Intelligent system and method for preparing roasting filler from anode production dust collection powder for aluminum electrolysis

Abstract

The invention provides a pollution-free and automatic system and method for preparing a roasting filler from collected dust powder, and aims to solve the problem that the collected dust powder is difficult to utilize in the production process of carbon for aluminum electrolysis. According to the intelligent system and method, the steps of raw material pretreatment of dust collection powder, intelligent batching, controllable pressure ball granulation, waste gas treatment and circulation and the like are integrated, and automatic production is achieved through a central control system based on the industrial internet of things. According to the implementation of the method, the labor intensity of dust collection powder preparation can be effectively reduced, meanwhile, pollution discharge is avoided, hazardous waste resource utilization is achieved, and the production efficiency and the product percent of pass are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the field of resource utilization of aluminum industry solid waste, and particularly to a system and method for preparing roasting filler from dust collection powder.

[0002] In the field of aluminum electrolysis anode manufacturing, the dust collection powder (mainly composed of petroleum coke fine powder and asphalt volatiles) generated in processes such as anode scrap crushing and calcination has long faced problems in resource utilization due to its high ash content and large particle fineness. Industry data shows that about 300 tons of dust collection powder is generated per 10,000 tons of anode production. Existing treatment methods mostly adopt open-air stacking or landfilling, which not only causes the loss of high-quality carbon raw materials (the annual loss is estimated to exceed hundreds of millions of yuan at current prices), but also leads to the PM2.5 value exceeding the standard due to material dispersion, forming a typical industrial solid waste pollution source. Especially the polycyclic aromatic hydrocarbon substances such as benzo[a]pyrene remaining in the dust collection powder are easily leached and pollute the soil and groundwater in the open-air environment, constituting a major environmental risk. Background Art

[0003] There are three major technical bottlenecks in current granulation technologies: First, the particles formed by simple mechanical pressing have insufficient strength and are prone to powdering during the roasting stage, resulting in abnormal porosity of the filler; Second, the open production process leads to dust escape rate and VOCs emission concentration exceeding the standard limits; Third, the traditional production mode has high labor intensity and poor operating environment. And conventional binders (such as lignosulfonates) will generate sulfur-containing waste gas during high-temperature roasting, forming cross-contamination with the electrolysis process. These defects seriously restrict the technical feasibility of preparing filler from dust collection powder. Summary of the Invention

[0004] In view of the problems existing in the current granulation technology, the present invention provides an automated system and method for preparing roasting filler from dust collection powder for aluminum electrolysis anodes, realizing the effective utilization of dust collection powder, reducing the production intensity, and having no pollution emissions.

[0005] To achieve the above object, the present invention adopts the following technical solutions:

[0006] An intelligent system and method for preparing roasting filler from dust collection powder for aluminum electrolysis anodes, characterized by comprising: a dust collection powder pretreatment system, an intelligent batching system, a fully enclosed granulation system, an environmental treatment system, and a central control system;

[0007] An intelligent system and method for preparing roasting filling materials from the dust collected during the production of anodes for aluminum electrolysis. It is characterized in that the dust collected is transported by a negative-pressure conveying pipeline and enters the raw material pretreatment system; the processed materials enter the intelligent batching system through the negative-pressure conveying pipeline, and are evenly mixed with adhesives and curing agents in a certain proportion to form granulating materials, which then enter the fully enclosed granulating system; subsequently, the materials are prepared into granules with appropriate particle sizes by a briquetting machine and then enter a microwave-hot air composite drying tower for drying and curing; the cured granules can be transported out to replace part of the anode roasting filling materials.

[0008] The dust pretreatment system is equipped with a negative-pressure conveying device with an anti-static diversion groove, an electromagnetic iron remover, a high-frequency ultrasonic screening machine, and an air classification device integrated with particle size detection, which can effectively remove impurities and abnormal particle size components in the dust collected.

[0009] The intelligent batching system includes a closed-loop ratioing system equipped with dual-channel redundant metering pumps, and realizes precise metering of the dust collected, modified asphalt-based binder, and water-based curing agent through loss-in-weight feeders, and can achieve intelligent mixing of the dust collected materials.

