Disc pressure filtration system and its control method and device

Abstract

An embodiment of the present invention provides a disk pressurized filtration system, its control method and device, which relate to the technical field of pressurized filtration. The disk pressurized filtration system is configured with a deep cone thickener. The deep cone thickener provides input materials for the pressurized filter press. According to the preset pressure parameter of the pressure chamber, the pressure of the pressure chamber of the pressurized filter press is controlled, and according to the preset rotation speed parameter of the pressurized filter fan, the pressurized filter fan of the pressurized filter press is controlled to output filter cake; based on the material concentration, the parameters of the filter cake, the pressure parameter of the pressure chamber and the rotation speed parameter of the pressurized filter fan, the energy consumption data of the pressurized filter press is calculated; when the parameters of the filter cake do not meet the preset parameter requirements, the pressure parameter of the pressure chamber and the rotation speed parameter of the pressurized filter fan are adjusted according to the energy consumption data until the parameters of the filter cake meet the preset parameter requirements. The present invention can automatically analyze and adjust each operating parameter, achieve energy consumption reduction, reduce operating costs, and achieve fully automatic unmanned operation.

Description

Technical Field

[0001] The present invention relates to the technical field of pressure filtration, and in particular to a disk pressure filtration system, a control method and a device thereof. Background Art

[0002] Pressure filtration technology is an internationally recognized advanced dehydration technology. The disk pressure filter designed according to this technology is an advanced solid-liquid separation device in the world at present. After years of research and development, it has reached the stage of mature technology and process. With the emergence of high-pressure filter presses, especially the rapid development of high-pressure filter press technology in recent years, some users have reported that, under the same throughput and the same moisture conditions, compared with high-pressure filter presses, disk pressure filters have deficiencies such as high energy consumption and large maintenance workload. Further measures need to be taken to reduce energy consumption, further improve the degree of automation, reduce the number of operators, and reduce potential safety hazards.

[0003] At present, domestic disk pressure filters continuously optimize the product structure and improve the overall performance of the machine. Mechanically, it is mainly optimized and designed from aspects such as reliability, maintainability, safety, and energy consumption; electrically, it is mainly optimized and designed from aspects such as reliability, environmental adaptability, and stability. However, full-automatic control has not been achieved yet, and operators are still needed to assist in the operation. Due to untimely adjustment by operators and mismatched adjustment of various parameters, the operation energy consumption of the disk pressure filter is high. In addition, the neck of the filter fan is easily worn through and air leakage occurs, and the filter cloth is not replaced in time, which easily leads to air leakage, resulting in high energy consumption of the entire system. Therefore, it is an urgent problem to be solved to realize the iterative upgrade of the full-automatic unmanned operation of the pressure filter, automatically analyze and adjust each operation parameter, and achieve energy consumption reduction and operation cost reduction. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a disk pressure filtration system, a control method and a device thereof, which can realize the full-automatic unmanned operation of the pressure filter, achieve energy consumption reduction, and reduce the operation cost.

[0005] First aspect, an embodiment of the present invention provides a control method for a disk pressure filtration system. The method is applied to a disk pressure filtration system, and the disk pressure filtration system is configured with a deep cone thickener, and the deep cone thickener is used to provide input materials for a pressure filter of the disk pressure filtration system. The method includes: providing input materials for the pressure filter through the deep cone thickener; and controlling the pressure in the pressure chamber of the pressure filter according to a preset pressure parameter of the pressure chamber, and controlling the pressure filter fan of the pressure filter according to a preset rotation speed parameter of the pressure filter fan, so that the pressure filter outputs filter cakes based on the input materials; obtaining the material concentration of the input materials and the parameters of the filter cakes; calculating the energy consumption data of the pressure filter based on the material concentration, the parameters of the filter cakes, the pressure parameter of the pressure chamber, and the rotation speed parameter of the pressure filter fan; when the parameters of the filter cakes do not meet the preset parameter requirements, adjusting the pressure parameter of the pressure chamber and the rotation speed parameter of the pressure filter fan according to the energy consumption data until the parameters of the filter cakes meet the preset parameter requirements.

[0006] Combined with the first aspect, an embodiment of the present invention provides a first implementation manner of the first aspect. The step of calculating the energy consumption data of the pressure filter based on the material concentration, the parameters of the filter cakes, the pressure parameter of the pressure chamber, and the rotation speed parameter of the pressure filter fan includes: calculating the dry coal slime treatment capacity and the pulp treatment capacity of the pressure filter based on the parameters of the filter cakes and the material concentration; calculating the air consumption during the pressure filtration process of the pressure filter based on the material concentration, the dry coal slime treatment capacity, and the pulp treatment capacity; calculating the air consumption during the through-flow process of the pressure filter based on the through-flow pressure corresponding to the pressure parameter of the pressure chamber and the dry coal slime treatment capacity; calculating the exhaust air of the lower chamber of the pressure filter based on the filtration pressure corresponding to the rotation speed parameter of the pressure filter fan and the laws of thermodynamics; calculating the energy consumption data of the pressure filter based on the air consumption during the pressure filtration process, the air consumption during the through-flow process, and the exhaust air of the lower chamber.

[0007] Combined with the first aspect, an embodiment of the present invention provides a second implementation manner of the first aspect. The method further includes: inputting the material concentration of the input materials into a pre-established energy-saving mathematical model to determine the rotation speed of the filter fan and the air supply pressure of the pressure filter based on the material concentration; the energy-saving mathematical model is constructed based on the relationship between the pressure parameter of the pressure chamber of the pressure filter, the rotation speed parameter of the pressure filter fan, and the energy consumption of the pressure filter; determining the rotation speed of the filter fan as the rotation speed parameter of the pressure filter fan, and determining the air supply pressure as the pressure parameter of the pressure chamber.

[0008] Combined with the first aspect, an embodiment of the present invention provides a third implementation manner of the first aspect. Among them, an air outlet regulating valve is installed in the pressurized bin of the pressure filter; the parameters of the filter cake include thickness parameters, moisture parameters, and filtrate concentration; when the parameters of the filter cake do not meet the preset parameter requirements, the steps of adjusting the pressure parameter of the pressurized bin and the rotation speed parameter of the pressure filter fan according to the energy consumption data include: judging whether the thickness parameter of the filter cake is within the preset thickness range. If not, calculate the target rotation speed parameter corresponding to the thickness parameter through the energy-saving mathematical model combined with the energy consumption data, and adjust the rotation speed parameter of the pressure filter fan based on the target rotation speed parameter; if so, obtain the moisture parameter and filtrate concentration of the filter cake; calculate the target pressure parameter corresponding to the moisture parameter and filtrate concentration through the energy-saving mathematical model combined with the energy consumption data, and based on the pressure parameter, adjust the opening degree of the air outlet regulating valve of the pressurized bin to adjust the pressure parameter of the pressurized bin.

[0009] Combined with the first aspect, an embodiment of the present invention provides a fourth implementation manner of the first aspect. Among them, the method further includes: monitoring the filtrate concentration of the filter cake, and judging whether the filtrate concentration exceeds a preset threshold. If so, generate a warning message.

[0010] Combined with the first aspect, an embodiment of the present invention provides a fifth implementation manner of the first aspect. Among them, the disk pressure filtration system further includes a flow meter, and the flow meter is installed at the air outlet of the air compressor of the pressure filter; the monitored value of the flow meter is used to represent the actual air consumption of the pressure filter; the method further includes: obtaining the monitored value of the flow meter, and based on the monitored value, adjusting the parameter representing energy consumption in the energy-saving mathematical model.

[0011] Combined with the first aspect, an embodiment of the present invention provides a sixth implementation manner of the first aspect. Among them, the method further includes: monitoring the material concentration, and when the material concentration is lower than the preset threshold, controlling the pressure filter to stop working.

[0012] In the second aspect, an embodiment of the present invention further provides a control device for a disk pressure filtration system. Among them, the device includes: a control module, configured to provide input materials for the pressure filter through a deep cone thickener; and control the pressure of the pressurized bin of the pressure filter according to the preset pressure parameter of the pressurized bin, and control the pressure filter fan of the pressure filter according to the preset rotation speed parameter of the pressure filter fan, so that the pressure filter outputs a filter cake based on the input materials; a data acquisition module, configured to acquire the material concentration of the input materials and the parameters of the filter cake; a data processing module, configured to calculate the energy consumption data of the pressure filter based on the material concentration, the parameters of the filter cake, the pressure parameter of the pressurized bin, and the rotation speed parameter of the pressure filter fan; an execution module, configured to adjust the pressure parameter of the pressurized bin and the rotation speed parameter of the pressure filter fan according to the energy consumption data when the parameters of the filter cake do not meet the preset parameter requirements until the parameters of the filter cake meet the preset parameter requirements.

[0013] In a third aspect, an embodiment of the present invention further provides a disk pressure filtration system. The disk pressure filtration system is configured with a deep cone thickener, and the deep cone thickener is used to provide input materials for the pressure filter of the disk pressure filtration system. The disk pressure filtration system includes a calculation center system control module, and the calculation center system control module is configured with the device of the above embodiment to execute the method of the above embodiment.

