A flash furnace copper matte transfer system and its automatic control method

Abstract

This invention discloses a flash furnace matte transfer system and its automatic control method. The system includes a transfer trolley, a ground wireless communication device, a ground control system, a matte bag crane, a bag crane wireless communication device, and a matte bag crane control system. This invention enables fully automatic control of flash furnace matte transfer, reducing manual operation and improving transfer efficiency. Furthermore, it ensures stable operation and precise positioning of the transfer trolley, effectively preventing matte overflow during tapping, significantly reducing labor costs and equipment failure rates, and minimizing safety risks.

Description

Technical Field

[0001] This invention relates to the field of chemical smelting technology, specifically to a flash furnace matte transfer system and automatic control method. Background Technology

[0002] Currently, the transfer of matte in the flash furnace is accomplished manually through three copper outlets, utilizing three matte ladle chambers and three sets of matte transfer trolleys. Operators use observation holes to maneuver the trolleys into and out of the matte ladle chambers to transfer the matte. After the copper loading is completed, a walkie-talkie is used to contact the ladle hoist to transport the matte ladle to the next process step. However, with continuously increasing production, this manual operation method is inefficient and can no longer meet operational demands. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention aims to provide a flash furnace matte transfer system and an automatic control method.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A flash furnace copper matte transfer system includes a transfer trolley, a ground wireless communication device, a ground control system, a copper matte hoist, a hoist wireless communication device, and a copper matte hoist control system.

[0006] The transfer trolley includes driven wheels, drive wheels, a reducer, a variable frequency motor, a forward deceleration limit sensor, a forward stop limit sensor, a reverse stop limit sensor, a reverse deceleration limit sensor, and a trolley platform. Drive wheels and driven wheels are respectively mounted on the rear and front sides of the bottom of the trolley platform. The variable frequency motor is driven by the reducer. One output shaft of the reducer is connected to one of the drive wheels, and the other output shaft is connected to the other drive wheel. A reverse stop limit sensor and a reverse deceleration limit sensor are located at the rear end of one side of the trolley platform, with the reverse stop limit sensor located in front of the reverse deceleration limit sensor. A forward deceleration limit sensor and a forward stop limit sensor are located at the front end of one side of the trolley platform, with the forward deceleration limit sensor located in front of the forward stop limit sensor.

[0007] Each copper matte hoist's control system is equipped with a wireless communication device. The ground control system is connected to the ground wireless communication device, and the ground control system and the copper matte hoist control system can communicate through the communication between the ground wireless communication device and the hoist wireless communication device. Each copper outlet of the flash furnace is equipped with a compartment. The compartment door is controlled by the ground control system, and the open and closed positions of the compartment door are respectively equipped with open and closed infrared sensors, both of which are connected to the ground control system.

[0008] Furthermore, an ultrasonic level gauge is installed above the copper outlet of the flash furnace. When the transfer trolley is located at the copper outlet, the ultrasonic level gauge corresponds exactly to the inside of the matte ladle carried by the transfer trolley, and is used to detect the matte level inside the matte ladle and transmit it to the ground control system.

[0009] Furthermore, the front and rear ends of the vehicle platform are respectively equipped with anti-collision cones.

[0010] Furthermore, a forward limit sensor is provided at the front end of one side of the vehicle platform. The forward limit sensor is located in front of the forward deceleration limit sensor and is connected to the ground control system.

[0011] Furthermore, the reverse stop limit sensor, reverse deceleration limit sensor, forward deceleration limit sensor, forward stop limit sensor, and forward extreme limit sensor all use proximity switches.

[0012] Furthermore, the system also includes an infrared sensor for copper foil, which is installed at the origin of the transfer trolley to detect whether the trolley platform is carrying copper foil and transmit the detection signal to the ground control system.

[0013] This invention also provides an automatic control method for the transfer of flash furnace matte using the above system, the specific process of which is as follows:

[0014] When the flash furnace reaches the matte production cycle, the operator triggers the instruction to produce matte from the chamber on the human-machine interface of the ground control system.

[0015] The ground control system detects whether the transfer trolley is currently at the origin; if so, it controls the compartment door to open.

[0016] When the compartment door is fully opened, the infrared sensor sends a signal to the ground control system. The ground control system then sends a control command to the transfer trolley, which in turn controls the transfer trolley carrying the empty ice copper jar to move from the origin position toward the copper outlet position.

