Compound fertilizer device product component control system and control method thereof

Abstract

The application discloses a compound fertilizer device product component control system and a control method thereof. The control system comprises a solid-phase material adding system, a mixing and granulating system and a product component proportion control system. The control method is used for back-calculation of the content of each component of a product through the instantaneous value and the cumulative value of the product component proportion of each metering scale and a urine flow meter. When short-time material feeding fluctuation occurs, whether the material feeding fluctuation causes the product component proportion to not satisfy the control index can be judged in combination with the material component of the system, the product component is controlled to be within the control qualified range, and when the product component proportion exceeds the range, personnel are automatically prompted to adjust the product component proportion, so that the production of unqualified products is reduced.

Description

Technical Field

[0001] This invention relates to the field of compound fertilizer production technology, specifically to a product component control system and control method for a compound fertilizer production unit. Background Technology

[0002] Currently, the main methods used in domestic compound fertilizer production include the molten slurry method, the solid pelleting method, and the blending method. However, there is no automatic control method for the proportion of components in the process control of the produced products. The proportion of product components is controlled by manually counting bags on-site and designing simple formulas. This method involves manually deducing the content of each component in the product, which has the drawback of not displaying the instantaneous value of the product component proportion. When there is a short-term fluctuation in the amount of feed, it is impossible to judge whether the fluctuation in the amount of feed has caused the product nutrient content to fail to meet the control indicators in combination with the nutrient content of the system materials. There is a possibility that the nutrient content of the entire batch of products is qualified, but the nutrient content of some products fluctuates, resulting in unqualified products entering the market. Summary of the Invention

[0003] To address the problems in the prior art, this invention provides a product component control system and control method for a compound fertilizer device.

[0004] A product component control system for a compound fertilizer device includes: a solid material addition system, a mixing and granulation system, and a product component ratio control system. The solid material addition system includes: weighing scale A, weighing scale B, weighing scale C, weighing scale D, weighing scale E, weighing scale F, weighing scale G, weighing scale H, potash fertilizer raw material scraper, potash fertilizer upper tower bucket elevator, potash fertilizer scraper, phosphate fertilizer raw material scraper, phosphate fertilizer upper tower bucket elevator, and phosphate fertilizer scraper. The mixing and granulation system includes: a primary mixing tank, a secondary mixing tank, an emulsifier, and a granulator; The feed end of the potash fertilizer raw material scraper is connected to weighing scales A, B, C, D, and E respectively; the discharge end of the potash fertilizer raw material scraper is connected to the potash fertilizer upper tower bucket elevator; the potash fertilizer upper tower bucket elevator is connected to the feed end of the primary mixing tank through the potash fertilizer scraper, the discharge end of the primary mixing tank is connected to the feed end of the secondary mixing tank, the discharge end of the secondary mixing tank is connected to the feed end of the emulsifier, and the discharge end of the emulsifier is connected to the granulator; the feed end of the primary mixing tank is connected to urine via a flow meter. The feed end of the phosphate fertilizer raw material scraper is connected to the weighing scales F, G, and H respectively; the discharge end of the phosphate fertilizer raw material scraper is connected to the phosphate fertilizer upper tower bucket elevator, and the phosphate fertilizer upper tower bucket elevator is connected to the feed end of the secondary mixing tank through the phosphate fertilizer scraper.

[0005] The product component ratio control system is connected to the measurement signal output terminals of the weighing scales A20, B, C, D, E, F, G, H, and urine flow meter, respectively. The product component ratio control system has "clear", "start", "convert", and "shift handover" buttons, and can display a product component ratio calculation trend chart. The "clear" button and the "shift handover" button are linked. The product component ratio control system can import electronic formula tables as shown below.