[0014] Combined with the third aspect, an embodiment of the present invention further provides a first implementation manner of the third aspect. The disk pressure filtration system further includes an intelligent remote maintenance system module for fault monitoring of the pressure filter.

[0015] The embodiments of the present invention bring the following beneficial effects: A disk pressure filtration system, its control method and device provided by the present invention use a deep cone thickener to provide input materials for the pressure filter; and, control the pressure in the pressure chamber of the pressure filter according to the preset pressure parameter of the pressure chamber, and control the pressure filter fan of the pressure filter according to the preset rotation speed parameter of the pressure filter fan, so that the pressure filter outputs filter cake based on the input materials; after calculating the energy consumption data of the pressure filter based on the material concentration of the input materials, the parameters of the filter cake, the pressure parameter of the pressure chamber and the rotation speed parameter of the pressure filter fan, when the parameters of the filter cake do not meet the preset parameter requirements, adjust the pressure parameter of the pressure chamber and the rotation speed parameter of the pressure filter fan according to the energy consumption data until the parameters of the filter cake meet the preset parameter requirements. The present invention can automatically analyze and adjust various operating parameters, reduce consumption, lower operating costs, and achieve fully automatic unmanned operation by detecting the parameters of the filter cake and adjusting the parameters of the pressure filter in combination with the feed concentration and the corresponding energy consumption data.

[0016] Other features and advantages of the present invention will be described in the following specification, and, in part, will be obvious from the specification, or will be understood by implementing the present invention. The objectives and other advantages of the present invention are achieved and obtained by the structures specifically pointed out in the specification and the drawings.

[0017] To make the above objectives, features and advantages of the present invention more obvious and understandable, the following specific preferred embodiments are given, and in conjunction with the accompanying drawings, the detailed description is as follows. Description of the Drawings

[0018] In order to more clearly illustrate the specific implementation manners of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for the description of the specific implementation manners or the prior art. Obviously, the following drawings are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0019] Figure 1Flow chart of a control method for a disc pressure filtration system provided by an embodiment of the present invention;

[0020] Figure 2 Flow chart of another control method for a disc pressure filtration system provided by an embodiment of the present invention;

[0021] Figure 3 Schematic diagram of a disc pressure filtration system provided by an embodiment of the present invention;

[0022] Figure 4 Schematic diagram of the corresponding structure of an air supply system module provided by an embodiment of the present invention;

[0023] Figure 5 Schematic diagram of the structure of a flocculant tank and a coagulant aid tank corresponding to a concentration system module provided by an embodiment of the present invention;

[0024] Figure 6 Schematic diagram of the structure of a control device for a disc pressure filtration system provided by an embodiment of the present invention;

[0025] Figure 7 Schematic diagram of the structure of a disc pressure filtration system provided by an embodiment of the present invention;

[0026] Figure 8 Schematic diagram of the structure of an electronic device provided by an embodiment of the present invention. Detailed implementation manners

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following describes the implementation manners of the present disclosure through specific specific examples. Those skilled in the art can easily understand other advantages and effects of the present disclosure from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present disclosure, rather than all of the embodiments. The present disclosure can also be implemented or applied through other different specific implementation manners. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present disclosure. It should be noted that, without conflict, the following embodiments and the features in the embodiments can be combined with each other. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present disclosure without creative efforts fall within the scope of protection of the present disclosure.

[0028] Pressure filtration technology is an internationally recognized advanced dehydration technology. The disc pressure filter designed based on this technology is an advanced solid-liquid separation device in the world. After years of research and development, it has now reached the stage of mature technology and process.

[0029] The excellent dewatering effect of the disc pressure filter has been increasingly valued by more and more coal preparation plants, and it is considered to be the most ideal equipment for reducing the moisture content of flotation clean coal and dewatering raw slime so far. The disc pressure filter has the characteristics of large processing capacity, low moisture content, and high degree of automation.

[0030] With the emergence of high-pressure filter presses, especially the rapid development of high-pressure filter press technology in recent years, some users have reported that, compared with high-pressure filter presses under the same processing capacity and moisture conditions, the disc pressure filter has deficiencies such as high energy consumption and large maintenance workload. Further measures need to be taken to reduce energy consumption, further improve the degree of automation, reduce the number of operators, and reduce potential safety hazards.

[0031] At present, domestic disc pressure filters are continuously optimizing their product structures and improving the performance of the whole machine. Mechanically, they are mainly optimized and designed from aspects such as reliability, maintainability, safety, and energy consumption; electrically, they are mainly optimized and designed from aspects such as reliability, environmental adaptability, and stability. However, full-automatic control has not been achieved, and operator assistance is still required. Due to untimely adjustment by the operator and mismatched adjustment of various parameters, the disc pressure filter has high operating energy consumption. In addition, the neck of the filter fan is prone to wear through and air leakage occurs, and air leakage is likely to occur if the filter cloth is not replaced in time. Relying solely on regular inspections by the operator is not enough, and real-time monitoring is not carried out, nor is it transmitted to the computer control system module, resulting in high energy consumption of the entire system.

[0032] Based on the operating experience of the disc pressure filter for many years, with the goal of reducing energy consumption without reducing the processing capacity and moisture index, combined with theoretical calculations and data analysis, the R & D personnel re-established a mathematical model for the main operating parameters of the disc pressure filter and found that the unit energy consumption of the disc pressure filter is directly proportional to the pressure in the pressurized bin and inversely proportional to the feed concentration. Under the conditions of meeting the processing capacity and moisture, the higher the feed concentration, the lower the energy consumption; the lower the working pressure, the lower the energy consumption. By reasonably adjusting the feed concentration and controlling the working pressure, significant energy consumption reduction of the pressure filter can be achieved. Through preliminary calculation, the energy consumption can be reduced by about 30% on the original operating basis. Therefore, increasing the feed concentration of the disc pressure filter is a key link. By means of the computer control system module, timely adjustment of each parameter, especially the control of important parameters such as the working pressure in the pressurized bin, the rotation speed of the main shaft, and the feed concentration, can achieve the purpose of energy conservation and consumption reduction.

[0033] At present, the concentration of flotation clean coal is generally between 80g / l - 150g / l. When directly filtered through a disc pressure filter, due to the low feed concentration, the filtration efficiency is low, the filter cake on the filter fan is thin, air leakage is easy to occur, and the energy consumption is high; because of the low feed concentration, the hourly processing capacity is small and the energy consumption is high.

[0034] Iteratively upgrading the pressure filter to achieve fully automatic unmanned operation, automatically analyzing and adjusting various operating parameters to achieve energy consumption reduction and lower operating costs is an urgent problem to be solved.

[0035] In addition, with the emergence of high-pressure filter presses, some users have reported that the disc pressure filter has a large amount of maintenance work. Due to untimely maintenance, there is air leakage everywhere, resulting in high energy consumption of the entire system. Because the disc pressure filter has a high degree of automation, some users cannot keep up with the maintenance, resulting in high energy consumption during system operation. Improving the maintenance speed is the key to reducing energy consumption.

[0036] In response to the above problems, based on years of operating experience of the disc pressure filter, without reducing the processing capacity and moisture index, aiming at reducing energy consumption, combining theoretical calculations and data analysis, the R & D personnel re-established a mathematical model for the main operating parameters of the disc pressure filter and obtained that the unit energy consumption of the disc pressure filter is directly proportional to the pressure in the pressure chamber and inversely proportional to the feed concentration. Under the conditions of meeting the processing capacity and moisture, the higher the feed concentration, the lower the energy consumption; the lower the working pressure, the lower the energy consumption. By reasonably adjusting the feed concentration and controlling the working pressure, significant energy consumption reduction of the pressure filter can be achieved. After preliminary calculation, the energy consumption can be reduced by about 30% on the original operating basis. Therefore, increasing the feed concentration of the disc pressure filter is a key link. By means of the computer control system module, adjusting each parameter in a timely manner, especially controlling important parameters such as the working pressure in the pressure chamber, the rotation speed of the main shaft, and the feed concentration, the purpose of energy conservation and consumption reduction can be achieved.

[0037] In addition, the current concentration of flotation clean coal is generally between 80 g / l and 150 g / l. When directly filtered by a disc pressure filter, due to the low feed concentration, the filtration efficiency is low, the filter cake on the filter fan is thin, it is easy to have air leakage, and the energy consumption is high; because of the low feed concentration, the hourly processing capacity is small, and the energy consumption is high.

[0038] In response to this, an embodiment of the present invention provides a disc pressure filtration system, its control method and device, which can achieve fully automatic unmanned operation of the pressure filter, achieve energy consumption reduction, and reduce operating costs.

[0039] For ease of understanding, first, a control method for a disc pressure filtration system provided by an embodiment of the present invention will be described in detail. The control method of the disc pressure filtration system is applied to the disc pressure filtration system, and the disc pressure filtration system is configured with a deep cone thickener, and the deep cone thickener is used to provide input materials for the pressure filter of the disc pressure filtration system; Figure 1 The flowchart of a control method for a disc pressure filtration system provided by an embodiment of the present invention is shown, as Figure 1 shown, and the method includes the following steps:

[0040] Step S102, supply input materials to the pressure filter by means of a deep cone thickener; and, control the pressure in the pressure chamber of the pressure filter according to a preset pressure parameter of the pressure chamber, and control the pressure filter fans of the pressure filter according to a preset rotation speed parameter of the pressure filter fans, so that the pressure filter outputs filter cake based on the input materials.