[0017] As the transfer trolley enters the compartment through the compartment door and approaches the copper outlet, the forward deceleration limit sensor and the forward stop limit sensor at the front of the trolley platform feed back status signals to the ground control system. The ground control system controls the trolley platform to decelerate and stop based on the status signals of the forward deceleration limit sensor and the forward stop limit sensor, so that the transfer trolley can accurately reach the copper outlet and stop.

[0018] After the transfer trolley arrives at the copper outlet, the ground control system delays the time set to close the compartment door. Once the infrared sensor detects that the compartment door is closed, it sends a signal to the ground control system. The ground control system then displays the closed status of the compartment door on the human-machine interface. The operator then opens the copper outlet of the flash furnace according to the closed status of the compartment door and operates the copper dispensing.

[0019] After the copper matte liquid level reaches the full level, the ground control system delays for a set time to control the compartment door to open. After receiving the signal from the infrared sensor that the door is in the open position, it delays for a set time to control the transfer trolley to start reversing and return to the original position. During the reversal, the system controls the transfer trolley to decelerate and stop according to the status signals of the reversal deceleration limit sensor and the reversal stop limit sensor to ensure that the transfer trolley accurately returns to the original position.

[0020] The ground control system sends data to the ladle crane's wireless communication device via a ground wireless communication device. The ladle crane's wireless communication device then transmits the data to the copper matte ladle crane at the smelting plant. The data includes the copper matte full level status and the status of the transfer trolley returning to its original position. Based on this data, the copper matte ladle crane control system controls the copper matte ladle crane to perform actions, transferring the copper matte ladles on the transfer trolley to the next process.

[0021] Furthermore, in the above method, the bun crane control system also controls the copper molten metal bun crane to lift empty copper molten metal buns onto a transfer trolley that is not carrying copper molten metal buns.

[0022] Furthermore, in the above method, the compartment door cannot operate when the transfer trolley is not at the origin or the copper outlet position.

[0023] Furthermore, in the above method, during the copper tapping process, the ultrasonic level gauge installed above the copper tapping port senses the level of the copper matte in the copper matte bag and transmits the level signal to the ground control system. When the ground control system determines that the copper matte level is about to reach the full level based on the level signal, the status information that the copper matte level is about to reach the full level is displayed on the human-machine interface. Based on this, the operator blocks the copper tapping port and stops the copper tapping.

[0024] The beneficial effects of this invention are as follows: It enables fully automated control of flash furnace matte transfer, reducing manual operation and improving transfer efficiency. Furthermore, it ensures smooth operation and precise positioning of the transfer trolley, effectively preventing matte overflow during the tapping process, significantly reducing labor costs and equipment failure rates, and minimizing safety risks. Attached Figure Description

[0025] Figure 1 This is a field deployment example diagram of the system in Embodiment 1 of the present invention;

[0026] Figure 2This is a plan view of the transfer trolley in Embodiment 1 of the present invention;

[0027] Figure 3 This is a side view of the transfer trolley in Embodiment 1 of the present invention;

[0028] Figure 4 This is a flowchart of the method in Embodiment 2 of the present invention. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings. It should be noted that this embodiment is based on the present technical solution and provides detailed implementation methods and specific operation processes, but the protection scope of the present invention is not limited to this embodiment.

[0030] Example 1

[0031] This embodiment provides a flash furnace copper matte transfer system, including a transfer trolley, a ground wireless communication device, a ground control system, a copper matte hoist, a hoist wireless communication device, and a copper matte hoist control system. A schematic diagram of the on-site deployment of the transfer trolley, ground wireless communication device, copper matte hoist, and hoist wireless communication device is shown below. Figure 1 As shown.

[0032] like Figure 2 As shown, the transfer trolley includes driven wheels 3, drive wheels 4, shafts 5, a reducer 6, a variable frequency motor 7, a forward deceleration limit sensor 8, a forward stop limit sensor 9, a backward stop limit sensor 10, a backward deceleration limit sensor 11, and a trolley platform 12. Drive wheels 4 and driven wheels 3 are respectively mounted on the rear and front sides of the bottom of the trolley platform 12. The variable frequency motor 7 is driven by the reducer 6. One output shaft of the reducer 6 is connected to one of the drive wheels 4, and the other output shaft is connected to the other drive wheel 4 (in this embodiment, they are connected via shaft 5). A backward stop limit sensor 10 and a backward deceleration limit sensor 11 are provided at the rear end of one side of the trolley platform 12, with the backward stop limit sensor 10 located in front of the backward deceleration limit sensor 11. A forward deceleration limit sensor 8 and a forward stop limit sensor 9 are provided at the front end of one side of the trolley platform 12, with the forward deceleration limit sensor 8 located in front of the forward stop limit sensor 9.

