Intelligent dust-settling device and method applied to copper smelting unmanned slag yard

Abstract

The application relates to the metallurgy field and discloses an intelligent dust-settling method applied to a copper smelting unmanned slag yard, which comprises the following steps: S1, installing an environment monitoring station around the slag yard, which is used for monitoring the air quality and weather conditions of the slag yard in real time; S2, installing a dust-settling device on the environment monitoring station, which is used for dust settling of the slag yard; the environment monitoring station is transmitted to a DCS control center through a 5G network covering the slag yard; the dust-settling device is composed of a mist sprayer, a water pipeline and a valve, the mist sprayer is provided with an independent control cabinet, a PLC control unit and a 10-inch touch screen are built in the control cabinet, the mist sprayer can be manually controlled on site, remotely controlled and connected to the DCS control center of the slag yard, the DCS control center detects the environment of the slag yard according to the environment information of the slag yard transmitted through the 5G network and controls the operation of the mist sprayer, and the working mode of the dust-settling device is adaptively adjusted according to the dust concentration change in a target area, so that intelligent control of the dust-settling system is realized.

Description

Technical Field

[0001] This invention relates to the field of metallurgical technology, specifically to an intelligent dust suppression device and method applied to unmanned slag dumps in copper smelting. Background Technology

[0002] In recent years, with the needs of national development, the copper smelting industry has grown increasingly larger, resulting in a significant increase in industrial dust. Industrial dust has become a major source of atmospheric particulate matter pollution, not only polluting the environment but also posing a threat to human health. With the introduction of the concept of green development and the increasing emphasis on environmental protection and air quality, industrial dust pollution control has become a crucial issue that the copper smelting industry must address seriously.

[0003] Existing equipment has the following drawbacks: Currently, most open-air storage yards in the copper smelting industry use traditional dust suppression methods such as water spraying. However, these methods cannot adaptively adjust to changes in dust concentration in the open-air storage yard, resulting in poor dust suppression effects and water waste. Therefore, achieving intelligent dust suppression in open-air storage yards has broad application prospects.

[0004] Therefore, this application proposes an intelligent dust suppression device and method for use in unmanned slag dumps in copper smelting to solve the aforementioned problems. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent dust suppression device and method for use in unmanned slag yards for copper smelting, in order to solve the problems mentioned above, such as the inability to adapt to changes in dust concentration in open-air yards, resulting in poor dust suppression effect and waste of water resources.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an intelligent dust suppression method applied to unmanned slag dumps in copper smelting, comprising the following steps:

[0007] S1. Install environmental monitoring stations around the slag dump to monitor the air quality and weather conditions of the slag dump in real time;

[0008] S2. Install dust suppression devices at environmental monitoring stations to suppress dust in slag dumps;

[0009] The environmental monitoring station transmits data to the DCS control center via the 5G network covering the slag dump.

[0010] The dust removal device consists of a mist sprayer, water pipes, and valves. The mist sprayer has its own independent control cabinet with a built-in PLC control unit and a 10-inch touch screen. The mist sprayer can be operated manually or remotely on-site and connected to the DCS control center of the slag dump. The DCS control center receives environmental information from the environmental monitoring station of the slag dump via a 5G network to control the operation of the mist sprayer.

[0011] The DCS control center controls the start and stop of the mist cannon through interval control logic, and adjusts the water content, spray angle and rotation speed of the mist cannon through PID control.

[0012] The interval control logic is as follows: when PM10 in the air is ≤50μg / m3, the fog cannon stops operating; when it rains, the fog cannon stops operating; when PM10 in the air is >50μg / m3, the fog cannon starts operating.

[0013] The spray moisture content loop control is: y = 0.1x - 5;

[0014] y represents the water consumption of the mist sprayer;

[0015] x represents the dust concentration;

[0016] The spray water content SP1 value is equal to the ratio of the water consumption y of the sprayer to the air volume z of the blower, i.e., SP1 = y / z.

[0017] The pitch angle loop control for the fog cannon is: c = 0.55x - 37.5;

[0018] c represents the pitch angle of the mist sprayer;

[0019] x represents the dust concentration;

[0020] The pitch angle SP2 of the mist cannon is equal to 0.55 times the dust concentration minus 37.5. As the dust concentration increases, the pitch angle gradually increases, with a maximum of 45°.