[0006] A control method for a compound fertilizer device product component control system includes: calculating the content of each component of the product by reverse calculation using the instantaneous value and cumulative value of the product component percentage of each metering scale and urine flow meter; when there is a short-term fluctuation in the amount of feed, judging whether the fluctuation in the amount of feed causes the product component percentage to fail to meet the control index by combining the system material composition; controlling the product component to be within the control range; and automatically prompting personnel to adjust the product component percentage if it exceeds the range, thereby reducing the generation of unqualified products. Furthermore, when performing reverse calculations, the instantaneous and cumulative values ​​of solid materials measured by each weighing scale and urine measured by the urine flow meter during the shift are simultaneously imported into the electronic formula table. The proportion of raw materials is manually entered into the formula table, and the content of each component of the product is calculated by the calculation formula in the electronic formula table, thereby realizing the automatic calculation of the proportion of product components.

[0007] Furthermore, the product component percentage cumulative value calculation steps are as follows: taking 12 hours (8:00-20:00) as the unit of time, the shift personnel reset the cumulative value of each weighing scale and the cumulative urine flow measurement in the formula table to zero by pressing the "zero" button or the "shift handover" button of each weighing scale. Then, it is automatically imported into the product component percentage calculation trend chart, and then the cumulative value of each weighing scale and the cumulative urine flow measurement of the next shift are calculated to calculate the product component percentage. Furthermore, the steps for calculating the instantaneous value of the product component proportion are as follows: the cumulative value of each weighing scale and urine flow meter used for 10 seconds is added to the cumulative value of each weighing scale and urine flow meter in the previous hour in the system to obtain the instantaneous cumulative value, which is then introduced into the formula table to calculate the instantaneous value of the product component proportion; if the device is operating normally and continuously, the instantaneous value range is the sum of the cumulative amount of each liquid and solid phase material in the previous hour of system operation and the cumulative value of each material used for 10 seconds to calculate the instantaneous component proportion of the product; if the device is in start-up, the cumulative value of each material is automatically calculated, and the instantaneous value is calculated according to the above steps after one hour of continuous operation.

[0008] Furthermore, when the system needs to switch production, before the system switches production and feeds materials, the cumulative values ​​of all materials in the previous formula are cleared by pressing the "Clear" button and imported into the trend chart of product component proportion calculation. When a similar formula device switches production online, the product component proportion calculation trend chart of the previous product is saved by pressing the "Convert" button, and the electronic formula table of the new product is imported to calculate the component proportion of the next product. The calculation logic of the cumulative component proportion and instantaneous component proportion of the product remains unchanged.

[0009] Furthermore, the calculation formula for the aforementioned formula table is as follows: G. Total Nitrogen (N) Calculation Formula: Total Nitrogen = Cumulative value of urine flow meter per unit time * 46.4% + Cumulative value of weighing scale #0 * Nitrogen content in the input material + Cumulative value of weighing scale A * Nitrogen content in the input material + ... + Cumulative value of weighing scale H * Nitrogen content in the input material) / Total value of each material usage.

[0010] H. Calculation formula for phosphorus pentoxide (P2O5): Phosphorus pentoxide = (Cumulative value of weighing scale #0 * value of phosphorus pentoxide in the input material + Cumulative value of weighing scale A * value of phosphorus pentoxide in the input material + ... + Cumulative value of weighing scale H * value of phosphorus pentoxide in the input material) / Total value of all materials used.

[0011] I. Potassium oxide (K2O) calculation formula: Potassium oxide = (Cumulative value of weighing scale #0 * Potassium oxide value in the input material + Cumulative value of weighing scale A * Potassium oxide value in the input material + ... + Cumulative value of weighing scale H * Potassium oxide value in the input material) / Total value of each material usage.

[0012] J. Total nutrient calculation formula: Total nutrients = Total nitrogen (N) + Phosphorus pentoxide (P2O5) + Potassium oxide (K2O).

[0013] K, Sulfur content (S) calculation formula: Sulfur content = (Cumulative value of weighing scale #0 * Sulfur ion value in the input material + Cumulative value of weighing scale A * Sulfur ion value in the input material + ... + Cumulative value of weighing scale H * Sulfur ion value in the input material) / Total value of each material usage.