[0033] Each copper matte hoist's control system is equipped with a wireless communication device. The ground control system is connected to the ground wireless communication device, and the ground control system and the copper matte hoist control system can communicate through the communication between the ground wireless communication device and the hoist wireless communication device. Each copper outlet of the flash furnace is equipped with a compartment. The compartment door is controlled by the ground control system, and the open and closed positions of the compartment door are respectively equipped with open and closed infrared sensors, both of which are connected to the ground control system.

[0034] In this embodiment, an ultrasonic level gauge is installed above the copper outlet of the flash furnace. When the transfer trolley is located at the copper outlet, the ultrasonic level gauge corresponds exactly to the inside of the matte ladle carried by the transfer trolley, and is used to detect the matte level inside the matte ladle and transmit it to the ground control system.

[0035] It should be noted that ultrasonic level gauges are digital level instruments controlled by a microprocessor. During measurement, ultrasonic pulses are emitted by a sensor (transducer). The sound waves are reflected by the liquid surface and received by the same sensor, converted into electrical signals by a piezoelectric crystal, and the distance from the sensor to the measured liquid surface is calculated from the time between the emission and reception of the sound waves. Accurate detection of the copper matte level can prevent overflow and avoid safety accidents.

[0036] In this embodiment, the front and rear ends of the vehicle platform 12 are respectively provided with anti-collision cones 1.

[0037] In this embodiment, a forward limit sensor 2 is also provided at the front end of one side of the trolley platform 12. The forward limit sensor 2 is located in front of the forward deceleration limit sensor 8 and is connected to the ground control system. The forward limit sensor 2 can transmit a signal to the control system that the transfer trolley has reached the forward limit position, further ensuring that the transfer trolley can stop in time and avoid collisions.

[0038] In this embodiment, the reverse stop limit sensor 10, the reverse deceleration limit sensor 11, the forward deceleration limit sensor 8, the forward stop limit sensor 9, and the forward extreme limit sensor 2 all employ proximity switches. The proximity switches accurately detect the deceleration and stop positions of the transfer trolley, enabling precise positioning of the transfer trolley.

[0039] In this embodiment, both the ground control system and the copper bun crane control system adopt PLC controllers, specifically Siemens S7-1200 PLC.

[0040] In this embodiment, as Figure 3As shown, the system also includes a copper ladle infrared sensor 13, which is installed at the origin of the transfer trolley to detect whether the trolley platform is carrying a copper ladle and transmit the detection signal to the ground control system. Only when the trolley platform is carrying a copper ladle will the ground control system control the transfer trolley to move to the copper outlet, and the copper ladle hoisting control system will control the hoist to perform the copper ladle hoisting operation.

[0041] In this embodiment, both the ground wireless communication device and the bunker crane wireless communication device are industrial Ethernet wireless communication modules. The industrial Ethernet wireless communication module supports high-speed dual-frequency transmission with anti-interference capabilities, a 1-master-multiple-slave wireless self-organizing network, a 2x2 two-transmit, two-receive wireless architecture, an air transmission speed of up to 300Mbps, compatibility with Siemens S7, Profinet, Modbus TCP / IP, and other communication protocols, and employs OFDM modulation and MINO technology, achieving a transmission distance of over 3KM.

[0042] Example 2

[0043] This embodiment provides an automatic control method for the transfer of flash furnace matte using the system described in Embodiment 1, such as... Figure 4 As shown, the specific process is as follows:

[0044] When the flash furnace reaches the matte production cycle, the operator triggers the instruction to produce matte from the chamber on the human-machine interface of the ground control system.

[0045] The ground control system detects whether the transfer trolley is currently at the origin; if so, it controls the compartment door to open.

[0046] When the compartment door is fully opened, the infrared sensor sends a signal to the ground control system. The ground control system then sends a control command to the transfer trolley, which in turn controls the transfer trolley carrying the empty ice copper jar to move from the origin position toward the copper outlet position.