[0021] The rotational speed loop control for the fog cannon is: d = 0.16x + 8;

[0022] d is the rotational speed of the fog cannon;

[0023] x represents the dust concentration;

[0024] The rotational speed SP3 of the mist sprayer is equal to 0.16 times the dust concentration plus 8.

[0025] The water used in the mist sprayer is fresh production water. The water mist generated by the remote mist sprayer forms a water mist layer in the upper space of the working area to suppress the spread of dust. The water mist fully combines with the dust and settles down. Part of the dust suppression water from the mist sprayer evaporates naturally, and part of it flows into the rainwater collection pool at the lowest position of the slag dump for storage.

[0026] Compared with the prior art, the beneficial effects of the present invention are:

[0027] This invention involves installing three mist cannons around the slag dump. Each mist cannon has a range of 70 meters. The mist cannon comprises a high-pressure water pump, annular nozzles, a blower, a hydraulic station (providing power for pitch angle and rotation speed control), mounting brackets, and a PLC control cabinet. The high-pressure water pump pressurizes the production water, which is then atomized into a water mist through the annular nozzles. The blower propels the water mist outwards. The hydraulic station controls the pitch angle and rotation of the mist cannon to achieve efficient dust suppression over a wide area. One environmental protection device (a total of six) is installed on each side of the mist cannon. The monitoring station monitors the air dust concentration and meteorological information in the slag dump area in real time, and transmits the information to the plant's DCS control center through a 5G private network covering the entire plant. When the dust concentration at the slag dump site is high, the water consumption of the mist sprayer can be increased. The DCS automatically controls the mist sprayer to adjust the spray angle and spray volume according to the air quality monitored by the environmental monitoring station, so as to achieve full coverage of the entire slag dump site. The working mode of the dust suppression device is adaptively adjusted according to the changes in dust concentration in the target area, realizing intelligent control of the dust suppression system. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the dust removal step in a slag dump according to an embodiment of the present invention;

[0029] Figure 2 This is the PID control diagram of the intelligent dust suppression device applied to copper smelting slag stockpile according to the present invention;

[0030] Figure 3 This is a schematic diagram of the intelligent dust suppression device of the present invention applied to copper smelting slag stockpile. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Please see Figure 1-3 This invention provides a technical solution: an intelligent dust suppression method applied to unmanned slag dumps in copper smelting, comprising the following steps:

[0033] S1. Install environmental monitoring stations around the slag dump to monitor the air quality and weather conditions of the slag dump in real time;

[0034] S2. Install dust suppression devices at environmental monitoring stations to suppress dust in slag dumps;

[0035] Data collected by the environmental monitoring station is transmitted to the DCS control center via the 5G network covering the slag dump.

[0036] The dust removal device consists of a mist sprayer, water pipes, and valves. The mist sprayer has its own independent control cabinet with a built-in PLC control unit and a 10-inch touch screen. It can be manually or remotely controlled on-site and connected to the DCS control center of the slag dump. The DCS control center analyzes the environmental information of the slag dump through the 5G network to control the operation of the mist sprayer. The DCS control center is used to control the start and stop of the mist sprayer, as well as adjust the moisture content, spray angle, and rotation speed of the mist sprayer.

[0037] It should be noted that during operation, three mist cannons are installed around the slag dump. Each mist cannon has a range of 70 meters. The mist cannon consists of a high-pressure water pump, annular nozzles, a blower, a hydraulic station (providing power for pitch angle and rotation speed control), mounting brackets, and a PLC control cabinet. The high-pressure water pump pressurizes the production water, which then forms a water mist through the annular nozzles. The blower then propels the water mist outwards. The hydraulic station controls the pitch angle and rotation of the mist cannon to achieve efficient dust suppression over a wide area. One mist cannon is installed on each side (a total of six). (1) Environmental monitoring stations monitor the air dust concentration and meteorological information in the slag dump area in real time, and transmit the information to the plant's DCS control center through a 5G private network covering the entire plant. When the dust concentration at the slag dump site is high, the water consumption of the mist sprayer can be increased. The DCS automatically controls the mist sprayer to adjust the spray angle and spray volume according to the air quality monitored by the environmental monitoring station, so as to achieve full coverage of the entire slag dump. The working mode of the dust suppression device is adaptively adjusted according to the changes in dust concentration in the target area, realizing intelligent control of the dust suppression system.

[0038] In one embodiment, the DCS control center controls the start and stop of the mist sprayer through zone control logic, and the DCS control center uses PID control to adjust the water content, spray angle and rotation speed of the mist sprayer.