[0041] A deep cone thickener is a highly efficient thickening device mainly used for the thickening and clarification of pulp. Its working principle is that in a conical container, through the action of gravity, solid particles settle at the bottom of the container, while the clearer liquid rises to the top and overflows. The deep cone thickener has a high thickening efficiency, can effectively reduce the load in the subsequent treatment stage, reduce the amount of liquid to be treated, and improve the overall treatment efficiency.

[0042] A pressure filter is a highly efficient solid-liquid separation device. It forces the liquid in the suspension to pass through the filter medium (such as filter cloth) by applying a pressure difference on both sides of the filter medium, while the solid particles are intercepted and form filter cake, thereby achieving solid-liquid separation. The main components and working principle of the pressure filter are as follows: Main components: 1. Pressure chamber: This is the core part of the pressure filter, used to hold the suspension to be filtered and apply pressure to it. 2. Filter medium: Usually composed of filter cloth, installed on the filter plate or filter fan, used to block solid particles. 3. Drive system: Includes hydraulic or pneumatic systems, used to generate and maintain high pressure in the pressure chamber. 4. Discharge device: Used to strip and discharge the formed filter cake from the filter medium. 5. Control system: Monitors and controls the operating parameters of the pressure filter, such as pressure, temperature, flow rate, etc. Working principle: 1. Pressurization: The suspension is pumped into the pressure chamber, and through the externally applied pressure (usually air or inert gas), the liquid is forced to pass through the filter medium, while the solid particles remain on the filter medium to form filter cake. 2. Drying: In some applications, after the filter cake is formed, the filter cake can be further dried by increasing the pressure or introducing hot gas to reduce its moisture content. 3. Discharge: When the filter cake reaches a predetermined thickness or the filtration cycle ends, the pressurization is stopped, and the filter cake is removed from the filter medium by mechanical or hydraulic means. 4. Cleaning and regeneration: After the filter cake is removed, the filter medium usually needs to be cleaned to remove residual solid particles and restore the filtration efficiency. Compared with traditional gravity filters, the pressure filter has higher filtration efficiency and lower moisture content of the filter cake, and is especially suitable for treating difficult-to-filter suspensions and applications that require low-moisture filter cakes. In actual operation, in order to achieve the optimal filtration effect, the operating parameters of the pressure filter, such as the pressure magnitude, filtration time, filter cloth type, etc., need to be adjusted according to the material characteristics.

[0043] In the embodiment of the present invention, the high-concentration material processed by the deep-cone thickener is conveyed into the pressure chamber of the pressure filter, which improves the concentration of the flotation clean coal, increases the feeding concentration of the disc pressure filter, increases the hourly throughput, and reduces the energy consumption.

[0044] Step S104: Obtain the material concentration of the input material and the parameters of the filter cake.

[0045] Step S106: Calculate the energy consumption data of the pressure filter based on the material concentration, the parameters of the filter cake, the pressure chamber pressure parameter, and the pressure filter fan rotation speed parameter.

[0046] Step S108: When the parameters of the filter cake do not meet the preset parameter requirements, adjust the pressure chamber pressure parameter and the pressure filter fan rotation speed parameter according to the energy consumption data until the parameters of the filter cake meet the preset parameter requirements.

[0047] The filter cake produced by the pressure filter is the accumulation of solid substances separated from the suspension or slurry during the filtration process. The formation of the filter cake is the core part of the pressure filtration technology. When the suspension or slurry passes through the filter medium under pressure, the liquid passes through the filter medium, while the solid particles are intercepted and gradually accumulate on the surface of the filter medium, forming a layer of filter cake. The thickness of the filter cake will increase over time until it reaches a certain thickness, at which point the resistance of the filter cake becomes too large, affecting the filtration rate. An appropriate filter cake thickness is crucial for maintaining high filtration efficiency and low energy consumption. The characteristics of the filter cake, such as particle size, shape, density, and humidity, will affect the filtration efficiency and the quality of the final product. For example, fine particles may result in a slower filtration speed, while a wetter filter cake may require additional drying steps.

[0048] The energy consumption data of the pressure filter comes from the following aspects: 1. To maintain the pressure inside the pressure filter, compressed air or a hydraulic system is usually required to provide power, which consumes energy. 2. During the filtration process, a pump is needed to send the suspension or slurry into the filter, and the operation of the pump also consumes electrical energy. In this regard, the embodiment of the present invention calculates the energy consumption of the pressure filter based on the various parameters of the pressure filter, as well as the concentration of the input material and the parameters of the output filter cake. Moreover, when the filter cake does not meet the preset requirements, the parameters of the pressure filter are adjusted while ensuring a reduction in energy consumption, so that the filter cake meets the preset requirements.

[0049] In specific implementation, the embodiment of the present invention tries to control a relatively low pressure value for the pressure filter. Under the condition of fixed concentration feeding within a reasonable empirical range, the liquid level in the feed tank is ensured to be stable (or the backflow is minimized), and the pressure filter works at a relatively small pressure value according to the empirical value. After the pressure is fixed, the rotation speed of the pressure filter fan is adjusted to achieve the balance of processing capacity. Further, the thickness of the filter cake is detected. If the thickness value is within a reasonable range, the moisture content of the filter cake and the concentration of the filtrate are calculated. If the thickness is insufficient, the rotation speed is reduced, and at the same time, a suitable pressure and rotation speed range are planned and solved. Otherwise, the pressure value is first adjusted and the rotation speed is adjusted accordingly.

[0050] Among them, when the pressure filter operates normally, the theoretical requirement for the main shaft rotation speed is 0.4 - 1.5 r / min, the thickness of the filter cake is 8 - 16 mm, the pressure in the pressure chamber is stable, and the coal slime dewatering effect is the best. In the practical process, the thickness of the filter cake of the pressure filter is directly related to the main shaft rotation speed. When the coal slime concentration and properties are certain, when the main shaft rotation speed slows down and the thickness of the filter cake is greater than 16 mm, the specific resistance of the filter cake is large, the moisture content is high, and the discharge is advanced in the filtration area. The early discharge in the filtration area causes the coal slime cake to fall into the pulp tank, resulting in serious pressure loss in the pressure chamber, leading to an extended loading time of the low-pressure fan and increased power consumption. When the main shaft rotation speed is fast and the thickness of the filter cake is less than 8 mm, the air permeability of the filter cake is good, but the pressure loss in the pressure chamber is serious, resulting in an extended loading time of the low-pressure fan and increased power consumption. In practice, when the parameters of the filter cake do not meet the preset requirements, the embodiment of the present invention adjusts the rotation speed of the main shaft of the filter fan (i.e., the rotation speed parameter of the pressure filter fan) in combination with the energy consumption data. The rotation speed is adjusted to about 1 r / min, and the thickness of the filter cake is about 10 mm, ensuring the product moisture, and the pressure in the pressure chamber is stable at about 200 kPa, with high efficiency and obvious energy-saving effect. The embodiment of the present invention can automatically analyze and adjust each operating parameter by detecting the parameters of the filter cake and combining the feed concentration and the corresponding energy consumption data, so as to achieve energy consumption reduction, reduce the operating cost, and realize fully automatic unmanned operation.

[0051] Further, in combination with the above embodiments, on the basis of the above embodiments, the embodiment of the present invention also provides another control method for a disk pressure filtration system. Figure 2 The flowchart of another control method for a disk pressure filtration system provided by the embodiment of the present invention is shown. Refer to Figure 2 , and the method includes the following steps:

[0052] Step S202, providing input materials for the pressure filter through a deep cone thickener; and controlling the pressure in the pressure chamber of the pressure filter according to the preset pressure parameter of the pressure chamber, and controlling the pressure filter fan of the pressure filter according to the preset rotation speed parameter of the pressure filter fan, so that the pressure filter outputs a filter cake based on the input materials.

[0053] Among them, in the embodiments of the present invention, a deep-cone thickener is used to concentrate the flotation feed. However, how to select the type needs to conduct sedimentation tests and theoretical calculations. Among them, the basic definitions of the parameters corresponding to the deep-cone thickener are as follows: Feed volume V1—M 2 / h; Overflow volume V2—M 2 / h; Underflow volume V3—M 2 / h; Feed concentration α3—g / L; Underflow concentration α4—g / L; Settling velocity υ—mm / s; Height of flowing water layer h—mm; Settling time t—s. The relationship equations are as follows: V1 = V2 + V3; α4 = V1×α3 / V3. The terminal settling velocity υ should be measured by experimental methods. It is a function of concentration and settling distance and can be measured by the clarifying layer velocity in a graduated cylinder.

[0054] The overflow water flow rate V2. To ensure the maximum flow rate of clear water overflowing, the formula is derived using the shallow pond principle as follows: Assume the deep cone is circular, the radius from the central feed tube is r1, and the radius to the overflow weir is r2. Any unknown change value at any point on the radius is dr.

