A staged early warning system for overflow particle size of hydrocyclones in grinding production

Abstract

This invention discloses a phased early warning system for overflow particle size in hydrocyclones during ore grinding production. The system includes a central control unit, a signal receiver, a data acquisition module, a particle size prediction module, and a monitoring and early warning module. The data acquisition module is used by the central control unit to acquire real-time data from various sensors. The particle size prediction module, connected to the data acquisition module, sends control signals to the central control unit. The monitoring and early warning module, connected to the particle size prediction module, provides feedback based on the current predicted data value to remind the operator to adjust the current working state according to the subsequent production status. This invention replaces manual sampling and detection, significantly improving the quality of ore grinding production and the efficiency of the entire beneficiation process. Simultaneously, it can effectively predict the state changes of overflow particle size over a future period, enabling error compensation and fault diagnosis of the measurement system, thereby improving measurement accuracy and reliability.

Description

Technical Field

[0001] This invention relates to the field of mining grinding technology, specifically to a phased early warning system for the overflow particle size of hydrocyclones in grinding production. Background Technology

[0002] With the rapid development of my country's economy and its established position as a global center for processing and manufacturing, my country's metallurgical industry is developing rapidly, leading to a surge in demand for mineral processing products. This has spurred the continuous development of the mineral processing industry. Grinding, a crucial part of the mineral processing industry, involves numerous industrial equipment. Hydrocyclones are commonly used to separate fine materials using centrifugal force. Particle size is a primary measure of the quality of the mineral particles overflowing from the hydrocyclone, but real-time detection is difficult, significantly reducing the quality of grinding production and impacting the efficiency of the entire mineral processing process, becoming a bottleneck. Currently, due to financial constraints, most domestic mines rely on overflow concentration instead of overflow particle size to determine whether production requirements are met. The drawback of this approach is that there is no quantitative relationship between the two, and their trends are not entirely consistent. Overflow concentration data cannot be integrated into the control system for advanced control, significantly hindering production efficiency. Furthermore, most manufacturers that test overflow particle size only perform offline analysis during actual production, failing to implement online measurement. The main reasons for this situation are that particle size analyzers are expensive and difficult for enterprises to afford, so they can only obtain the grinding particle size detection value through manual sampling and testing. Particle size analyzers themselves have a relatively complex structure, require a large amount of daily maintenance, and are prone to failure, which affects industrial production.

[0003] Therefore, researching how to stably detect the overflow particle size distribution of hydrocyclones during the grinding process has become an urgent problem for enterprises. However, there are still certain limitations in how to stably detect the overflow particle size distribution. Summary of the Invention

[0004] The purpose of this invention is to provide a phased early warning system for the overflow particle size of hydrocyclones in grinding production, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] This invention discloses a phased early warning system for the overflow particle size of hydrocyclones in grinding production, comprising a central control unit, a signal receiver, a data acquisition module, a particle size prediction module, and a monitoring and early warning module. The data acquisition module is used by the central control unit to acquire real-time data collected by various sensors. The particle size prediction module is connected to the data acquisition module and is used to send control signals to the central control unit. The monitoring and early warning module is connected to the particle size prediction module and is used to provide feedback based on the current predicted data value to remind the operator to adjust the current working state according to the subsequent production status.

[0007] The data acquisition module consists of sensors, connecting lines, a PLC1-N data transmission unit, and a main control receiving and merging unit installed on the feeder, ball mill, hydrocyclone, feed pump equipment, and pipelines. It collects real-time particle size-related data under various production conditions through sensors and then sends it to the main control unit for operation. The main control receiving and merging unit is located inside the main control unit and is used to receive information sent by the PLC1-N data transmission unit.

[0008] The frequency converter, current transformer, grinding sound analyzer, valve, flow meter, concentration meter, belt scale, pressure transmitter, particle size analyzer, grade meter, and level gauge are connected in parallel and then connected to the PLC1-N data transmission unit.

[0009] The data acquisition module controls the ore feeding frequency through a frequency converter; detects the current through a current transformer; detects the grinding sound through a grinding sound analyzer; controls parameters such as the water feeding rate through valves; detects the water supply, pump pool replenishment water, and ore feeding flow rate through a flow meter; detects the ore feeding concentration and overflow concentration through a concentration meter; detects the ore feeding rate through a belt scale; detects the ore feeding pressure of the hydrocyclone through a pressure transmitter; detects the overflow particle size through a particle size analyzer; detects the grade through a grade meter; and detects the pump pool liquid level through a level gauge. Under the detection of the above instruments and equipment, the PLC1-N data transmission unit sends the detection data to the central control computer, and the main control receiving and merging unit receives and merges these detection data into the database, which facilitates the timely acquisition of production data by the company's technical personnel, and enables them to analyze the data and make corresponding decisions.