[0039] With this design, the DCS control center monitors the environment of the slag dump using the 5G network and controls the automatic start and stop of the mist cannons based on the dust content of the slag dump. When the mist cannons are turned on, the PID control can automatically adjust the moisture content, spray angle, and rotation speed of the mist cannons according to the dust conditions of the slag dump. The working mode of the mist cannons is adaptively adjusted according to the changes in dust concentration in the target area, thus realizing intelligent control of the dust suppression system.

[0040] In one embodiment, the DCS control center stops the fog cannon when PM10 in the air is ≤50μg / m3, stops the fog cannon when it rains, and starts the fog cannon when PM10 in the air is >50μg / m3.

[0041] With this design, when the dust concentration in the control zone is below 50 μg / m3, dust removal is not required, and the mist sprayer can be turned off. On rainy days, rainwater can adsorb and suppress dust in the air, so there is no need to treat the dust through the mist sprayer.

[0042] In one embodiment, the mist sprayer uses PID control to automatically adjust the spray water content, pitch angle, and rotation speed.

[0043] With this design, the water consumption of the mist cannon is controlled by adjusting the opening of the pneumatic regulating valve and the data displayed by the electromagnetic flow meter through PID control. The water used by the mist cannon is fresh production water, and its inlet is equipped with an independent self-cleaning filter to ensure water quality. The DCS analyzes the real-time monitoring data of dust concentration in the air transmitted from the environmental monitoring station, determines the range of the concentration, and issues different operating commands (commands include adjusting the opening of the pneumatic regulating valve, starting and stopping the mist cannon, adjusting the pitch angle and rotation speed of the mist cannon, etc.) to achieve efficient dust suppression in the target area.

[0044] In one embodiment, the spray moisture content loop is controlled as follows: y = 0.1x - 5;

[0045] y represents the water consumption of the mist sprayer;

[0046] x represents the dust concentration;

[0047] The spray water content SP1 value is equal to the ratio of the water consumption y of the sprayer to the air volume z of the blower, i.e., SP1 = y / z.

[0048] With this design, when PM10 in the air > 50 μg / m3, the water consumption y of the mist cannon is linearly related to the dust concentration x (y = 0.1x - 5, y maximum 10 t / h), and PID control is used. The spray water content SP1 value is equal to the ratio of the mist cannon water consumption y to the fan air volume z (i.e., SP1 = y / z), OP1 value is the pneumatic regulating valve opening adjustment value, and PV1 is the spray water content. When the dust suppression effect in the dusty area is not good, the SP1 setting value is increased by 1, but SP1 cannot exceed the water consumption limit. After each change, wait 15 to 20 minutes to observe the effect.

[0049] In one embodiment, the pitch angle loop control of the fog cannon is: c = 0.55x - 37.5;

[0050] c represents the pitch angle of the mist sprayer;

[0051] x represents the dust concentration;

[0052] The pitch angle SP2 of the mist cannon is equal to 0.55 times the dust concentration minus 37.5. As the dust concentration increases, the pitch angle gradually increases, with a maximum of 45°.

[0053] With this design, when PM10 in the air > 50 μg / m3, the pitch angle c of the fog cannon is linearly related to the dust concentration x (c = 0.55x - 37.5, c ranges from -10° to 45°, with horizontal spraying of the fog cannon as 0°), and PID control is used. The pitch angle SP2 value is equal to 0.55 times the dust concentration minus 37.5 (i.e., SP2 = 0.55x - 37.5). OP2 is the frequency control value of the pitch hydraulic pump, and PV2 is the pitch angle control value. When the dust concentration in the dust zone increases or decreases, the SP2 setpoint increases or decreases by 10, but SP2 cannot exceed the range of the pitch angle. After each change, the effect is observed after 15 to 20 minutes. It can be seen that when the dust concentration > 50 μg / m3, the pitch angle gradually increases with the increase of dust concentration, with a maximum of 45°.

[0054] In one embodiment, the rotational speed loop control of the fog cannon is: d = 0.16x + 8

[0055] d is the rotational speed of the fog cannon;

[0056] x represents the dust concentration;

[0057] The rotational speed SP3 of the mist sprayer is equal to 0.16 times the dust concentration plus 8.