[0055] The horizontal velocity equation at any point on the radius is as follows: υr = V2 / (2×Π×r×h / 1000) / 3600, where 3600 is the number for converting hours (h) to seconds (s) (1 hour equals 3600 seconds), and 1000 is used to convert centimeters (cm) to meters (m).

[0056] List the differential equation: dt = dr / υr; dt = dr / (V2 / (7.2×Π×r×h)) = 7.2×Π×r×h×dr / V2;

[0057] Integrate with respect to time:

[0058] t = 7.2×Π×h / V2∫rdr = (7.2×Π×h / V2)×(r2 - r1) / 2;

[0059] t = 3.6×Π×h×(r2 - r1) / V2.

[0060] Assume is the boundary condition for the deep-cone thickener to produce clear water, then we can get:

[0061]

[0062] V3 > V1×α3 / α4.

[0063] However, to ensure clear water production, a margin should be left for V3; at the same time, calculate the reasonable concentration of the underflow.

[0064] Furthermore, the pressure parameters of the pressurized bin and the rotational speed parameters of the pressurized filter fan in the embodiments of the present invention are determined through the following steps: Input the material concentration of the input material into a pre-established energy-saving mathematical model to determine the rotational speed of the filter fan and the air supply pressure of the pressure filter based on the material concentration; determine the rotational speed of the filter fan as the rotational speed parameter of the pressurized filter fan, and determine the air supply pressure as the pressure parameter of the pressurized bin. Among them, the energy-saving mathematical model is constructed based on the relationship between the pressure parameter of the pressurized bin of the pressure filter, the rotational speed parameter of the pressurized filter fan, and the energy consumption of the pressure filter.

[0065] The cross-flow pressure value of the pressure filter is not a fixed parameter. It depends on various factors, including the design of the filter, the characteristics of the material being processed, and the operating conditions, etc. Usually, this pressure value will be given in the technical specifications or operation manuals of the equipment as a reference for guiding operations. Generally speaking, the working pressure range of the pressure filter is approximately between 0.3 and 0.5 MPa (megapascals), but this is only a common reference range. During actual operation, in order to achieve the best filtration effect and filter cake moisture, operators will adjust the pressure according to the specific situation of the material. If the cross-flow pressure is too low, it may lead to a decrease in filtration efficiency and an increase in the water content of the filter cake; conversely, if the pressure is too high, it may cause additional load on the equipment, affect the equipment life, or cause problems such as filter cloth damage. Therefore, maintaining an appropriate cross-flow pressure is crucial for ensuring filtration efficiency and product quality. For the setting of the specific cross-flow pressure value, it is recommended to consult the operation manual of the corresponding pressure filter or consult the equipment supplier and technical personnel to obtain the most accurate operation parameters.

[0066] In specific implementation, the energy consumption equation of the pressure filter is derived through the following process, and then an energy-saving mathematical model can be established to enable the system to operate autonomously according to the concentration characteristics and moisture requirements of the incoming material. The basic definitions of the pressure filter are as follows: Rotational speed of the filter fan N - revolutions / min; Area of a single filter fan S - m²; Thickness of the filter cake H - mm; Filtration pressure P1 - kg; Filtration time T1 - min; Cross-flow pressure P2 - kg; Cross-flow time T2 - min; Dry coal slime processing capacity Q - t / min; Slurry processing capacity V - m³ / min; Feed concentration α1 - g / L; Filtrate concentration α2 - g / L; Moisture content of the filter cake Mt - %; Bulk density of the filter cake 1 t / m³; True density of the filter cake 1.5 t / m³; Flow rate of the air compressor under standard conditions A - m³ / min.

[0067] The bulk density of the filter cake, also known as the packing density, refers to the mass of the filter cake per unit volume, usually expressed in g / cm 3 or kg / m 3Representation. The bulk density of the filter cake is affected by various factors, including but not limited to the composition of the filter cake, particle size distribution, moisture content, and the pressure during the preparation process, etc. The true density of the filter cake refers to the mass per unit volume of the solid deposit (filter cake) formed during the filtration process in an absolutely dense state. This value is usually used to evaluate the compactness of the solid after filtration and its handling characteristics in specific industrial processes, such as in the mining, chemical, wastewater treatment, and other fields. When calculating the true density of the filter cake, all pores and voids need to be excluded, and only the volume occupied by the solid material itself is considered.

[0068] The relationship equations are as follows:

[0069] Formula 1: Q = S × H × N × 1, where 1 is the bulk density of the material, Q is the dry slime treatment capacity, S is the area of a single filter sector, H is the filter cake thickness, and N is the number of revolutions of the filter sector.

[0070] Formula 2: Q = V × α1 / 1000, where Q is the dry slime treatment capacity, V is the pulp treatment capacity, and α1 is the feed concentration.

[0071] Formula 3: Relationship equation for treatment capacity. The greater the filtration pressure, the greater the treatment capacity; the greater the concentration, the less water needs to be discharged per unit treatment capacity, and the greater the treatment capacity; the greater the filter cake thickness, the greater the difficulty of draining water, and the smaller the treatment capacity.

[0072] The dry slime treatment capacity Q = f(α1, P1, H). α1 is the feed concentration, P1 is the filtration pressure, and H is the filter cake thickness. However, the specific relationship equation needs to be determined through experiments.

[0073] Formula 4: Moisture calculation equation. Generally speaking, it is inversely proportional to the cross-flow air volume and inversely proportional to the treatment capacity.

[0074] Continuing the derivation according to the above logic: Mt = 1 / [P2 / K3 × (S × H × N)].

[0075] In the above formulas, Mt is the filter cake moisture, P2 is the cross-flow pressure, S is the area of a single filter sector, H is the filter cake thickness, and N is the number of revolutions of the filter sector. The filter cake moisture is inversely proportional to the material thickness and the cross-flow pressure. However, whether it is the above linear relationship needs to be determined through experiments.

[0076] Formula 5: Regarding the filtrate concentration, it should be inversely proportional to the filter cake thickness and directly proportional to the cross-flow pressure. α2 = f(P2, H). Where α2 is the filtrate concentration, P2 is the cross-flow pressure, and H is the filter cake thickness. However, the specific relationship equation needs to be determined through experiments. This parameter is a control parameter. When the user gives the requirement for the filtrate concentration range, the system will continuously calculate the risk of filtrate concentration exceeding the standard during the process of adjusting system parameters and give the adjustment limit.

[0077] In summary, based on the above derivations, the corresponding filter fan rotation speed and air supply pressure (i.e., cross-flow pressure) of the pressure filter can be determined through the energy-saving mathematical model based on the material concentration of the feed, and then the pressure chamber pressure parameter and the pressure filter fan rotation speed parameter can be determined.

[0078] Step S204: Obtain the material concentration of the input material and the parameters of the filter cake.

[0079] Step S206: Calculate the energy consumption data of the pressure filter based on the material concentration, the parameters of the filter cake, the pressure chamber pressure parameter, and the pressure filter fan rotation speed parameter.

[0080] Combining the above steps, the energy consumption data is calculated through the following steps: 1) Calculate the dry coal slime treatment capacity and the slurry treatment capacity of the pressure filter based on the parameters of the filter cake and the material concentration. 2) Calculate the air consumption during the pressure filtration process of the pressure filter based on the material concentration, the dry coal slime treatment capacity, and the slurry treatment capacity. 3) Calculate the air consumption during the cross-flow process of the pressure filter based on the cross-flow pressure corresponding to the pressure chamber pressure parameter and the dry coal slime treatment capacity. 4) Calculate the exhaust air of the lower chamber of the pressure filter based on the filtration pressure corresponding to the pressure filter fan rotation speed parameter and the laws of thermodynamics. 5) Calculate the energy consumption data of the pressure filter based on the air consumption during the pressure filtration process, the air consumption during the cross-flow process, and the exhaust air of the lower chamber.

[0081] Among them, the calculation of the dry coal slime treatment capacity and the slurry treatment capacity refers to the above formulas. The main energy consumption of the pressure filter is high-pressure air, which can be directly represented by the air consumption (the high-pressure air volume required to process unit mass of dry coal slime) A (M 3 / t), and this air consumption is the standard air volume (1 standard atmosphere, the air intake volume at the inlet of the air compressor).

[0082] For this pressure filter, this air consumption is related to the following 4 factors:

[0083] Factor 1: A1 air consumption during the pressure filtration process: The first factor has a linear relationship with the unit drainage volume, A1 = K1×V×(1 - α1 / 1500) / Q. 1500 is the reference value, and in one embodiment, it is obtained based on the design specifications of the equipment, industry standards, or experimental data analysis. After the transformation of this formula, it is as follows:

[0084] A1 = K1×V×(1 - α1 / 1500) / (V×α1 / 1000)

[0085] = K1×(1 - α1 / 1500) / (α1 / 1000)

[0086] = K1×(1000 - α1 / 1.5) / α1

[0087] = K1×(1000 / α1 - 0.67)

[0088] Among them, V is the pulp treatment capacity, α1 is the feed concentration, and Q is the dry coal slime treatment capacity.

[0089] Factor 2: K1 is related to the amount of air dissolved in the filtrate under high pressure. K1 = f(P1), where P1 is the filtration pressure, and this relational equation can refer to the general formula in fluid mechanics.