[0010] Preferably, the granularity prediction module includes a training unit, a prediction unit, an identification unit, and a transmission unit. The training unit, prediction unit, identification unit, and transmission unit are all located inside the main controller. The transmission unit sends control signals to the corresponding PLC actuator through a wireless sensor network or serial port.

[0011] Preferably, the monitoring and early warning module includes a PLCN receiving unit, a PLCN display, and a PLCN indicator light. The PLCN receiving unit is located inside the main control unit and establishes a data communication connection with the sending unit; the PLCN display and the PLCN indicator light are located on the main control unit's operating console.

[0012] Preferably, the switching button is located on the main control unit's operating panel and is used to view the relevant curves of overflow particle size under different production conditions; the signal receiver is located on the back of the main control unit and is connected to the main control unit to receive transmitted information.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0014] (1) The phased early warning system for overflow particle size in this grinding production solves the problem of automatically detecting the overflow particle size distribution of the hydrocyclone over a period of time, replacing manual sampling and detection, greatly improving the quality of grinding production and the efficiency of the entire mineral processing process; at the same time, it can effectively predict the state changes of overflow particle size in the future. If the overflow particle size distribution range exceeds the set alarm standard, a red light signal will be sent to the monitoring and early warning module to remind it, which can perform error compensation and fault diagnosis for the measurement system, thereby improving the measurement accuracy and reliability.

[0015] (2) The industrial test results of the present invention applied to iron ore beneficiation plants and copper ore beneficiation plants show that the early warning system of the present invention can improve the beneficiation production efficiency by more than 15%, increase the iron concentrate grade by 0.8-1.2%, and increase the copper concentrate grade by 0.4%-0.6%. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the system structure of the present invention;

[0017] Figure 2 This is a schematic diagram of the structure of the feeder and other equipment pipes and connecting lines of the present invention;

[0018] Figure 3 This is a top view of the overall structure of the present invention;

[0019] Figure 4 This is a material production process diagram of the present invention;

[0020] Figure 5 This is a production flow chart of the first stage of grinding according to the present invention;

[0021] Figure 6 This is a diagram of the data acquisition module of the present invention;

[0022] Figure 7 This is a diagram of the particle size prediction module of the present invention;

[0023] Figure 8 This is a diagram of the monitoring and early warning module of the present invention.

[0024] In the diagram: 1. Central control unit; 121. Sensor; 122. Connecting cable; 100. Data acquisition module; 101. PLC1-N data transmission unit; 102. Main control receiving and merging unit; 110. Feeder, hydrocyclone equipment and pipelines; 108. Frequency converter; 109. Current transformer; 111. Grinding sound analyzer; 112. Valve; 113. Flow meter; 114. Concentration meter; 115. Belt scale; 116. Pressure transmitter; 117. Particle size analyzer; 118. Grade meter; 119. Level gauge; 200. Particle size prediction module; 201. Training unit; 202. Prediction unit; 203. Identification unit; 204. Transmission unit; 300. Monitoring and early warning module; 301. PLCN receiving unit; 302. PLCN display; 303. PLCN indicator light; 304. Switch button; 401. Signal receiver. Detailed Implementation

[0025] 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.

[0026] Please see Figure 1-8 This embodiment of a phased early warning system for overflow particle size in a hydrocyclone during grinding production includes a central control unit 1, a signal receiver 401, a data acquisition module 100, a particle size prediction module 200, and a monitoring and early warning module 300. The signal receiver 401 is located on the back of the central control unit 1 and connected to it, and is used to receive transmitted information. The data acquisition module 100 is used to collect real-time data on particle size and related influencing factors under different production states during actual grinding production. The particle size prediction module 200 is connected to the data acquisition module 100 and is used to use the prediction results based on a time-series neural network model to identify the overflow particle size corresponding to the collected data and predict subsequent production results, and to make judgments based on the predicted value and the set range value. The monitoring and early warning module 300 is connected to the particle size prediction module 200. When the predicted overflow particle size exceeds the error range of its set value, the PLCN indicator light 303 lights up, which is used to provide feedback based on the current predicted data value, so as to remind the operator to adjust the current working state according to the subsequent production state.

[0027] In the above embodiment, the data acquisition module 100 consists of sensors 121 and connecting lines 122 installed on equipment such as feeders, ball mills, hydrocyclones, and feed pumps, as well as pipelines 110. By providing different types of sensors 121 and connecting lines 122 to establish a connection between the production equipment and the main control unit 1, the collected information related to overflow particle size is sent to the main control receiving and merging unit 102 located inside the main control unit 1 through the PLC1-N data sending unit 101. Then, the main control unit 1 performs particle size prediction and displays the results on the PLCN display 302. At the same time, the relevant curves of overflow particle size under different production conditions can be viewed through the switching button 304. If the predicted overflow particle size exceeds the error range of its set value, the PLCN indicator light 303 lights up to provide feedback based on the current predicted data value, so as to remind the operator to adjust the current working state according to the later production state.