[0014] L. Chlorine content (CL) calculation formula: Chlorine content = (cumulative value of weighing scale #0 * chloride ion value in the input material + cumulative value of weighing scale A * chloride ion value in the input material + ... + cumulative value of weighing scale H * chloride ion value in the input material) / total amount of each material used.

[0015] Compared with existing technologies, the present invention has the following beneficial effects: This system and method enables the control of the component ratios in the batch production of compound fertilizer products. In a decentralized chemical control system, the proportions of raw materials are manually input through a distribution table, and the content of each component in the product is calculated using formulas from the distribution table, combined with a weighing scale and a urine flow meter. Compared to the traditional method of manually calculating the product component ratios in compound fertilizer plants, this method is simpler to operate, more applicable, more accurate, and more efficient; it also allows for more precise control and adjustment of product quality. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the product component control system of a compound fertilizer device according to the present invention. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will now be clearly and completely described with reference to the accompanying drawings: like Figure 1 As shown, a product component control system for a compound fertilizer device according to the present invention includes: a solid material addition system, a mixing and granulation system, and a product component ratio control system 8. The solid material addition system includes: weighing scale A20, weighing scale B1, weighing scale C2, weighing scale D3, weighing scale E4, weighing scale F5, weighing scale G6, weighing scale H7, potash fertilizer raw material scraper 10, potash fertilizer upper tower bucket elevator 11, potash fertilizer scraper 12, phosphate fertilizer raw material scraper 13, phosphate fertilizer upper tower bucket elevator 14, and phosphate fertilizer scraper 15. The mixing and granulation system includes: a primary mixing tank 16, a secondary mixing tank 17, an emulsifier 18, and a granulator 19; The feed end of the potash fertilizer raw material scraper 10 is connected to weighing scales A20, B1, C2, D3, and E4 respectively for weighing the feed material; the discharge end of the potash fertilizer raw material scraper 10 is connected to the potash fertilizer upper tower bucket elevator 11; the potash fertilizer upper tower bucket elevator 11 is connected to the feed end of the primary mixing tank 16 through the potash fertilizer scraper 12, the discharge end of the primary mixing tank 16 is connected to the feed end of the secondary mixing tank 17, the discharge end of the secondary mixing tank 17 is connected to the feed end of the emulsifier 18, and the discharge end of the emulsifier 18 is connected to the granulator 19; the feed end of the primary mixing tank 16 is connected to urine via a flow meter 9. After being weighed, the potash fertilizer raw materials are fed into the potash fertilizer raw material scraper 10. The materials are then lifted to the top of the granulation tower by the potash fertilizer upper tower bucket elevator 11 and enter the primary mixing tank 16 via the potash fertilizer scraper 12. At the same time, urine enters the primary mixing tank 16 through the flow meter 9 and is heated by steam to form a molten slurry containing nitrogen and potassium oxide.

[0018] The feed end of the phosphate fertilizer raw material scraper 13 is connected to the weighing scales F5, G6, and H7 respectively; the discharge end of the phosphate fertilizer raw material scraper 13 is connected to the phosphate fertilizer upper tower bucket elevator 14, and the phosphate fertilizer upper tower bucket elevator 14 is connected to the feed end of the secondary mixing tank 17 through the phosphate fertilizer scraper 15. After being weighed, the phosphate fertilizer raw materials are fed into the secondary mixing tank 17 via the phosphate fertilizer raw material scraper 13 and the phosphate fertilizer upper tower bucket elevator 14. At the same time, the primary mixing tank 16 is heated by steam to form a molten slurry containing two components, nitrogen and potassium oxide, which enters the secondary mixing tank 17 and is heated by steam to form a molten slurry containing three components, nitrogen, potassium oxide and phosphorus pentoxide.