[0090] Factor 3: The air consumption in the A3 through-flow process: The calculation of this air volume is similar to the characteristic curve of the air duct.

[0091] It is preliminarily determined that its formula should be: A3 = (P2 / K3) / Q. After formula transformation, it is as follows:

[0092] A3 = (P2 / K3) / (S × H × N), and the calculation of K3 can fully refer to the calculation formula of the filtration medium resistance coefficient. K3 = f(H).

[0093] Factor 4: The exhaust air A4 of the lower bin. According to the first law of thermodynamics, this air consumption is linearly proportional to the discharge times and the discharge pressure. A4 = K4 × Q × P1 / Q = K4 × P1.

[0094] Among them, K4 is directly related to the exhaust air process and is related to the following aspects: 1. The physical characteristics of the exhaust air system: including the size, shape, length of the exhaust air pipe and the smoothness of the material, which will all affect the air resistance and thus indirectly affect the value of K4. 2. The design and configuration of the discharge port: The design of the discharge port, such as the opening size, shape and its layout position in the equipment, will affect the discharge efficiency and the required pressure, further affecting K4. 3. The control system and valve regulation: The opening and closing strategies of the valves in the automatic control system, as well as its response speed and accuracy, will also affect the actual pressure demand during exhaust air, so it may affect the setting of K4. 4. The maintenance status and equipment aging: The wear, blockage of the equipment during long-term operation and the quality of regular maintenance will cause changes in the exhaust air efficiency, which may also be a practical operation and maintenance factor determining K4. 5. Safety and environmental regulations: In some cases, the safety specifications and environmental protection requirements of the factory or industry may limit the maximum exhaust air pressure, thereby affecting the setting of K4 to meet these external regulations.

[0095] Based on the above formula: A = A1 + A3 + A4 = K1 × (1000 / α1 - 0.67) + (P2 / K3) / (S × H × N) + K4 × P1.

[0096] Among them, α1 is the feed concentration, P2 is the through-flow pressure, S is the area of a single filter fan, H is the filter cake thickness, N is the filter fan rotation speed, and P1 is the filtration pressure. Based on the above formula, the unit energy consumption of the pressure filter is directly proportional to the pressure of the pressure chamber; and inversely proportional to the feed concentration. For (S × H × N) in this equation, when the system is stable, it is a fixed value and can be temporarily not considered.

[0097] The dry coal slime processing capacity refers to the total amount of coal slime that a pressure filter can process and convert into a dry state within a unit time. This indicator is one of the important parameters for measuring the working efficiency of the filter. In a pressure filter, the dry coal slime processing capacity is affected by various factors, including but not limited to: filtration pressure, feed concentration, filter cake thickness, filter fan rotation speed, and filter cake moisture. The pulp processing capacity refers to the volume or mass of pulp that a specific device or system can process within a unit time. In the mining and mineral processing industries, the pulp processing capacity is one of the important indicators for measuring the efficiency and production capacity of a concentrator or ore processing plant.

[0098] Step S208: Determine whether the thickness parameter of the filter cake is within a preset thickness range. If not, calculate the target rotation speed parameter corresponding to the thickness parameter by combining the energy-saving mathematical model with the energy consumption data, and adjust the rotation speed parameter of the pressure filter fan based on the target rotation speed parameter.

[0099] Step S210: If so, obtain the moisture parameter and filtrate concentration of the filter cake; calculate the target pressure parameter corresponding to the moisture parameter and filtrate concentration by combining the energy-saving mathematical model with the energy consumption data, and adjust the opening degree of the air outlet regulating valve of the pressure chamber based on the pressure parameter to adjust the pressure parameter of the pressure chamber.

[0100] Specifically, the parameters of the filter cake include the thickness parameter, moisture parameter, and filtrate concentration. In addition, an air outlet regulating valve is installed in the pressure chamber of the pressure filter to control the pressure difference P2 of the cross-flow part, and at the same time, the cross-flow air outlet pressure is detected. Further, the embodiments of the present invention also monitor the material concentration, and when the material concentration is lower than the preset threshold, the pressure filter is controlled to stop working.

[0101] Specifically, the energy-saving control logic of the pressure filter in the embodiments of the present invention is as follows:

[0102] 1) Combining the above analysis, the embodiments of the present invention first increase the feed concentration. For the material coming from the bottom flow of the thickener, as long as the overflow water can be ensured to be clear, the concentration should be as high as possible, otherwise the feed should be suspended and processed after the concentration increases. Among them, the pressure filter in the embodiments of the present invention has upper and lower limit values for the concentration. When the concentration is too high, it cannot be processed, and when the concentration is too low, it cannot be processed and no cake can be formed. This limit value is given according to experience. The overall logic is to try to select the upper limit value. Therefore, the embodiments of the present invention also configure a concentration meter and a flow meter for the feed system.

[0103] 2) Through the above analysis, the embodiments of the present invention try to control a lower pressure value. The range of this limit value will be given later, but the overall logic is to try to select the lower limit value for the pressure. Therefore, the embodiments of the present invention add a cross-flow pressure air outlet regulating valve to control the pressure difference P2 of the cross-flow part, and at the same time, the cross-flow air outlet pressure needs to be detected.

[0104] 3) Processing capacity balance: Under the condition of fixed-concentration feeding within a reasonable range of experience, it is necessary to ensure the stable liquid level (or minimum reflux) in the feed tank. At this time, it is necessary to work at a relatively small pressure according to the empirical value. After the pressure is fixed, adjust the rotation speed of the pressure filter fan to achieve the processing capacity balance.

[0105] 4) After adjusting according to item 3), the pressure filter works to output the filter cake. Further, detect the thickness of the filter cake. If the thickness value is within a reasonable range, calculate the moisture content of the filter cake and the concentration of the filtrate. If the thickness is insufficient, reduce the rotation speed. At the same time, according to the previous formulas 3, 4, and 5, plan and solve the appropriate pressure and rotation speed range, and repeat step 3) within a reasonable range. Otherwise, first adjust the pressure value and adjust the rotation speed accordingly. The above system can be developed using PLC.

[0106] Among them, when the pressure maintenance experiment of the pressure chamber in the coal preparation plant is carried out, it is required that the pressure in the pressure chamber is filled to 0.35 MPa, the pressure is maintained for 20 minutes, and the pressure relief range does not exceed 0.05 MPa. If it is within the range, it indicates that the sealing performance of the pressure chamber is good. If the pressure relief range exceeds 0.05 MPa, it indicates that the sealing performance is poor, and it is necessary to check each component and replace or repair the air-leaking components in time. The industrial switch module and the intelligent remote maintenance system module are required to remind the user and supervise the user's maintenance to achieve the purpose of energy conservation and consumption reduction.

[0107] The pressure in the pressure chamber is a necessary condition to ensure the moisture content of the product. Only when the pressure reaches a certain level can the moisture content of the product be guaranteed. When the factors such as the feed and the spindle rotation speed of the pressure filter remain unchanged, theoretically, the greater the pressure in the pressure chamber, the greater the processing capacity and the greater the air consumption. When the pressure in the pressure chamber rises to a certain limit value, no matter how the pressure changes, the moisture content of the coal slime filter cake changes little or does not change, and the working pressure continues to increase, increasing the operating load and power consumption of the low-pressure fan, resulting in high energy consumption. Through the calculation center system control module, through calculation, reasonably control the pressure in the chamber to achieve the purpose of energy conservation. The accuracy of the tank liquid level gauge is a necessary condition for guiding the production of the pressure filter, and at the same time can reduce the air leakage of the filter fan and reduce energy consumption. Through the detection system module, energy consumption can be reduced.

[0108] During the operation of the pressure filter, it is always in a state of consuming air. Depending on the coal slime quality, the required air consumption varies. Generally, for a single pressure filter (taking the GPJ120 type as an example), 2 - 3 low-pressure blowers (2 units of 250 kW and 1 unit of 132 kW) are required for normal operation. The largest energy-consuming equipment in the entire system is the low-pressure blower. Only by reducing unnecessary air volume waste can the utilization rate of the blower be improved, which is the fundamental link for the entire system to achieve energy conservation and consumption reduction. Specific measures: 1) Install a frequency converter on the low-pressure blower motor. By setting the pressure value, adjust the motor speed. When the pressure reaches the required value of the pressure filter, through the adjustment of the motor speed by the frequency converter, the motor work becomes more reasonable, ensuring normal production while reasonably reducing the equipment power consumption to achieve the purpose of energy conservation and consumption reduction. 2) Strengthen the maintenance of the low-pressure blower. Regularly replace the air filter and oil filter of the blower, and timely observe the differential pressure state of the filter element of the oil and gas separator. Replace it in time when it reaches the limit value (limit value 1.7), and timely detect the intake vacuum degree of the air filter element (0.05). When it is found that the vacuum degree of the air filter element is relatively high, clean or blow it to keep the air intake and compression of the blower smooth at all times, achieving a good operating effect, making the operating state of each low-pressure blower reach the best, the gas production reach the maximum, thereby reducing the number of operating blowers and achieving the purpose of energy conservation and consumption reduction. Using the detection system module, computer system control module, and intelligent remote maintenance system module to control the blower can effectively reduce energy consumption.

