the basis of the original calculated dosage.

9. The intelligent linkage automatic control method for fly ash stabilization according to claim 7, wherein The said Step S1034 includes: If the on-line ICP-MS detector automatically analyzes that the leaching toxicity of the wet ash meets the standard, open the discharge valve after 3.5 minutes, and delay for 90 seconds after discharging to reset to the standby state.

10. The intelligent linkage automatic control method for fly ash stabilization according to claim 5, wherein The said method further includes: When it is detected that the vibration amplitude, temperature, or flow rate of each device exceeds the normal range, automatically switch to the standby device, prompt the fault location through sound and light alarm, and record the fault data for later maintenance. Among them, each device includes a rotary feeder, a transfer pump, or a stirrer.

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