[0047] As the transfer trolley enters the compartment through the compartment door and approaches the copper outlet, the forward deceleration limit sensor and the forward stop limit sensor at the front of the trolley platform feed back status signals to the ground control system. The ground control system controls the trolley platform to decelerate and stop based on the status signals of the forward deceleration limit sensor and the forward stop limit sensor, so that the transfer trolley can accurately reach the copper outlet and stop.

[0048] After the transfer trolley reaches the copper outlet, the ground control system delays for 5 seconds to close the compartment door. Once the infrared sensor detects that the compartment door is closed, it sends a signal to the ground control system. The ground control system displays the closed status of the compartment door on the human-machine interface. The operator then opens the copper outlet of the flash furnace according to the closed status of the compartment door and operates the copper dispensing.

[0049] After the copper matte liquid level reaches full, the ground control system controls the compartment door to open after a 5-minute delay. After receiving the signal from the infrared sensor indicating that the door is fully open, it controls the transfer trolley to start reversing after a 10-second delay, returning to the original position. During the reversal, the system controls the transfer trolley to decelerate and stop based on the status signals of the reversal deceleration limit sensor and the reversal stop limit sensor, ensuring that the transfer trolley accurately returns to the original position.

[0050] The ground control system sends data to the ladle crane's wireless communication device via a ground wireless communication device. The ladle crane's wireless communication device then transmits the data to the copper matte ladle crane at the smelting plant. The data includes the full level status of the copper matte and the status data of the transfer trolley returning to its original position. Based on this data, the copper matte ladle crane control system controls the copper matte ladle crane to perform actions, transferring the copper matte ladle on the transfer trolley to the next process (in this embodiment, it is transferred to the converter).

[0051] In this embodiment, the bun crane control system also controls the copper foil bun crane to lift empty copper foil buns onto a transfer trolley that is not carrying copper foil buns.

[0052] In this embodiment, to prevent the compartment door from malfunctioning, the compartment door cannot move when the transfer trolley is not at its origin or copper outlet position.

[0053] In this embodiment, during the copper tapping process, the ultrasonic level gauge installed above the copper tapping port senses the level of the copper matte in the copper matte ladle and transmits the level signal to the ground control system. When the ground control system determines that the copper matte level is about to reach the full level based on the level signal, the status information that the copper matte level is about to reach the full level is displayed on the human-machine interface. Based on this, the operator blocks the copper tapping port and stops the copper tapping.

[0054] In this embodiment, the ground control system communicates with the variable frequency motor of the transfer trolley. By controlling the variable frequency motor, the system controls the speed of the transfer trolley. Specifically, it can control the transfer trolley to run at high speed when unloaded and at medium speed when fully loaded, and control the transfer trolley to decelerate and stop, making the operation of the transfer trolley more stable.

[0055] For those skilled in the art, various corresponding changes and modifications can be made based on the above technical solutions and concepts, and all such changes and modifications should be included within the protection scope of the claims of this invention.

Claims

1. An automatic control method for transferring matte in a flash furnace, characterized in that, The specific process is as follows: When the flash furnace reaches the matte production cycle, the operator triggers the instruction to produce matte from the chamber on the human-machine interface of the ground control system. The ground control system detects whether the transfer trolley is currently at the origin; if so, it controls the compartment door to open. When the compartment door is fully opened, the infrared sensor sends a signal to the ground control system. The ground control system then sends a control command to the transfer trolley, which in turn controls the transfer trolley carrying the empty ice copper jar to move from the origin position toward the copper outlet position. As the transfer trolley enters the compartment through the compartment door and approaches the copper outlet, the forward deceleration limit sensor and the forward stop limit sensor at the front of the trolley platform feed back status signals to the ground control system. The ground control system controls the trolley platform to decelerate and stop based on the status signals of the forward deceleration limit sensor and the forward stop limit sensor, so that the transfer trolley can accurately reach the copper outlet and stop. After the transfer trolley arrives at the copper outlet, the ground control system delays the time set to close the compartment door. Once the infrared sensor detects that the compartment door is closed, it sends a signal to the ground control system. The ground control system then displays the closed status of the compartment door on the human-machine interface. The operator then opens the copper outlet of the flash furnace according to the closed status of the compartment door and operates the copper dispensing. After the copper matte liquid level reaches the full level, the ground control system delays for a set time to control the compartment door to open. After receiving the signal from the infrared sensor that the door is in the open position, it delays for a set time to control the transfer trolley to start reversing and return to the original position. During the reversal, the system controls the transfer trolley to decelerate and stop according to the status signals of the reversal deceleration limit sensor and the reversal stop limit sensor to ensure that the transfer trolley accurately returns to the original position. The ground control system sends data to the ladle crane's wireless communication device via a ground wireless communication device. The ladle crane's wireless communication device then transmits the data to the copper matte ladle crane at the smelting plant. The data includes the copper matte full level status and the status of the transfer trolley returning to its original position. Based on this data, the copper matte ladle crane control system controls the copper matte ladle crane to perform actions, transferring the copper matte ladles on the transfer trolley to the next process.