[0109] Theoretically, when the pressure filter operates normally, the main shaft speed is 0.4 - 1.5 r / min, the filter cake thickness is 8 - 16 mm, the pressure in the pressure chamber is stable, and the coal slime dewatering effect is the best. In the practical process, the thickness of the filter cake of the pressure filter is directly related to the main shaft speed. When the coal slime concentration and properties are certain, if the main shaft speed slows down and the filter cake thickness is greater than 16 mm, the filter cake specific resistance is large, the moisture content is high, and early discharging occurs in the filtration zone. Early discharging in the filtration zone causes the coal slime cake to fall into the pulp tank, resulting in serious pressure loss in the pressure chamber, leading to an extended loading time of the low-pressure blower and increased power consumption. If the main shaft speed is fast and the filter cake thickness is less than 8 mm, the filter cake has good air permeability, resulting in serious pressure loss in the pressure chamber, leading to an extended loading time of the low-pressure blower and increased power consumption. In practice, the main shaft speed is adjusted to about 1 r / min, and the filter cake thickness is about 10 mm, ensuring the product moisture content, and the pressure in the pressure chamber is stable at about 200 kPa, with high efficiency and obvious energy-saving effect. By using the detection system module, computer system control module, and intelligent remote maintenance system module to control the main shaft speed, energy consumption can be effectively reduced.

[0110] Furthermore, the embodiment of the present invention also monitors the filtrate concentration of the filter cake and determines whether the filtrate concentration exceeds a preset threshold. If so, a warning message is generated. Detect the filtrate water concentration. When it is found that the concentration becomes high, perform maintenance in time and check and replace the filter cloth.

[0111] In specific implementation, the disk pressure filtration system of the embodiment of the present invention includes a detection system module, a monitoring system module, and an intelligent remote maintenance system module. The detection system module can achieve the efficient operation of the equipment and reduce energy consumption by constantly detecting various operating parameters. The monitoring system module is added at important corners of the equipment. By observing in the centralized control room at all times, faults can be promptly processed, and the operation efficiency can be improved. Through the intelligent remote maintenance system module, users can be promptly guided and repairs can be carried out in a timely manner, improving the working efficiency of the equipment and reducing energy consumption.

[0112] Specifically, the detection system module online detects the filtrate water concentration. When the concentration is found to be high, a warning prompt is given in a timely manner, and maintenance is carried out in a timely manner. By checking and replacing the filter cloth, filtrate pipe, and filter fan, energy consumption can be effectively reduced. Further, the detection system module also online detects the filter cake thickness and adjusts various operating parameters in a timely manner, which can effectively reduce energy consumption. Further, the system also includes a thickening system module, a calculation center system control module, and an air supply system module. Through the thickening system module, a deep cone thickener is adopted to increase the concentration of flotation clean coal, increase the feed concentration of the disk pressure filter, increase the hourly processing capacity, and reduce energy consumption. Through the calculation center system control module, the feed concentration of the system is controlled, and at the same time, the rotation speed of the main shaft is controlled to reduce energy consumption. The air supply system module is provided with a pressure sensor, and through the calculation center system control module, the air supply pressure is controlled to reduce energy consumption. Among them, in the production site, reasonable selection of the working pressure according to the on-site coal quality and slime situation is a direct factor in improving the production efficiency and energy conservation and consumption reduction of the pressure filter. When the pressure filter is used to process flotation clean coal, the pressure in the pressure chamber should be adjusted to 200 - 350 kPa, which can reduce energy consumption. By controlling the pressure in the pressure chamber through the detection system module, the computer system control module, and the intelligent remote maintenance system module, energy consumption can be effectively reduced.

[0113] Further, the disk pressure filtration system of the embodiment of the present invention further includes a flow meter, which is installed at the air outlet of the air compressor of the pressure filter; the monitored value of the flow meter is used to represent the actual air consumption of the pressure filter; the embodiment of the present invention also obtains the monitored value of the flow meter and adjusts the parameter representing energy consumption in the energy-saving mathematical model based on the monitored value. In specific implementation, a vortex flow meter is added at the air outlet of the air compressor in the embodiment of the present invention to measure the air consumption and calculate the actual air consumption per unit processing capacity to test whether the energy-saving control system is effective.

[0114] Specifically, Figure 3 shows a schematic diagram of a disk pressure filtration system corresponding to the embodiment of the present invention. The Figure 3Used to illustrate the connections between the pressure filter and the feeding system module, thickening system module, air supply system module, monitoring system module, detection system module, industrial switch module, computing center system control module, and intelligent remote maintenance system module. Further, Figure 4 shows Figure 3 the corresponding structural schematic diagram of the air supply system module in Figure 4 as shown, including a high-pressure fan and a low-pressure fan, and pressure control is achieved through a regulating valve. Further, the thickening system module is equipped with a flocculant tank and a coagulant aid tank for generating the input material. Figure 5 shows the structural schematic diagrams of the flocculant tank and the coagulant aid tank corresponding to the thickening system module. Among them, the flocculant tank and the coagulant aid tank are provided with flow meters, and their data can be displayed and transmit 4-20mA signals; the dosing ratio of the collector and the foaming agent is set to a fixed value of 2:1 for easy adjustment. Further, after normal adjustment, within a concentration change of ±5% and a flow change of ±5%, the dosing amount (flocculant and coagulant aid) does not need to be adjusted. After normal adjustment, when other data are within 5% (assumed to be unchanged), when the concentration change exceeds the A value (assumed to be 5%), the dosing amount is adjusted by a certain proportion of the a value, and the a value is adjustable. After normal adjustment, when other data are within 5% (assumed to be unchanged), when the flow change exceeds the B value (assumed to be 5%), the dosing amount is adjusted by a certain proportion of the b value, and the b value is adjustable.

[0115] Another control method for the disk pressure filter system provided by the embodiments of the present invention realizes adjustable feeding concentration by setting a deep cone thickener for the pressure filter, and, in combination with the feeding concentration, the main shaft rotation speed of the pressure filter fan of the pressure filter, the pressure value of the pressure chamber, etc., calculates the energy consumption data of the pressure filter. Further, when the output filter cake does not meet the requirements, the system automatically adjusts the working parameters of the pressure filter in combination with the energy consumption data, so that not only can a qualified filter cake be output, but also the pressure filter can be maintained within a low energy consumption range. In addition, when the feeding concentration meets the requirements, the system can automatically control the pressure filter to stop working, correspondingly, the air consumption of the pressure filter stops, further reducing the energy consumption. And, the pressure filter fan stops working until the feeding concentration reaches the requirements and then starts again, which can control multiple parameters of the pressure filter, realize the automatic operation of the pressure filter, complete the iterative upgrade of the full-automatic unmanned operation of the pressure filter, automatically analyze and adjust each operation parameter, enable the equipment to operate efficiently, reduce energy consumption, and reduce the operation cost.

[0116] Further, on the basis of the above embodiments, the embodiments of the present invention also provide a control device for a disk pressure filter system, Figure 6 shows the structural schematic diagram of a control device for a disk pressure filter system provided by the embodiments of the present invention, as Figure 6As shown in the figure, the device includes: a control module 100, configured to provide input material to a pressure filter through a deep cone thickener; and control the pressure in the pressure chamber of the pressure filter according to a preset pressure parameter of the pressure chamber, and control the pressure filter fan of the pressure filter according to a preset rotation speed parameter of the pressure filter fan, so that the pressure filter outputs filter cake based on the input material; a data acquisition module 200, configured to acquire the material concentration of the input material and the parameters of the filter cake; a data processing module 300, configured to calculate the energy consumption data of the pressure filter based on the material concentration, the parameters of the filter cake, the pressure parameter of the pressure chamber, and the rotation speed parameter of the pressure filter fan; an execution module 400, configured to adjust the pressure parameter of the pressure chamber and the rotation speed parameter of the pressure filter fan according to the energy consumption data when the parameters of the filter cake do not meet the preset parameter requirements until the parameters of the filter cake meet the preset parameter requirements.

[0117] The control device of a disk pressure filtration system provided by an embodiment of the present invention has the same technical features as the above method embodiment, so it can also solve the same technical problems and achieve the same technical effects.

[0118] Further, based on the above embodiment, an embodiment of the present invention also provides another control device of a disk pressure filtration system. The data processing module 300 is further configured to calculate the dry coal slime treatment capacity and the slurry treatment capacity of the pressure filter based on the parameters of the filter cake and the material concentration; calculate the air consumption during the pressure filtration process of the pressure filter based on the material concentration, the dry coal slime treatment capacity, and the slurry treatment capacity; calculate the air consumption during the through-flow process of the pressure filter based on the through-flow pressure corresponding to the pressure parameter of the pressure chamber and the dry coal slime treatment capacity; calculate the exhaust air of the lower chamber body of the pressure filter based on the filtration pressure corresponding to the rotation speed parameter of the pressure filter fan and the laws of thermodynamics; calculate the energy consumption data of the pressure filter based on the air consumption during the pressure filtration process, the air consumption during the through-flow process, and the exhaust air of the lower chamber body.