[0028] In one embodiment of the present invention, the grinding material production process is as follows: Figure 4 As shown, the raw ore undergoes a fine crushing and dry separation process to produce small-sized mineral particles, which are then loaded into a cylindrical silo. The particles in the silo are further screened using a vibrating screen. If the particle size is less than 16 mm, the qualified material is sent to the roller mill buffer silo. Particles larger than 16 mm are re-crushed and screened. The fine particles in the roller mill buffer silo are then subjected to magnetic separation and screening using a high-pressure roller mill. Waste is discarded by the cylindrical magnetic separator. The qualified material is then sent to a ball mill and hydrocyclone for grinding and classification. The grinding stage of the production process is as follows: Figure 5 As shown, the specific grinding process is as follows: First, the ore particles in the ore bin are fed onto the feed belt via the feeding equipment. The feed belt then transports the raw ore into the ball mill. Here, the belt scale records the amount of raw ore. Then, based on the initially set ball-to-material ratio, the number of steel balls to be placed into the ball mill is calculated and added, along with an appropriate amount of water. As the ball mill rotates, the ore, steel balls, and water continuously rub against each other, causing the ore to be continuously crushed and refined, gradually turning into a slurry. The refined slurry is then sent to the slurry tank through the internal pipes of the ball mill. A certain amount of water is added to the slurry tank to adjust the slurry concentration. The diluted slurry is then pumped into the hydrocyclone by the pressure of the underflow pump. The centrifugal force of the hydrocyclone classifies and screens the slurry. The qualified fine-particle slurry is sent to subsequent operations, while the unqualified slurry is returned to the ball mill for further grinding through a return sand process, thus forming a closed-loop grinding cycle.

[0029] Depend on Figure 6As can be seen, in the above embodiment, the frequency converter 108, current transformer 109, grinding sound analyzer 111, valve 112, flow meter 113, concentration meter 114, belt scale 115, pressure transmitter 116, particle size analyzer 117, quality meter 118, and level gauge 119 are connected in parallel and then connected to the PLC1-N data transmission unit 101. The PLC1-N data transmission unit 101 is connected to the main control receiving and merging unit 102.

[0030] In the above embodiment, the data acquisition module 100 controls the feeding frequency through the frequency converter 108; detects the current through the current transformer 109; detects the grinding sound through the grinding sound analyzer 111; controls parameters such as the water supply rate through the valve 112; detects parameters such as the water supply volume, pump pool replenishment volume, and feeding flow rate through the flow meter 113; detects the feeding concentration and overflow concentration through the concentration meter 114; detects the feeding volume through the belt scale 115; detects the hydrocyclone feeding pressure through the pressure transmitter 116; detects the overflow particle size through the particle size analyzer 117; detects the grade through the grade meter 118; and detects the pump pool level through the level gauge 119. Under the detection of these instruments and equipment, the PLC1-N data transmission unit 101 sends the various detection data to the central control unit 1, and the main control receiving and merging unit 102 receives and merges these detection data into the database, which facilitates the timely acquisition of production data by the enterprise's technical personnel, and enables them to analyze the data and make corresponding decisions.

[0031] like Figure 8 As shown, the granularity prediction module 200 in this embodiment includes a training unit 201, a prediction unit 202, an identification unit 203, and a sending unit 204. The training unit 201, prediction unit 202, identification unit 203, and sending unit 204 are all located inside the main control unit 1. The training unit 201 calls the model and uses the production data of the first D minutes obtained by the data merging unit. The prediction unit 202 predicts the fluctuation of the overflow granularity in the next T minutes. The identification unit 203 compares the predicted overflow granularity production data of the next T minutes with the overflow granularity range to determine whether the overflow granularity data for each minute is within the corresponding range and marks the corresponding time overflow granularity. The sending unit 204 sends the encoded streaming data to the corresponding PLC actuator through a wireless sensor network or serial port.

[0032] like Figure 8As shown, the monitoring and early warning module 300 in this embodiment includes a PLCN receiving unit 301, a PLCN display 302, and a PLCN signal light 303. The PLCN receiving unit 301 is located inside the main control unit 1 and establishes a data communication connection with the sending unit 204. The PLCN display 302 and the PLCN signal light 303 are located on the operating panel of the main control unit 1. The PLCN receiving unit 301 is used to connect to the central control sending unit 204 to parse the main control information and obtain the overflow particle size value and flag bit corresponding to the corresponding interval. The PLCN display 302 displays the overflow particle size value at the corresponding time in the waveform diagram to obtain a clearer predictive monitoring system. The PLCN signal light 303 indicates the overflow particle size that exceeds or falls below the expected range and informs the staff that the current grinding parameters can be adjusted appropriately.