2. The method according to claim 1, characterized in that, The bun crane control system also controls the copper ballast crane to lift empty copper ballast ...

3. The method according to claim 1, characterized in that, The compartment door cannot be moved if the transfer trolley is not at its original position or the copper outlet position.

4. The method according to claim 1, characterized in that, During the copper tapping process, an ultrasonic level gauge installed above the copper outlet senses the level of the matte liquid in the matte ladle and transmits the level signal to the ground control system. The ground control system determines that the matte liquid level is about to reach the full level based on the level signal. When the ground control system determines that the matte liquid level is about to reach the full level, the status information of the matte liquid level about to reach the full level is displayed on the human-machine interface. Based on this, the operator blocks the copper outlet and stops the copper tapping.

5. A flash furnace matte transfer system for implementing the method of any one of claims 1-4, characterized in that, It includes a transfer trolley, a ground wireless communication device, a ground control system, a copper-clad bun crane, a bun crane wireless communication device, and a copper-clad bun crane control system; The transfer trolley includes driven wheels, drive wheels, a reducer, a variable frequency motor, a forward deceleration limit sensor, a forward stop limit sensor, a reverse stop limit sensor, a reverse deceleration limit sensor, and a trolley platform. Drive wheels and driven wheels are respectively mounted on the rear and front sides of the bottom of the trolley platform. The variable frequency motor is driven by the reducer. One output shaft of the reducer is connected to one of the drive wheels, and the other output shaft is connected to the other drive wheel. A reverse stop limit sensor and a reverse deceleration limit sensor are located at the rear end of one side of the trolley platform, with the reverse stop limit sensor located in front of the reverse deceleration limit sensor. A forward deceleration limit sensor and a forward stop limit sensor are located at the front end of one side of the trolley platform, with the forward deceleration limit sensor located in front of the forward stop limit sensor. Each copper matte hoist's control system is equipped with a wireless communication device. The ground control system is connected to the ground wireless communication device, and the ground control system and the copper matte hoist control system can communicate through the communication between the ground wireless communication device and the hoist wireless communication device. Each copper outlet of the flash furnace is equipped with a compartment. The compartment door is controlled by the ground control system, and the open and closed positions of the compartment door are respectively equipped with open and closed infrared sensors, both of which are connected to the ground control system.

6. The flash furnace matte transfer system according to claim 5, characterized in that, An ultrasonic level gauge is installed above the copper outlet of the flash furnace. When the transfer trolley is located at the copper outlet, the ultrasonic level gauge corresponds exactly to the inside of the copper matte ladle carried by the transfer trolley, and is used to detect the copper matte level inside the ladle and transmit it to the ground control system.

7. The flash furnace matte transfer system according to claim 5, characterized in that, The front and rear ends of the vehicle platform are respectively equipped with anti-collision cones.

8. The flash furnace matte transfer system according to claim 5, characterized in that, The front end of one side of the vehicle platform is also equipped with a forward limit sensor, which is located in front of the forward deceleration limit sensor and is connected to the ground control system.

9. The flash furnace matte transfer system according to claim 8, characterized in that, The reverse stop limit sensor, reverse deceleration limit sensor, forward deceleration limit sensor, forward stop limit sensor, and forward limit sensor all use proximity switches.

10. The flash furnace matte transfer system according to claim 5, characterized in that, The flash furnace copper matte transfer system also includes a copper matte ladle infrared sensor, which is installed at the origin of the transfer trolley to detect whether the trolley platform is carrying a copper matte ladle and transmit the detection signal to the ground control system.

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