[0119] The control module 100 is further configured to input the material concentration of the input material into a pre-established energy-saving mathematical model to determine the rotation speed of the filter fan and the air supply pressure of the pressure filter based on the material concentration; the energy-saving mathematical model is constructed based on the relationship between the pressure parameter of the pressure chamber of the pressure filter, the rotation speed parameter of the pressure filter fan, and the energy consumption of the pressure filter; determine the rotation speed of the filter fan as the rotation speed parameter of the pressure filter fan, and determine the air supply pressure as the pressure parameter of the pressure chamber.

[0120] Further, an air outlet regulating valve is installed in the pressurized chamber of the pressure filter; the parameters of the filter cake include thickness parameters, moisture parameters, and filtrate concentration; the above-mentioned execution module 400 is further configured to determine whether the thickness parameter of the filter cake is within a preset thickness range. If not, the target rotation speed parameter corresponding to the thickness parameter is calculated through the energy-saving mathematical model in combination with the energy consumption data, and the rotation speed parameter of the pressure filter fan is adjusted based on the target rotation speed parameter; if so, the moisture parameter and the filtrate concentration of the filter cake are obtained; the target pressure parameter corresponding to the moisture parameter and the filtrate concentration is calculated through the energy-saving mathematical model in combination with the energy consumption data, and based on the pressure parameter, the opening degree of the air outlet regulating valve of the pressurized chamber is adjusted to adjust the pressure parameter of the pressurized chamber.

[0121] The above-mentioned execution module 400 is further configured to monitor the filtrate concentration of the filter cake and determine whether the filtrate concentration exceeds a preset threshold. If so, a warning message is generated.

[0122] Further, the disc pressure filtration system further includes a flow meter, and the flow meter is installed at the air outlet of the air compressor of the pressure filter; the monitored value of the flow meter is used to represent the actual air consumption of the pressure filter; the above-mentioned data processing module 300 is further configured to obtain the monitored value of the flow meter and adjust the parameter representing the energy consumption in the energy-saving mathematical model based on the monitored value.

[0123] Further, the above-mentioned execution module 400 is further configured to monitor the material concentration, and when the material concentration is lower than a preset threshold, control the pressure filter to stop working.

[0124] Based on the above embodiments, an embodiment of the present invention further provides a disc pressure filtration system, and the disc pressure filtration system is configured with a deep cone thickener, and the deep cone thickener is used to provide input materials for the pressure filter of the disc pressure filtration system; wherein, the disc pressure filtration system includes a computing center system control module, and the computing center system control module is configured with the control device of the above-mentioned disc pressure filtration system for executing the control method of the above-mentioned disc pressure filtration system. Further, the disc pressure filtration system further includes an intelligent remote maintenance system module for monitoring faults of the pressure filter.

[0125] In specific implementation, in combination with the above embodiments, an embodiment of the present invention provides a comprehensive filtration system device for a disc pressure filter, including a feeding module, a pressure filter module, a air supply system module, a monitoring system module, a detection system module, and an industrial switch module; characterized in that: it further includes a thickening system module, a computing center system control module, and an intelligent remote maintenance system module.

[0126] Figure 7 The structural schematic diagram of a disc pressure filtration system provided by an embodiment of the present invention is shown. Refer to Figure 7, a deep cone thickener is provided for the pressure filter, and a liquid level gauge and a flow meter are provided between the two. At the same time, data is obtained through an industrial switch and transmitted to the computing center for parameter calculation. Among them, the filtrate water line is between the pressure filter and the turbidity meter, and the filter cake material line is between the pressure filter and the collecting belt. Further, a feed pump and an underflow pump are provided between the deep cone thickener and the pressure filter, and the pressure filtration is realized by means of pump circulation, which can improve the filter cake production efficiency.

[0127] In specific implementation, the concentration system module is characterized in that: a deep cone thickener is adopted to increase the concentration of flotation clean coal, increase the feed concentration of the disc pressure filter, increase the hourly processing capacity, and reduce energy consumption. Through the computing center system control module, the feed concentration of the system is controlled, and at the same time, the rotation speed of the main shaft is controlled to reduce energy consumption. The detection system module achieves the efficient operation of the equipment and reduces energy consumption by constantly detecting various operating parameters. The monitoring system module adds a monitoring system module in important corners of the equipment, observes in real time in the centralized control room, promptly processes faults, and improves the operation efficiency. The air supply system module is provided with a pressure sensor, and the air supply pressure is controlled through the computing center system control module to reduce energy consumption.

[0128] Intelligent remote maintenance system module, characterized by: including remote programming, data dashboard, process monitoring, equipment management monitoring, alarm information management, and equipment consumable management. Among them, the above-mentioned remote programming accesses the on-site PLC of the pressure filter remotely, with simple and safe programming. If the pressure filter fails, it can remotely monitor and modify the PLC program online, better handle the temporary faults occurring to users, improve customer satisfaction, and enhance the timeliness of problem handling. The above-mentioned data dashboard records the main operation data of the pressure filter and displays the main operation data record of the pressure filter in the form of historical trends and real-time trends. The above-mentioned process monitoring remotely monitors the operation of the on-site pressure filter in real time. According to different settings of operation permissions, remote start-stop control of the equipment and remote equipment operation monitoring can be realized. The above-mentioned equipment management monitoring remotely monitors the life cycle of each component of the pressure filter in real time. There is a life cycle progress bar beside each component of the pressure filter (such as motors, valves, sensors, etc.), which displays the life cycle status of the equipment in the form of a percentage in real time. The above-mentioned alarm information management remotely manages and records the equipment alarms and consumable alarms that occur during the operation of the pressure filter. By statistically analyzing the number and frequency of alarm information occurring during the operation, it is possible to know earlier where what kind of problems will occur, and handle them when the problems are in the budding state, achieving predictive maintenance. The above-mentioned equipment consumable management encodes the materials of all mechanical and electrical components of the pressure filter. Each component is managed according to its life cycle. When the replacement cycle is reached, it will be prompted in real time in the consumable management table. Data such as consumable name, consumable specification model, and last replacement date are clear at a glance.

[0129] As the degree of intelligence of the disk pressure filter gradually increases, the user's maintenance level of the equipment has not been improved synchronously. Delayed maintenance leads to high failure rates, low production efficiency, and high energy consumption during equipment operation. Developing an intelligent remote maintenance system module can help users operate, guide users in a timely manner, and perform maintenance in a timely manner, improving the working efficiency of the equipment and reducing energy consumption. It is also the most crucial step in energy conservation. In addition, developing an intelligent remote maintenance system module can reduce the enterprise's off-site service costs.

[0130] Among them, the upper and lower filtrate pneumatic gate valves of the pressure filter operate frequently, have a large amount of wear, and a high failure rate, resulting in the upper and lower filtrate pneumatic gate valves being fully open for a long time, causing a large pressure loss in the bin and affecting the operation efficiency of the pressure filter. Delayed maintenance by the operator leads to air leakage. In the embodiment of the present invention, the valve is transformed into an automatic control, and through the calculation center system control module, the opening of the valve is adjusted in a timely manner according to production and slime properties, achieving the purpose of energy conservation.

[0131] In the embodiments of the present invention, the main filtrate pipe, filter fan, filter cloth and the main and passive side distribution valves are regularly replaced and maintained according to their minimum historical usage cycles to ensure the integrity and reliability of the components and reduce pressure loss. The intelligent remote maintenance system module can remotely remind users to replace them regularly and provide remote guidance for installation and maintenance.

[0132] Furthermore, in the embodiments of the present invention, a liquid level sensor is provided. The liquid level sensor is the only means to detect the height of the coal slurry level in the storage tank of the disc pressure filter. It is required that the liquid level in the tank must be maintained between 550 and 650 mm. At this time, the filter fan can be completely immersed, and each filter cloth is completely wrapped by the slurry, reducing the air consumption of the filter cloth to the lowest level and ensuring the minimum pressure loss of the filter cloth and the filter fan. It is required to detect the accuracy of the liquid level gauge in the tank every 15 days. In case of the inconsistency between the on-site calibrated liquid level and the liquid level displayed in the centralized control room, re-calibration or on-site adjustment should be carried out in a timely manner. By controlling the liquid level of the feed tank through the detection system module, the computer system control module and the intelligent remote maintenance system module, the energy consumption can be effectively reduced.

[0133] The embodiments of the present invention also provide an electronic device, including a memory, a processor, and a computer program stored on the memory and executable on the processor. When the processor executes the computer program, the steps of the method shown in any of the above Figures 1 to 2 are implemented. The embodiments of the present invention also provide a computer-readable storage medium, on which a computer program is stored. When the computer program is run by the processor, the steps of the method shown in any of the above Figures 1 to 2 are implemented.

[0134] The embodiments of the present invention also provide a schematic structural diagram of an electronic device, as shown in Figure 8 which is the schematic structural diagram of the electronic device. Among them, the electronic device includes a processor 81 and a memory 80. The memory 80 stores computer-executable instructions that can be executed by the processor 81. The processor 81 executes the computer-executable instructions to implement the method shown in any of the above Figures 1 to 2 embodiments.