[0010] The fully enclosed granulating system integrates a pressure-adjustable briquetting machine with multi-spectral quality detection, a microwave-hot air composite drying tower, and a particle size screening and recycling device with a material return function, and can prepare the materials into 3-6 mm granules with good mechanical strength.

[0011] The noise isolation enclosure, gas circulation treatment unit, and workshop negative-pressure dust collection device in the environmental treatment system can effectively reduce the dust in the workshop and simultaneously achieve efficient utilization of gas and water.

[0012] The central control system based on the industrial Internet of Things integrates a digital twin operation platform, an equipment vibration spectrum early warning module, and a UWB personnel positioning unit, providing guarantees for the remote control of the workshop, equipment fault prediction and analysis, personnel safety, etc.

[0013] Optionally, an LIBS on-line component analyzer is configured at the outlet of the pretreatment system, and data interaction with the central control system is carried out through the OPC UA protocol to guide the ratio adjustment in real time.

[0014] Optionally, the intelligent batching system uses an intelligent bin for the dust collected equipped with a fluidized bed anti-caking device, and the curing agent bin integrates a constant temperature heat tracing system.

[0015] Optionally, the microwave-hot air composite drying tower uses a composite drying method of microwave and low-temperature hot air to achieve rapid drying and curing of the granules. Description of the Drawings

[0016] Figure 1 This is the process flow chart of the intelligent system and method for preparing roasting filling materials from the dust collected during the production of anodes for aluminum electrolysis applicable to the present invention. Specific Embodiments

[0017] The following will combine with the attached Figure 1 drawings and specific embodiments to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0018] The present invention provides an intelligent system for preparing roasting filler from anode production dust in aluminum electrolysis, including a dust pretreatment system, an intelligent batching system, a fully enclosed granulation system, an environmental treatment system, and a central control system;

[0019] 1) The dust pretreatment system is equipped with a negative pressure conveying device (working pressure 0.05 - 0.15 MPa) with an anti-static diversion groove, an electromagnetic iron remover (iron content ≤ 0.03 wt% after treatment), a high-frequency ultrasonic screening machine (removing agglomerates > 3 mm at 28 - 40 kHz), and an air classification device integrated with particle size detection (classification accuracy of 200 - 800 meshes); among them, the raw material negative pressure conveying device is equipped with an anti-static diversion groove and a material accelerator, the electromagnetic iron remover is provided with a gradient magnetic field intensity adjustment module, the high-frequency ultrasonic screening machine is equipped with an amplitude automatic compensation device, the air vortex classification device is integrated with an on-line particle size detection unit, a laser-induced breakdown spectroscopy on-line composition analyzer is set at the outlet of the pretreatment system and connected to the raw material database of the central control system through a data bus, and the qualified treated materials are connected to the intelligent batching system through an air lock type discharge valve.

[0020] 2) The intelligent batching system includes a dust intelligent bin, a binder intelligent bin, and a curing agent constant temperature storage tank. Each bin is connected to a loss-in-weight metering feeder through a negative pressure conveying pipeline and then connected to a closed mixer. A temperature sensor and a moisture monitor are installed in the mixer to analyze the state of the mixed materials in real time. The metering pump group is equipped with a dual-channel redundancy system and a self-calibration function module.

[0021] 3) The fully enclosed granulation system integrates a pressure-adjustable briquetting machine (forming pressure 20 - 50 MPa) with multi-spectral quality detection, a microwave-hot air composite drying tower (microwave frequency 300 - 500 MHz), and a particle size screening and recycling device with a material return function, which can prepare the materials into 3 - 6 mm particles with good mechanical strength; among them, the briquetting machine integrates a multi-spectral imaging quality detection module to monitor the briquetting quality in real time. A gaseous pollutant component sensor is installed at the gas outlet of the drying tower and connected to the environmental treatment system. The screening and recycling device returns the materials with unqualified particle size to the pretreatment system.