[0019] The product component ratio control system 8 (DCS control system) is connected to the measurement signal output terminals of the weighing scales A20, B1, C2, D3, E4, F5, G6, H7, and urine flow meter 9, respectively. In practice, solid materials containing potassium oxide and liquid urine are sent to a primary mixing tank, where they are heated with steam to 110-125°C to melt and form a slurry, ensuring the mixing process meets the required conditions. Simultaneously, the molten slurry flows to a secondary mixing tank, where solid materials containing phosphorus pentoxide are added. The mixture is then heated with steam to 95-115°C to melt and form a slurry, ensuring its fluidity for granulation. The molten slurry containing nitrogen, potassium oxide, and phosphorus pentoxide is then rapidly rotated and cut to form a low-temperature eutectic, homogeneous slurry compound. This compound then enters a granulator, where it is centrifuged through a special nozzle to form uniformly sized droplets. These droplets are then sprayed into a naturally ventilated and cooled granulation tower. As they fall, they undergo sufficient heat exchange with the rising cold air, solidifying into granules with good granule properties. System return material is added to the primary and secondary mixing tanks to adjust the slurry viscosity, meeting the granulation slurry fluidity requirements. Throughout the process, the proportions of each component in the product are controlled to meet the national standards for compound fertilizers.

[0020] The product component ratio control system 8 has "clear", "start", "convert", and "shift handover" buttons, and can display a product component ratio calculation trend chart. The "clear" button and the "shift handover" button are linked. Pressing one of them will simultaneously perform "clear" or "shift handover". The product component ratio control system 8 can import the electronic formula table shown below.

[0021] Table 1 Electronic Recipe Table

[0022] A control method for a compound fertilizer device product component control system includes: using the instantaneous and cumulative values ​​of the product component proportions of each weighing scale and urine flow meter 9 to back-calculate the content of each component in the product; when there is a short-term fluctuation in the amount of feed, it can be combined with the system material composition to determine whether the fluctuation in the amount of feed causes the product component proportions to fail to meet the control indicators, and control the product components within the control range; if they exceed the range, it will automatically prompt personnel to adjust the product component proportions to reduce the generation of unqualified products. Specifically, the instantaneous and cumulative values ​​of solid materials measured by each weighing scale and urine measured by urine flow meter 9 during the shift are synchronously imported into the electronic formula table. The proportion of raw materials is manually entered into the formula table, and the content of each component of the product is calculated by the calculation formula in the electronic formula table, so as to realize the automatic calculation of the proportion of product components.

[0023] Specifically, the calculation logic for the cumulative value of product component proportion is as follows: taking 12 hours (8:00-20:00) as the unit of time, the shift personnel reset the cumulative value of each weighing scale and the cumulative urine flow measurement in the formula table by pressing the "zero" button or the "shift handover" button of each weighing scale. Then, it is automatically imported into the product component proportion calculation trend chart, and then the cumulative value of each weighing scale and the cumulative urine flow measurement of the next shift are calculated to calculate the product component proportion. Specifically, the calculation logic for the instantaneous value of product component proportion is as follows: The cumulative value of each weighing scale and urine flow meter 9 during 10 seconds of operation is added to the cumulative value of each weighing scale and urine flow meter 9 during the previous hour in the system to obtain the instantaneous cumulative value, which is then introduced into the formula table to calculate the instantaneous value of product component proportion. If the device is operating normally and continuously, the instantaneous value range is the sum of the cumulative amount of each liquid and solid phase material during the previous hour of system operation and the cumulative value of each material during 10 seconds of operation to calculate the instantaneous component proportion of the product. If the device is in start-up, the cumulative value of each material is automatically calculated, and the instantaneous value is calculated according to the above steps after 1 hour of continuous operation.

[0024] Product component ratio calculation control logic for switching production: Before the unit switches production and feeds materials, press the "Clear" button to clear the cumulative value of all materials in the previous formula and import it into the trend chart of product component ratio calculation; when a similar formula unit switches production online, press the "Convert" button to save the product component ratio calculation trend chart of the previous product, import the electronic formula table of the new product for the component ratio calculation of the next product, and the calculation logic of product cumulative component ratio and instantaneous component ratio remains unchanged.

[0025] The calculation formula for the aforementioned formula table is as follows: M, Total Nitrogen (N) Calculation Formula: Total Nitrogen = Cumulative value of urine flow meter per unit time * 46.4% + Cumulative value of weigher #0 * Nitrogen content in the input material + Cumulative value of weigher A * Nitrogen content in the input material + ... + Cumulative value of weigher H * Nitrogen content in the input material) / Total value of each material usage.