[0135] In Figure 8In the illustrated embodiment, the electronic device further includes a bus 82 and a communication interface 83. Among them, the processor 81, the communication interface 83, and the memory 80 are connected through the bus 82. Among them, the memory 80 may include a high-speed random access memory (RAM), and may also include a non-volatile memory, such as at least one disk memory. Through at least one communication interface 83 (which can be wired or wireless), a communication connection is realized between the system network element and at least one other network element, and the Internet, wide area network, local area network, metropolitan area network, etc. can be used. The bus 82 may be an ISA (Industry Standard Architecture) bus, a PCI (Peripheral Component Interconnect) bus, or an EISA (Extended Industry Standard Architecture) bus, etc., and may also be an AMBA (Advanced Microcontroller Bus Architecture) bus. Among them, AMBA defines three buses, including an APB (Advanced Peripheral Bus) bus, an AHB (Advanced High-performance Bus) bus, and an AXI (Advanced eXtensible Interface) bus. The bus 82 can be divided into an address bus, a data bus, a control bus, etc. For the sake of convenience of representation, Figure 8 only one bidirectional arrow is used in the figure, but it does not mean that there is only one bus or one type of bus.

[0136] The processor 81 may be an integrated circuit chip with the ability to process signals. In the implementation process, each step of the above method can be completed by the integrated logic circuit of the hardware in the processor 81 or the instructions in the form of software. The above-mentioned processor 81 may be a general-purpose processor, including a central processing unit (CPU for short), a network processor (NP for short), etc.; it may also be a digital signal processor (DSP for short), an application specific integrated circuit (ASIC for short), a field-programmable gate array (FPGA for short), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components. The general-purpose processor may be a microprocessor or the processor may also be any conventional processor, etc. The steps of the method disclosed in the embodiments of the present application can be directly embodied as being executed and completed by the hardware decoding processor, or executed and completed by a combination of the hardware and software modules in the decoding processor. The software module may be located in a mature storage medium in the art such as a random access memory, a flash memory, a read-only memory, a programmable read-only memory, or an electrically erasable programmable memory, a register, etc. This storage medium is located in the memory, and the processor 81 reads the information in the memory and combines its hardware to complete the foregoing Figures 1 to 2 any of the shown methods.

[0137] A computer program product of a disk pressurized filtration system, its control method and device provided by an embodiment of the present invention includes a computer-readable storage medium storing program codes, and the instructions included in the program codes can be used to execute the methods described in the foregoing method embodiments. For the specific implementation, reference can be made to the method embodiments, and details are not described herein again. Those skilled in the art can clearly understand that for the convenience and brevity of description, the specific working process of the system described above can refer to the corresponding process in the foregoing method embodiments, and details are not described herein again. In addition, in the description of the embodiments of the present invention, unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be a mechanical connection or an electrical connection; it may be a direct connection or an indirect connection through an intermediate medium, and it may be the communication inside two components. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0138] When the above-mentioned functions are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or a part of this technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in various embodiments of the present invention. The aforementioned storage medium includes: various media that can store program codes, such as USB flash drives, mobile hard disks, read-only memories (ROM, Read-Only Memory), random access memories (RAM, Random Access Memory), magnetic disks, or optical discs.

[0139] Finally, it should be noted that the above embodiments are only specific embodiments of the present invention, used to illustrate the technical solutions of the present invention, rather than limiting it. The protection scope of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: any person skilled in the art within the technical scope disclosed by the present invention can still modify the technical solutions recorded in the foregoing embodiments, or can easily think of changes, or perform equivalent replacements on some of the technical features; and these modifications, changes, or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered by the protection scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims.

Claims

1. A control method for a disc pressure filtration system, characterized in that: Applied to a disc pressure filtration system, the disc pressure filtration system is equipped with a deep cone concentrator, the deep cone concentrator is used to provide input materials to the pressure filter of the disc pressure filtration system; the method comprises: Providing input material to the pressure filter through the deep cone concentrator; and controlling the pressure bin pressure of the pressure filter according to a preset pressure bin pressure parameter, and controlling the pressure filter fan of the pressure filter according to a preset pressure filter fan speed parameter, so that the pressure filter outputs filter cake based on the input material; Obtaining the material concentration of the input material and the parameters of the filter cake; The energy consumption data of the pressurized filter is calculated based on the material concentration, the parameters of the filter cake, the pressurized bin pressure parameters, and the pressurized filter fan speed parameters; wherein the energy consumption data of the pressurized filter is calculated based on the air consumption of the filtration process corresponding to the material concentration and the filter cake parameters, the air consumption of the flow process corresponding to the pressurized bin pressure parameters, and the exhaust air of the lower bin body corresponding to the pressurized filter fan speed parameters; When the parameters of the filter cake do not meet the preset parameter requirements, the pressure parameters of the pressurizing bin and the parameters of the number of revolutions of the pressurizing filter fan are adjusted according to the energy consumption data until the parameters of the filter cake meet the preset parameter requirements; The parameters of the filter cake include thickness parameters, moisture parameters and filtrate concentration; the pressurized chamber of the pressurized filter is equipped with an air outlet regulating valve; When the parameters of the filter cake do not meet the preset parameter requirements, the step of adjusting the pressure parameters of the pressurizing bin and the speed parameters of the pressurizing filter fan according to the energy consumption data includes: Determine whether the thickness parameter of the filter cake is within a preset thickness range; if not, calculate the target speed parameter corresponding to the thickness parameter by combining the energy consumption data with a pre-established energy-saving mathematical model, and adjust the speed parameter of the pressurized filter fan based on the target speed parameter; the energy-saving mathematical model is constructed based on the relationship between the pressurized bin pressure parameter of the pressurized filter, the speed parameter of the pressurized filter fan and the energy consumption of the pressurized filter; If yes, obtain the moisture parameter and filtrate concentration of the filter cake; calculate the target pressure parameter corresponding to the moisture parameter and filtrate concentration through the energy-saving mathematical model combined with the energy consumption data, and based on the pressure parameter, adjust the opening of the air outlet regulating valve of the pressurizing bin to adjust the pressure parameter of the pressurizing bin.

2. The method according to claim 1, characterized in that The air consumption of the filter press during the filtration process is calculated based on the material concentration and the dry coal slime processing capacity and the slurry processing capacity of the filter press. The dry coal slime processing capacity and the slurry processing capacity of the filter press are calculated based on the parameters of the filter cake and the material concentration; The air consumption of the flow process of the pressure filter is calculated based on the flow pressure corresponding to the pressure parameter of the pressure bin and the dry coal slime processing capacity; The exhaust of the lower bin of the pressure filter is calculated based on the filter pressure corresponding to the pressure filter fan rotation number parameter and the laws of thermodynamics.

3. The method according to claim 2, characterized in that The method further comprises: Inputting the material concentration of the input material into a pre-established energy-saving mathematical model to determine the number of rotations of the filter fan and the air supply pressure of the pressure filter based on the material concentration; The filter fan rotation number is determined as the pressurized filter fan rotation number parameter, and the air supply pressure is determined as the pressurized bin pressure parameter.

4. The method according to claim 3, characterized in that The method further comprises: The filtrate concentration of the filter cake is monitored, and it is determined whether the filtrate concentration exceeds a preset threshold, and if so, an early warning message is generated.

5. The method according to claim 1, characterized in that The disc pressure filter system also includes a flow meter, which is installed at the air outlet of the air compressor of the pressure filter; the monitoring value of the flow meter is used to characterize the actual air consumption of the pressure filter; The method further comprises: The monitoring value of the flow meter is obtained, and based on the monitoring value, the parameters representing the energy consumption in the energy-saving mathematical model are adjusted.

6. The method according to claim 1, characterized in that The method further comprises: The material concentration is monitored, and when the material concentration is lower than a preset threshold, the pressure filter is controlled to stop working.

7. A control device for a disc pressure filtration system, characterized in that: The device is used to perform the method according to any one of claims 1 to 6, and the device comprises: A control module, for providing input material to a pressure filter through a deep cone concentrator; and controlling the pressure bin pressure of the pressure filter according to a preset pressure bin pressure parameter, and controlling the pressure filter fan of the pressure filter according to a preset pressure filter fan speed parameter, so that the pressure filter outputs a filter cake based on the input material; A data acquisition module, used to acquire the material concentration of the input material and the parameters of the filter cake; A data processing module, used for calculating the energy consumption data of the pressure filter based on the material concentration, the parameters of the filter cake, the pressure parameters of the pressure bin, and the parameters of the speed of the pressure filter fan; The execution module is used to adjust the pressure parameter of the pressurizing bin and the speed parameter of the pressurizing filter fan according to the energy consumption data when the parameters of the filter cake do not meet the preset parameter requirements, until the parameters of the filter cake meet the preset parameter requirements.

8. A disc type pressure filtration system, characterized in that: The disc pressure filtration system is equipped with a deep cone thickener, which is used to provide input materials to the pressure filter of the disc pressure filtration system; Wherein, the disc pressure filtration system comprises a computing center system control module, and the computing center system control module is configured with the device described in claim 7, which is used to execute the method described in any one of claims 1-6.

9. The disc pressure filtration system according to claim 8, characterized in that: The disc pressure filter system also includes an intelligent remote maintenance system module for performing fault monitoring on the pressure filter.

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