[0022] 4) The environmental treatment system includes a noise isolation enclosure, a gas circulation treatment unit, and a workshop negative pressure dust collection device. The gas circulation treatment unit is equipped with a volatile organic compound catalytic oxidation module and a wastewater condensation and filtration module;

[0023] 5) The central control system based on the industrial Internet of Things integrates a digital twin operation platform, a device vibration spectrum warning module, and a UWB personnel positioning unit.

[0024] On the other hand, the present invention provides an intelligent method for preparing roasting filler from the dust collected during the production of anodes for aluminum electrolysis. The specific embodiments are as follows:

[0025] Step 1) Pretreatment of the collected dust: The dust collected during the manufacture of aluminum electrolysis anodes is transported to an electromagnetic iron remover under a negative pressure of 0.05 MPa through a raw material negative pressure conveying device equipped with an anti-static diversion groove. Through the gradient magnetic field intensity adjustment module, the iron content of the treated material is ≤ 0.03 wt%. Then, the material passes through a high-frequency ultrasonic sieve shaker with a frequency of 28 kHz to remove agglomerated materials larger than 3 mm, and then enters an air flow vortex classifier to achieve precise classification of materials with particle sizes of 20 - 800 mesh using a centrifugal force field. The laser-induced breakdown spectroscopy on-line composition analyzer at the outlet of the pretreatment system detects the material composition in real time and transmits it to the central control system. The qualified material after treatment enters the intelligent batching system through an air lock type discharge valve;

[0026] Step 2) Intelligent batching: The collected dust, binder, and curing agent enter the loss-in-weight metering feeder through negative pressure conveying pipelines respectively. Under the control of the central control system, precise metering of the collected dust, a modified asphalt-based binder that is low-temperature dried and non-volatile, and a water-based curing agent is carried out according to the set ratio, and then they are transported to a closed mixer. The temperature sensor and moisture monitor in the mixer analyze the state of the mixed material in real time. The dual-channel redundant system and self-calibration function module of the metering pump group ensure the batching accuracy, and the uniformly mixed granulated material enters the fully enclosed granulation system;

[0027] Step 3) Fully enclosed granulation: The granulated material enters a pressure-adjustable briquetting machine and is formed under a pressure of 20 MPa. The quality of the briquetting is monitored in real time through a multi-spectral imaging quality detection module. The formed particles enter a microwave-hot air drying tower, and the drying tower uses a composite drying method of 300 MHz microwave frequency and low-temperature hot air for rapid drying and curing. The gaseous pollutant composition sensor at the gas outlet of the drying tower monitors the exhaust gas composition and transmits it to the environmental treatment system. The particle size screening and recovery device outputs qualified particles with a particle size of 3 - 6 mm for replacing part of the anode roasting filler, and the materials with unqualified particle sizes are returned to the pretreatment system;

[0028] Environmental treatment: The workshop walls are covered with noise isolation enclosures to reduce the noise generated during equipment operation. A negative pressure dust collection device in the workshop collects dust to prevent it from escaping. The gas circulation treatment unit is equipped with a catalytic oxidation module for volatile organic compounds and a wastewater condensation and filtration module to treat the exhaust gas discharged from the drying tower. The treated gas is recycled for the drying process, and the condensed water is recycled for the granulation process, achieving efficient utilization of gas and water resources;

[0029] Central control system operation: The central control system based on the industrial Internet of Things uses a distributed sensor network to collect the process parameters of each system in real time. The digital twin operation platform simulates and monitors the entire production process in real time based on the collected data. The preventive maintenance warning module analyzes the vibration spectrum of the equipment through machine vision to predict equipment failures and issue warnings. The adaptive optimization algorithm library dynamically adjusts the process parameters according to the raw material characteristics to ensure efficient and stable production. The system integrates a worker position monitoring unit based on UWB positioning to monitor the position of workers in the workshop in real time and ensure the safety of workers.