[0026] N, Phosphorus pentoxide (P2O5) calculation formula: Phosphorus pentoxide = (Cumulative value of weighing scale #0 * Phosphorus pentoxide value in the input material + Cumulative value of weighing scale A * Phosphorus pentoxide value in the input material + ... + Cumulative value of weighing scale H * Phosphorus pentoxide value in the input material) / Total value of all materials used.

[0027] O. Potassium oxide (K2O) calculation formula: Potassium oxide = (Cumulative value of weighing scale #0 * Potassium oxide value in the material added + Cumulative value of weighing scale A * Potassium oxide value in the material added + ... + Cumulative value of weighing scale H * Potassium oxide value in the material added) / Total value of all materials used.

[0028] P. Total nutrient calculation formula: Total nutrient = Total nitrogen (N) + Phosphorus pentoxide (P2O5) + Potassium oxide (K2O).

[0029] Q. Sulfur content (S) calculation formula: Sulfur content = (cumulative value of sulfur ions in the material weighed by weighing scale A + cumulative value of sulfur ions in the material weighed by weighing scale A + ... + cumulative value of sulfur ions in the material weighed by weighing scale H) / total amount of each material used.

[0030] R. Chlorine content (CL) calculation formula: Chlorine content = (cumulative value of weighing scale #0 * chloride ion value in the input material + cumulative value of weighing scale A * chloride ion value in the input material + ... + cumulative value of weighing scale H * chloride ion value in the input material) / total amount of each material used.

[0031] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and its improved concept, should be covered within the scope of protection of the present invention.

Claims

1. A control method for a product component control system of a compound fertilizer device, characterized in that: By using the instantaneous and cumulative values ​​of the product component proportions of each weighing scale and urine flow meter, the content of each component in the product is calculated backwards. When there is a short-term fluctuation in the amount of material fed, the system can determine whether the fluctuation in the amount of material fed causes the product component proportion to fail to meet the control index, and control the product component to be within the control range. If it exceeds the range, the system will automatically prompt personnel to adjust the product component proportion to reduce the generation of unqualified products. The steps for calculating the cumulative value of product component proportion are as follows: taking 12 hours as the unit of time, the shift personnel reset the cumulative value of each weighing scale and the cumulative urine flow measurement in the formula table to zero by pressing the "zero" button or the "handover" button of each weighing scale. Then, it is automatically imported into the product component proportion calculation trend chart. Then, the cumulative value of each weighing scale and the cumulative urine flow measurement of the next shift are calculated to calculate the product component proportion. The steps for calculating the instantaneous value of the product component proportion are as follows: The cumulative value of each metering scale and urine flow meter's usage over 10 seconds is added to the cumulative value of each metering scale and urine flow meter in the previous hour within the system, and this is used as the instantaneous cumulative value. This value is then introduced into the formula table to calculate the instantaneous value of the product component proportion. If the device is operating normally and continuously, the instantaneous value is calculated by adding the cumulative amount of each liquid and solid phase material in the previous hour to the cumulative value of each material over 10 seconds. If the device is in startup, the cumulative value of each material is automatically calculated, and the instantaneous value is calculated again after one hour of continuous operation, following the steps described above. The system includes: a solid material addition system, a mixing and granulation system, and a product component ratio control system; The solid material addition system includes: weighing scale A, weighing scale B, weighing scale C, weighing scale D, weighing scale E, weighing scale F, weighing scale G, weighing scale H, potash fertilizer raw material scraper, potash fertilizer upper tower bucket elevator, potash fertilizer scraper, phosphate fertilizer raw material scraper, phosphate fertilizer upper tower bucket elevator, and phosphate fertilizer scraper. The feed end of the potash fertilizer raw material scraper is connected to weighing scales A, B, C, D, and E respectively; the discharge end of the potash fertilizer raw material scraper is connected to the potash fertilizer upper tower bucket elevator; the potash fertilizer upper tower bucket elevator is connected to the feed end of the primary mixing tank through the potash fertilizer scraper, the discharge end of the primary mixing tank is connected to the feed end of the secondary mixing tank, the discharge end of the secondary mixing tank is connected to the feed end of the emulsifier, and the discharge end of the emulsifier is connected to the granulator; the feed end of the primary mixing tank is connected to urine via a flow meter. The feed end of the phosphate fertilizer raw material scraper is connected to the weighing scales F, G, and H respectively; the discharge end of the phosphate fertilizer raw material scraper is connected to the phosphate fertilizer upper tower bucket elevator, and the phosphate fertilizer upper tower bucket elevator is connected to the feed end of the secondary mixing tank through the phosphate fertilizer scraper. The mixing and granulation system includes: a primary mixing tank, a secondary mixing tank, an emulsifier, and a granulator; The product component ratio control system is connected to the measurement signal output terminals of weighing scales A, B, C, D, E, F, G, and H, and the urine flow meter, respectively. The product component ratio control system has "zero", "start", "conversion", and "shift handover" buttons, and can display the product component ratio calculation trend chart. The "zero" button and the "shift handover" button are linked. The product component ratio control system can import the electronic formula table shown below.