[0058] With this design, when PM10 in the air > 50 μg / m3, the rotation speed d of the mist cannon is linearly related to the dust concentration x (d = 0.16x + 8), using PID control. The rotation speed SP3 value of the mist cannon is equal to 0.16 times the dust concentration plus 8 (i.e., SP3 = 0.16x + 8). OP3 is the frequency control value of the rotary hydraulic pump, and PV3 is the rotation speed control value (PV3 = 16~32). The rotation angle range of the mist cannon is 0~160°, with a minimum rotation speed of 16° / min, requiring 20 minutes for one round trip; the maximum rotation speed is 32° / min, requiring 10 minutes for one round trip. When the dust concentration in the dust zone increases or decreases, the SP3 setting value increases or decreases by 2, but SP3 cannot exceed the range of the rotation speed. After each change, wait 15 to 20 minutes to observe the effect.

[0059] In one embodiment, the water used by the mist sprayer is fresh production water. The water mist generated by the remote mist sprayer forms a water mist layer in the upper space of the working area to suppress the spread of dust. The water mist fully combines with the dust and settles down. Part of the dust-suppressing water from the mist sprayer evaporates naturally, and part of it flows by gravity into the rainwater collection pool at the lowest position of the slag dump for storage.

[0060] With this design, some of the water mist after dust settling evaporates naturally on the slag heap, while the rest flows by gravity into the rainwater collection pond at the lowest point of the slag heap for storage. This rainwater can be used as supplementary water for the slow cooling of the slag, without causing environmental pollution.

Claims

1. An intelligent dust suppression method applied to unmanned slag dumps in copper smelting, characterized in that, Includes the following steps: S1. Install environmental monitoring stations around the slag dump to monitor the air quality and weather conditions of the slag dump in real time; S2. Install dust suppression devices at environmental monitoring stations to suppress dust in slag dumps; The environmental monitoring station transmits data to the DCS control center via the 5G network covering the slag dump. The dust removal device consists of a mist sprayer, water pipes, and valves. The mist sprayer has its own independent control cabinet with a built-in PLC control unit and a 10-inch touchscreen. The mist sprayer can be operated manually or remotely on-site and connected to the DCS control center of the slag dump. The DCS control center receives environmental information from the environmental monitoring station via a 5G network to control the operation of the mist sprayer. The DCS control center uses interval control logic to control the start and stop of the mist sprayer. The interval control logic is as follows: when PM10 in the air is ≤50μg / m³, the mist sprayer stops operating; when it rains, the mist sprayer stops operating; when PM10 in the air is >50μg / m³, the mist sprayer starts operating. The DCS control center uses PID control to adjust the moisture content, spray angle, and rotation speed of the mist sprayer. The spray moisture content loop control is: y=0.1x-5, where y is the water consumption of the sprayer, x is the dust concentration, and the spray moisture content SP1 value is equal to the ratio of the water consumption of the sprayer y to the air volume of the fan z, i.e., SP1=y / z. The pitch angle loop control of the fog cannon is: c = 0.55x - 37.5, where c is the pitch angle of the fog cannon, x is the dust concentration, and the pitch angle SP2 value of the fog cannon is equal to 0.55 times the dust concentration minus 37.

5. As the dust concentration increases, the pitch angle gradually increases, with a maximum of 45°. The rotation speed loop control of the fog cannon is: d = 0.16x + 8, where d is the rotation speed of the fog cannon, x is the dust concentration, and the SP3 value of the fog cannon rotation speed is equal to 0.16 times the dust concentration plus 8. The water used by the mist sprayer is fresh production water. The water mist generated by the remote mist sprayer forms a water mist layer in the upper space of the working area to suppress the spread of dust. The water mist fully combines with the dust and settles down. Part of the dust suppression water from the mist sprayer evaporates naturally, and part of it flows into the rainwater collection pool at the lowest position of the slag dump for storage. The DCS control center uses PID control to adjust the water content, spray angle, and rotation speed of the mist cannon. The maximum y in the spray water content loop is 10t / h; the pitch angle is limited to -10° to 45°; the rotation angle range is 0° to 160°, and the rotation speed is limited to 16° / min to 32° / min. When the dust suppression effect in the dusty area is not good, increase the SP1 setting by 1, and wait 15 to 20 minutes to observe the effect after each change; When the dust concentration in the dust zone increases or decreases, the SP2 setting value increases or decreases by 10, and the SP3 setting value increases or decreases by 2. After each change, wait 15 to 20 minutes to observe the effect.

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