Claims

1. An intelligent system and method for preparing roasting filling materials from the dust collected during the production of anodes for aluminum electrolysis, characterized in that, It includes a dust collection powder pretreatment system, an intelligent batching system, a fully enclosed granulation system, an environmental treatment system, and a central control system based on the industrial Internet of Things. The system realizes the whole-process dynamic monitoring of process parameters through a distributed sensor network, uses an adaptive closed-loop control algorithm to adjust production parameters in real time, and connects each subsystem through a closed pneumatic conveying pipeline to form a dust-free continuous production line.

2. The system according to claim 1, wherein The dust collection powder pretreatment system includes a raw material negative pressure conveying device, an electromagnetic iron remover, a high-frequency ultrasonic screening machine, and an air flow vortex classification device. Among them, the raw material negative pressure conveying device is equipped with an anti-static diversion groove and a material accelerator. The electromagnetic iron remover is provided with a gradient magnetic field intensity adjustment module. The high-frequency ultrasonic screening machine is equipped with an amplitude automatic compensation device. The air flow vortex classification device integrates an online particle size detection unit. A laser-induced breakdown spectroscopy online composition analyzer is set at the outlet of the pretreatment system and connected to the raw material database of the central control system through a data bus. The qualified materials after treatment are connected to the intelligent batching system through an air lock type discharge valve.

3. The system according to claim 1, wherein The intelligent batching system includes a dust collection powder intelligent bin, a binder intelligent bin, and a curing agent constant temperature storage tank. Each bin is connected to a loss-in-weight metering feeder through a negative pressure conveying pipeline and finally connected to a closed mixer to form a raw material ratio closed-loop control system. A temperature sensor and a moisture monitor are installed in the mixer to analyze the state of the mixed materials in real time. The metering pump group is equipped with a dual-channel redundancy system and a self-calibration function module.

4. The system according to claim 1, wherein The fully enclosed granulation system consists of a pressure-adjustable briquetting machine, a microwave-hot air drying tower, and a particle size screening and recycling device. Among them, the briquetting machine integrates a multi-spectral imaging quality detection module to monitor the briquetting quality in real time. A gaseous pollutant composition sensor is installed at the gas outlet of the drying tower and connected to the environmental treatment system. The screening and recycling device returns the materials with unqualified particle size to the pretreatment system.

5. The system according to claim 1, wherein The environmental treatment system includes a noise isolation cover covering the workshop walls, a workshop negative pressure dust collection device, and a gas circulation treatment unit. Among them, the gas circulation treatment unit is provided with a volatile organic compound catalytic oxidation module and a waste water condensation and filtration module. The treated gas is recycled for the drying process, and the condensed water is recycled for the granulation process.

6. The system according to claim 1, wherein The central control system includes a digital twin operation platform, a preventive maintenance warning module, and an adaptive optimization algorithm library. Among them, the preventive maintenance warning module analyzes the vibration spectrum of the equipment through machine vision. The adaptive optimization algorithm library dynamically adjusts the process parameters according to the raw material characteristics. The system also integrates a worker position monitoring unit based on UWB positioning.

7. The system according to claim 2, wherein The working process of the pretreatment system is specifically as follows: The raw material negative pressure conveying device conveys the dust collection powder under a negative pressure of 0.05 - 0.15 MPa. After being treated by the electromagnetic iron remover, the iron content of the material is ≤ 0.03 wt%. The ultrasonic screening machine removes the agglomerated materials > 3 mm at a frequency of 28 - 40 kHz. The air classification device realizes the precise classification of materials with a particle size of 200 - 800 meshes through a centrifugal force field.

8. The full-automatic production method based on the system described in claims 1-7, characterized in that, Including: The dust collected is transported through a negative pressure pipeline, enters the batching system after pretreatment, and is mixed with a binder and a curing agent in proportion to form a granulating material. After being pressed into shape, dried by microwave-hot air composite drying and screened, granules that replace the anode baking filler are obtained. Among them, the water-based curing agent is used as the curing agent, and the binder is a modified asphalt-based thermosetting material with low-temperature drying and no volatiles.

9. The method according to claim 8, wherein During the drying process of the granules, the water-based curing agent solidifies to provide sufficient strength for the granules; during the anode baking process, the binder forms a polycondensation cross-linked structure to obtain granules with a petroleum coke-like structure.

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