2. The control method for a compound fertilizer device product component control system according to claim 1, characterized in that: When performing reverse calculations, the instantaneous and cumulative values ​​of solid materials measured by each weighing scale and urine measured by the urine flow meter during the shift are simultaneously imported into the electronic formula table. The proportion of raw materials is manually entered into the formula table, and the content of each component of the product is calculated by the calculation formula in the electronic formula table, so as to realize the automatic calculation of the proportion of product components. The calculation formula for the aforementioned formula table is as follows: A. Total nitrogen (N) calculation formula: Total nitrogen = Cumulative value of urine flow meter per unit time * 46.4% + Cumulative value of weigher #0 * Nitrogen content in the input material + Cumulative value of weigher A * Nitrogen content in the input material + ... + Cumulative value of weigher H * Nitrogen content in the input material) / Total value of each material usage; B. Calculation formula for phosphorus pentoxide (P2O5): Phosphorus pentoxide = (cumulative value of weighing scale #0 * phosphorus pentoxide value in the input material + cumulative value of weighing scale A * phosphorus pentoxide value in the input material + ... + cumulative value of weighing scale H * phosphorus pentoxide value in the input material) / total amount of each material used; C. Potassium oxide (K2O) calculation formula: Potassium oxide = (cumulative value of weighing scale #0 * potassium oxide value in the material added + cumulative value of weighing scale A * potassium oxide value in the material added + ... + cumulative value of weighing scale H * potassium oxide value in the material added) / total value of all materials used; D. Total nutrient calculation formula: Total nutrients = Total nitrogen (N) + Phosphorus pentoxide (P2O5) + Potassium oxide (K2O); E. Sulfur content (S) calculation formula: Sulfur content = (cumulative value of weighing scale #0 * sulfur ion value in the input material + cumulative value of weighing scale A * sulfur ion value in the input material + ... + cumulative value of weighing scale H * sulfur ion value in the input material) / total value of each material used; F. Calculation formula for chlorine content (CL): Chlorine content = (cumulative value of weighing scale #0 * chloride ion value in the input material + cumulative value of weighing scale A * chloride ion value in the input material + ... + cumulative value of weighing scale H * chloride ion value in the input material) / total amount of each material used.

3. The control method for a compound fertilizer device product component control system according to claim 2, characterized in that: When the system needs to switch production, before the system switches production and feeds materials, press the "Clear" button to clear the cumulative value of all materials in the previous formula and import it into the trend chart of product component ratio calculation. When switching production online for similar formulation devices, press the "Convert" button to save the product component ratio calculation trend chart of the previous product, import the electronic formula table of the new product to calculate the component ratio of the next product, and the calculation logic of the cumulative component ratio and instantaneous component ratio of the product remains unchanged.

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