[0033] This invention provides a staged early warning system for the overflow particle size of hydrocyclones in ore grinding production. It has been successfully applied in iron ore beneficiation plants and copper ore beneficiation plants. By using this early warning system, the efficiency of the grinding-classification system is significantly improved, the qualified particle size of the feed to the beneficiation system is significantly improved, and the occurrence of over-grinding is greatly reduced. The overall beneficiation production efficiency is increased by more than 15%, the iron concentrate grade is increased by 0.8-1.2%, and the copper concentrate grade is increased by 0.4%-0.6%.

[0034] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0035] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A staged early warning system for the overflow particle size of hydrocyclones in grinding production, comprising a main control unit (1), a signal receiver (401), a data acquisition module (100), a particle size prediction module (200), and a monitoring and early warning module (300), characterized in that: The data acquisition module (100) is used by the main controller (1) to acquire data collected in real time from each sensor (121); the particle size prediction module (200) is connected to the data acquisition module (100) and is used to send control signals to the main controller (1); the monitoring and early warning module (300) is connected to the particle size prediction module (200) and is used to provide feedback based on the current predicted data value to remind the operator to adjust the current working state according to the later production state; The data acquisition module (100) consists of sensors (121), connecting lines (122), PLC1-N data transmission unit (101), and main control receiving and merging unit (102) installed on the feeder, ball mill, hydrocyclone, feed pump equipment, and pipeline (110). The sensor (121) collects real-time data related to particle size under various production conditions and then sends it to the main control unit (1) for operation. The main control receiving and merging unit (102) is located inside the main control unit (1) and is used to receive the information sent by the PLC1-N data transmission unit (101). The frequency converter (108), current transformer (109), grinding sound analyzer (111), valve (112), flow meter (113), concentration meter (114), belt scale (115), pressure transmitter (116), particle size analyzer (117), quality indicator (118), and level gauge (119) are connected in parallel and then connected to the PLC1-N data transmission unit (101); The data acquisition module (100) controls the feeding frequency via a frequency converter (108); detects the current via a current transformer (109); detects the grinding sound via a grinding sound analyzer (111); controls the water supply speed via a valve (112); detects the water supply, pump pool replenishment water, and feeding flow rate via a flow meter (113); detects the feeding concentration and overflow concentration via a concentration meter (114); detects the feeding rate via a belt scale (115); and detects the hydrocyclone feeding pressure via a pressure transmitter (116). Force; overflow particle size is detected by particle size analyzer (117); grade is detected by grade meter (118); pump pool level is detected by level gauge (119); under the detection of the above instruments and equipment, each detection data is sent to the main control computer (1) through PLC1-N data sending unit (101), and these detection data are received and merged into the database through the main control receiving and merging unit (102), so that the enterprise's technical personnel can obtain production data in a timely manner, analyze the data, and make corresponding decisions.

2. The hydrocyclone overflow particle size stage early warning system in grinding production according to claim 1, characterized in that: The granularity prediction module (200) includes a training unit (201), a prediction unit (202), an identification unit (203), and a sending unit (204). The training unit (201), the prediction unit (202), the identification unit (203), and the sending unit (204) are all located inside the main controller (1). The sending unit (204) sends the control signal to the corresponding PLC actuator through a wireless sensor network or serial port.

3. The hydrocyclone overflow particle size stage early warning system in grinding production according to claim 1, characterized in that: The monitoring and early warning module (300) includes a PLCN receiving unit (301), a PLCN display (302), and a PLCN signal light (303). The PLCN receiving unit (301) is located inside the main control unit (1) and establishes a data communication connection with the sending unit (204). The PLCN display (302) and the PLCN signal light (303) are located on the operating panel of the main control unit (1).

4. The hydrocyclone overflow particle size stage early warning system in grinding production according to claim 1, characterized in that: A switching button (304) is provided on the control panel of the main control unit (1) to view the relevant curves of overflow particle size under different production conditions; the signal receiver (401) is located on the back of the main control unit (1) and is connected to the main control unit (1) to receive transmitted information.

5. A staged early warning system for overflow particle size in hydrocyclone production according to claim 2, characterized in that: The monitoring and early warning module (300) includes a PLCN receiving unit (301), a PLCN display (302), and a PLCN indicator light (303). The PLCN receiving unit (301) is located inside the main control unit (1) and establishes a data communication connection with the sending unit (204). The PLCN display (302) and the PLCN indicator light (303) are located on the operating panel of the main control unit (1). A switching button (304) is provided on the operating panel of the main control unit (1) for viewing the relevant curves of overflow particle size under different production conditions. The signal receiver (401) is located on the back of the main control unit (1) and is connected to the main control unit (1) for receiving transmitted information.

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